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.

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.

A tufted carpet comprising a secondary backing which defines a volume being a parallelepiped having three pair of parallel faces, a first pair of parallel faces defining a upper surface of the secondary backing and a lower face of the tufted carpet, at least a second pair of parallel faces being inclined with respect to the first pair of parallel faces under an angle ?1 less than 90?, preferably in the range of 10 to 87?, the angle being the smallest angle measured between the planes defining the first pair of parallel faces and second pair of parallel faces.

The invention relates to a carpet tile or carpet strip for the contract market, in particular office and commercial buildings, comprising a machine-woven carpet having warp and weft yarns, a needled felt, an intermediate layer between the needled felt and the machine-woven fabric, wherein a polyester synthetic latex coating is applied to the back face of the machine-woven fabric, wherein the synthetic latex coating penetrates into the fabric from the back face of the fabric to a depth of at least 30% of a perpendicular distance between the back face and the front face of the fabric. The invention also relates to a process for manufacturing a carpet tile or a carpet strip for the contract market, in particular office and commercial buildings.

A low-weight carpet tile and process for making the same, wherein the carpet tile comprises a facecloth having a plurality of face yarns tufted through a primary backing, an extruded polymer secondary backing layer, and a reinforcing scrim layer partially embedded within the extruded polymer secondary backing layer. The top surface and bottom surface of the carpet tile are defined by the facecloth and the reinforcing scrim layer, respectively. A polymer-based resin is extruded onto the facecloth to form an at least substantially uniform secondary backing layer, and the reinforcing scrim layer is laid onto the extruded polymer secondary backing layer while the extruded polymer secondary backing layer remains above a softening temperature for the resin. The entire multi-layer web is then passed through a nip to embed the reinforcing scrim layer into the extruded polymer secondary layer, and the entire web is chilled.

The invention comprises a method. The method comprises applying a quantity of an aqueous dispersion of thermoplastic polymer particles to a primary backing and loop backs of a tufted carpet or a tufted synthetic turf, wherein the thermoplastic particles have an average particle size less than 1,000 microns. The method also comprises heating the aqueous dispersion to a temperature sufficient to remove water therefrom, and heating the thermoplastic particles on the primary backing and loop backs to a temperature at or above the melting temperature of the thermoplastic particles. The method further comprises allowing the heated thermoplastic polymer particles to cool below their melting temperature whereby the loop backs are adhered to the primary backing.

Disclosed is a completely recyclable artificial turf, which solves the problem of difficult totting of the existing artificial turf, has high tufting efficiency, has high strength of artificial turf, and is capable of being integrally recycled. The completely recyclable artificial turf of the present invention comprises artificial yarn and base fabric, wherein the base fabric includes woven fabric, the artificial yarn is tufted on the base fabric including woven fabric, the root of the artificial yarn is melted or locally melted, and the artificial yarn is integrated with the base fabric into a whole after cooling and shaping, wherein the material of the artificial yarn has a melting point lower than that of the material of the base fabric.

A dimensionally stable universal floor covering includes a tufted textile having stitches and a reinforcement layer of fibers and adhesive providing dimensional stability for the entire floor covering. The fibers and adhesive are mixed and then moved by an applicator towards the stitches. A slip path is formed to improve the movement of the fibers and adhesive. A releasable adhesive or gecko-like cover system is provided which also provides additional strength and stability and a releasable attachment of the universal floor covering to a supporting surface.

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

A damping layer comprises a large number of yarns combined to form a textile, wherein at least some of the yarns are foamed synthetic yarns. Such a textile, which consists of a mix of foamed and non-foamed synthetic yarns, is relatively strong and light and can lead to more efficient use of the foamed material. The foamed synthetic yarn may be formed into upstanding loops which provide additional resiliency and damping.