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.

A method of forming a multi-layer needled non-woven article, comprising forming a web of a fiber base layer, an intermediate film and a fiber top layer, wherein the intermediate film is disposed between the fiber base layer and the fiber top layer; needle punching the web with a plurality of needles; and wherein, during needle punching, fibers of the fiber base layer are carried by the needles, extended through perforations in the intermediate film formed by the needles and entangled with fibers of the fiber top layer.

A carpet tile includes a textile top member and a cushion mat that is coupled with the textile top member via a thermoplastic material. The textile top member includes carpet yarns and a backing that is coupled with the carpet yarns so that the backing structurally supports the carpet yarns. The cushion mat includes a polymeric material component having polymer fibers that are randomly oriented and entangled together and a scrim reinforcement that is disposed within the polymeric material component. The scrim reinforcement reinforces and stabilizes the polymeric material component and is entirely covered and concealed by the intermeshed polymer fibers.

Stabilizing a textile sheet structure was achieved by forming a plurality of discrete fiber tufts extending from a first face of a fibrous layer of the textile sheet structure, through the fibrous layer and beyond a second face opposite the first face. Each discrete fiber tuft included a plurality discrete fibers. Each discrete fiber tuft was anchored to the first face and the second face of the fibrous layer by joining together the plurality of each discrete fiber tuft at the first face and the second face and bonding the joined plurality of discrete fiber tuft to the first face and the second face.

A super anti-slip composite carpet with a three-dimensional TPE elastic structure, which is formed by compounding a fabric layer (1) and a TPE layer (2), wherein TPE is composed of 80-90% of styrene oxide-butadiene block copolymer and 10-20% of polypropylene, and the TPE layer (2) has a thickness of 1-2 mm. The compounding process thereof includes: step 1, preheating a transparent TPE to 80° C., and adding to a material barrel of a casting machine, stirring the TPE by a screw, and heating to a heating temperature of 140° C.-200° C. in 6-9 sections, to obtain a paste-like TPE; step 2, extruding the paste-like TPE through a metal joining pipe into a die head; step 3, making the paste-like TPE flow out through the die head in a planar cascade shape, and at the same time, passing the paste-like TPE flowed out from the die head together with a back part of a carpet fabric through a gap between an embossed roller and a rubber roller, so as to compound with the bottom surface of the fabric layer. The carpet has a good anti-slip effect and no edge warping, and is light resistant, aging resistant, non-toxic and tasteless, safe and reliable.

A flooring product may include an upper flooring material and a glassless wet-laid nonwoven mat. The glassless wet-laid nonwoven mat may include a plurality of polymeric fibers and a binder. The plurality of polymeric fibers have a linear mass density of between about 1.0 denier and 4.0 denier. The plurality of polymeric fibers have lengths of between about 6 mm and 25 mm. The binder has a loss on ignition of at least about 20%. The glassless wet-laid nonwoven mat has a hot-wet % of at least about 20%.

A method of making a floor covering including a tufted textile substrate and a reinforcement backing system. A layer of reinforcement fibers is positioned on the ends of yarn stitches. Applicators are operationally connected such that adhesive is forced into the reinforcement fiber layer towards a primary backing substrate, and adhesive is also substantially simultaneously directed to form a pool of adhesive between the applicators, and a portion of the pool of adhesive is also substantially simultaneously applied as a layer of adhesive on the reinforcement fiber layer.

A subject matter of the invention is a three-dimensionally deformable velour carpet for a floor paneling, a luggage compartment paneling or a load floor paneling of a motor vehicle, which has a needled structure on the visible side produced by structured brushes in the brush belt.

A temporary antimicrobial roll-up floor cover includes a rugged upper layer that is impervious to water and pervious water vapor, and a lower antimicrobial wicking layer that quickly spreads water while transmitting water vapor, to facilitate evaporation of moisture that gets under the cover. The cover may also include one or more of a central layer containing a microporous membrane, a coating or film layer which may be perforated, and a stiffener lattice that resists folding, gathering and puckering without preventing the cover from rolling up. The coating layer adds additional resistance to folding, gathering and puckering without preventing the cover from rolling up. The coating may be perforated to increase water vapor transmission through the cover. One or more antimicrobial agents is incorporated into the wicking layer during extrusion of the airlaid mat forming the wicking layer.

A temporary roll-up floor cover includes a rugged upper layer that is impervious to water and pervious water vapor, and a lower antimicrobial wicking layer that quickly spreads water while transmitting water vapor, to facilitate evaporation of moisture that gets under the cover. The cover may also include one or more of a central layer containing a microporous membrane, a coating or film layer which may be perforated, and a stiffener lattice that resists folding, gathering and puckering without preventing the cover from rolling up. The coating layer adds additional resistance to folding, gathering and puckering without preventing the cover from rolling up. The coating may be perforated to increase water vapor transmission through the cover. One or more antimicrobial agents may be incorporated into the floor cover, for example, into the wicking layer during extrusion of the airlaid mat forming the wicking layer.