A soft-substrate carpet made from recycled yarns includes a carpet fiber layer and a recycled fiber layer in a top-to-bottom order, wherein the carpet fiber layer comprises carpet fibers and a first non-woven scrim, the carpet fibers being tufted on the first non-woven scrim, and the recycled fiber layer comprises recycled fibers and a second non-woven scrim, the recycled fibers being tufted on the second non-woven scrim; the carpet fiber layer and the recycled fiber layer are permanently bonded.

The present invention relates polyester tufted carpet where the tufts are engaged with a primary polyester backing and where a polyester extrusion coating is applied to the backside of the primary backing to lock the tufts which therefore avoids the use of a latex adhesive

A process for fabricating a molded carpet laminate includes supporting a carpet layer in a molding tool that has mold dies that define a mold cavity. The mold dies are then moved from an open position to a partially closed position. In the partially closed position, a heated polymer material is injected into the mold cavity. The heated polymer material incompletely fills the mold cavity on the working side of the carpet layer. The mold dies are then moved from the partially closed position to a closed position to spread the heated polymer material and fill the mold cavity on the working side of the carpet layer to form a molded polymer wall. The molded polymer wall adheres to the working side of the carpet layer to form a molded carpet laminate. The mold dies are then moved from the closed position and the molded carpet laminate is cooled.

A filled polyolefin composition made from or containing butene-1 copolymers having high melt flow and an inorganic filler. The compositions are useful for carpet backing.

Disclosed is composite comprising four layers, two of the layers is a polymer film and two of the layers are non-woven materials, that is suitable for use as a primary backing material and/or a secondary backing material in the manufacture of textile carpet compositions. Also disclosed is a method for making the disclosed composite.

A soft-substrate carpet made from recycled yarns includes a carpet fiber layer and a recycled fiber layer in a top-to-bottom order, wherein the carpet fiber layer comprises carpet fibers and a first non-woven scrim, the carpet fibers being tufted on the first non-woven scrim, and the recycled fiber layer comprises recycled fibers and a second non-woven scrim, the recycled fibers being tufted on the second non-woven scrim; the carpet fiber layer and the recycled fiber layer are permanently bonded.

A carpet and a method of making a carpet are described. The carpet and the method of making the carpet does not involve the use of a latex precoat. This is useful for recycling purposes.

The invention comprises a method of making synthetic turf. The method comprises applying an ethylene-vinyl acetate copolymer adhesive to a first primary surface of a tufted primary backing to form a coating thereon and wherein the primary backing is tufted with a plurality of synthetic filaments to form a face pile extending outwardly from a second primary surface of the synthetic turf opposite the first primary surface and heating the ethylene-vinyl acetate copolymer adhesive to a temperature above its melting point so that the ethylene-vinyl acetate copolymer adhesive melts and at least partially flows into the primary backing. The method also comprises heating a linear low-density polyethylene film to a temperature below the softening point of the film and pressing the heated linear low-density polyethylene film into contact with the polymer coated first primary surface of the tufted primary backing. The method further comprises allowing the ethylene-vinyl acetate copolymer adhesive and the linear low-density polyethylene film to cool, whereby the linear low-density polyethylene film is adhered to the tufted primary backing.

A moisture resistant carpet composition exhibiting exceptional delamination strength and methods of making same are disclosed.

The present invention relates to a carpet backing layer composition, comprising: —100 parts by weight of a polyolefins or a blend of polyolefins and optionally a blend of oils, wax and tackifiers, said polyolefin or polyolefin blend comprising at least 0% by weight of (co)polymerized C3-C8 alfa-olefins—between 100 and 900 parts by weight of one or more inorganic filler(s) characterized by a volume median particle diameter (D50) comprised between 10 and 1000 μm; —the backing layer composition having a heat of fusion within the temperature range of from 10 to 40° C. (ΔH.sup.10.fwdarw.40° C.) that is less than 12.5% of the heat of fusion of the backing layer within the temperature range of from 10 to 170° C. (ΔH.sup.10.fwdarw.170° C.), the heat of fusion being measured by Differential Scanning calorimetry. The invention further relates to a carpet comprising a carpet backing layer obtained from the carpet backing layer composition and a method for the preparation of the carpet.