This invention relates to tufted floorcovering articles, including carpet tiles and broadloom carpet. In particular, this invention relates to tufted floorcovering articles made from the family of polymers known as polyester. Specifically, this invention relates to tufted carpet tile products made from polyester. The polyester carpet tiles meet commercial performance specifications and are fully end-of-life recyclable.

The present invention pertains to a method for manufacturing a laminated textile product comprising providing a first intermediate product comprising a primary backing having a front surface and a back surface, and yarns stitched into the primary backing, the yarns extending from the front surface of the backing material, feeding the intermediate product along a body having a heated surface, the back surface being pressed against the said heated surface, to at least partly melt the yarns present in the intermediate product to bond the yarns to the backing, wherein the part of the back surface that is pressed against the heated surface has a relative speed with respect to the heated surface, so as to provide a second intermediate product having a calendered back surface, providing a dimensionally stable carrier sheet or secondary backing, and connecting the second intermediate product to the carrier sheet by providing a hot melt adhesive between the calendered surface and the sheet, and pressing the sheet to the second intermediate product to form the textile product.

This invention relates to tufted floorcovering articles, including carpet tiles and broadloom carpet. In particular, this invention relates to tufted floorcovering articles made from the family of polymers known as polyester. Specifically, this invention relates to tufted carpet tile products made from polyester. The polyester carpet tiles meet commercial performance specifications and are fully end-of-life recyclable.

An example method for forming a pile fabric includes: providing a primary backing material (configured as a sheet), a layer of thermoplastic material (disposed at the back side of the primary backing material), and a plurality of pile tufts extending through the primary backing material and at least partially into the layer of thermoplastic material with back stitch portions of the pile tufts being disposed at the back side of the primary backing material; and heating only the back of the pile fabric to melt the back stitch portions of the pile tufts and the layer of thermoplastic material to form a melt bond disposed at the back side of the primary backing material to secure the pile tufts to the primary backing material.

A novel carpet tile is provided with a roller applied polyurethane adhesive layer at a rate of less than 45 ounces per square yard, resulting in a lightweight backing with exceptional dimensional stability.

Floor coverings having a greige good, an adhesive layer, and a secondary backing material. The greige good has a primary backing component having adjoined first and second portions, and a plurality of fibers. The secondary backing material has an attached portion and a first exposable portion, with the attached portion adhered to the first portion of the primary backing component by contact with the adhesive layer. The second portion of the primary backing component is unattached to the first exposable portion of the secondary backing material, and the first exposable portion defines a portion of the first end edge of the floor covering. The second portion of the primary backing component is selectively moveable relative to the first portion to a position in which at least a portion of the second portion of the primary backing component does not overlie the first exposable portion of the secondary backing material.

Textile fabrics consolidated with a binder that is made from a binder system are described. The binder system may include: a) 30% or less by dry weight of at least one polymer based on polyvinyl alcohol; b) 70% or more by dry weight of at least one starch, wherein the at least one starch comprises 50% by weight or more of one or more natural starches based on the total weight of the at least one starch; c) 0 to 10% by dry weight of at least one crosslinker; d) 0 to 10% by dry weight of at least one filler; and e) 0 to 10% by dry weight of at least one additive, wherein a sum of components a) through e) is 100% by dry weight of the binder system. Method of making the textile fabrics consolidated with binders made from the binder systems are also described.

Recyclable tufted carpet products and methods of preparing the same are provided. In particular, the recyclable tufted carpet product includes a primary backing having an air permeability greater than 100 l/m.sup.2/sec at 200 Pa/20 cm.sup.2, the primary backing comprising a polyester nonwoven; a plurality of yarns tufted through the primary backing such that a pile is provided at a first surface of the primary backing and a plurality of yarn loops are provided at a second surface of the primary backing; and an adhesive that anchors the plurality of yarn loops to the second surface of the primary backing.

A one step method for integrally attaching a backing cover to a universal fiber-reinforced backing before curing. The manufacturing method includes attaching a porous cover to a reinforcement configuration of fibers and adhesive before curing. The cover is pressed against the fibers and adhesive for compressing, collapsing, and flattening the ends of the stitch portions. The compressing and collapsing actions cause adhesive and fibers to be directed toward and forced into the porous cover. Adhesive and reinforcement fibers provide an integral attachment of the cover to the reinforced backing before and after curing.

A carpet tile having a greige good, an adhesive layer, and a secondary backing material. The greige good has a primary backing component and a plurality of fibers attached to the primary backing component. The adhesive layer has an adhesive composition and a reinforcement material that is at least partially embedded within the adhesive composition. The adhesive layer is applied to a back surface of the primary backing component. The secondary backing material is adhered to the primary backing component by contact with a portion of the adhesive composition that flows through the reinforcement material. The reinforcement material and the secondary backing material are co-laminated onto the adhesive composition.