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.

This invention relates to a carpet tile that includes a polyolefin secondary backing layer. In particular, this invention relates to modular carpet tiles having at least one layer of polyolefin-containing thermoplastic polymer in the secondary backing of the carpet tile. By modifying the composition of the carpet tiles in this manner, the carpet tiles are able to withstand the high temperatures associated with surface printing of the tiles, while still maintaining cold temperature flexibility.

The invention provides a flame retardant polyolefin composition comprising a) an ethylene based plastomer with a density in the range of 0.850 to 0.915 g/cm.sup.3 and an MFR.sub.2 in the range 0.5-30 g/10 min; b) a propylene based plastomer with a density in the range of 0.860 to 0.910 g/cm.sup.3 and an MFR.sub.2 in the range 0.01-30 g/10 min; and c) a flame retardant.

This disclosure relates to a composite comprising (a) a rubber layer comprising a cured rubber and optionally a first copolymer having carboxyl groups or anhydride groups; and (b) a foam layer comprising a crosslinked ethylene vinyl acetate and optionally a second copolymer having carboxyl groups or glycidyl methacrylate groups; wherein the foam layer has at least one surface adhering to the rubber layer directly, and provided that either the first copolymer or the second copolymer is present, and the composite is free of glues or adhesive films in the interface between the rubber layer and the foam layer.

This invention relates to a washable multi-component floor mat. The floor mat contains a textile component and a base component. The textile component and the base component are attached to one another by at least one surface attraction means and at least one edge attachment means. The textile component is designed to be soiled, washed, and re-used, thereby providing ideal end-use applications in areas such as building entryways. The present invention eliminates the need to wash the base component of the floor mat which results in environmental, cost and labor conservation.

Various fabric products incorporating exterior hydrostatic barriers and processes for manufacturing such fabric products are provided.

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.

A tufted carpet constructed by embedding pile yarns on a primary base fabric, where a ratio at which a surface of the primary base fabric is visible accounts for 5% to 85% as viewed from above the tufted carpet. The primary base fabric is formed by entangling a color fiber, a characteristic fiber, and a low melt fiber on a spunbonded base fabric or a woven base fabric. The color fiber imparts an appearance design to the surface of the primary base fabric; the characteristic fiber has at least one function selected from the group consisting of deodorization, antibacterial, anti-allergen, and anti-mite; and the low melt fiber melts at a lower temperature than melting points of the other color fiber and characteristic fiber, and fixes these fibers on the surface of the primary base fabric by thermocompression-bonding. The resulting carpet exhibits excellent shape stability, economical efficiency, and lightness.

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 fabric made of yarns interlooping with each other or passing through an inner layer at looping intervals. The fabric is embossed with a micro-pattern extending into the yarns or into a layer underneath the fabric. The micro-pattern contains a pre-defined pattern of a plurality of binding points attaching the yarns to the inner layer or to the added underlayer. This micro-pattern has an inter-point spacing between adjacent binding points that is less than the interlooping intervals. The fabric can also be embossed with a macro-pattern separate from and coarser than the micro-pattern. The macro-pattern establishes a desired aesthetic in the fabric, and the micro-pattern does not interfere with the desired aesthetic.