The invention pertains to a method to manufacture a textile product comprising a first sheet having polyester yarns fastened to this sheet to form a pile thereon, the method comprising providing the sheet, stitching the polyester yarns through the sheet to form the pile on a first surface of the sheet and loops of the yarns at a second surface of the sheet, contacting the second surface of the sheet with a surface of a hot body to at least partly melt the loops of the yarns to fasten the yarns to the sheet, wherein the second surface is actively cooled to force the temperature to be below the glass transition temperature of the polyester yarns within 60 seconds after the contacting of the second surface with the hot body. The invention also pertains to a device for applying this method.

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 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 cushion, comprising a reinforcing scrim layer within a polymer layer. The top surface and bottom surface of the carpet tile are defined by the facecloth and the cushion, respectively. A polymer-based resin is extruded onto the facecloth to form an at least substantially uniform secondary backing layer, and the cushion 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 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.

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.

Recyclable tufted fabrics and methods of preparing the same are provided. In particular, the recyclable tufted fabric includes a fabric backing, a plurality of yarns tufted through the fabric backing such that a pile is provided at a first surface of the fabric backing and a plurality of yarn loops are provided at a second surface of the fabric backing, and a liquid adhesive that anchors the plurality of yarn loops to the second surface of the fabric backing.

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 carpet tile includes a textile top member and a carrier 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 carrier mat includes a polymeric material component, a reinforcement, and a binder that is uniformly distributed throughout the polymeric material component and reinforcement component. The polymeric material component includes polymer fibers that are randomly oriented and entangled together. The reinforcement is disposed within the polymeric material component so that the reinforcement is entirely covered and concealed by the entangled polymer fibers to prevent exposure to a user. The reinforcement mechanically reinforces and stabilizes the polymeric material component and carpet tile.

The current invention concerns a covering, such as a floor covering, wall covering or ceiling covering, said covering comprising a surface layer, and a substrate layer attached to said surface layer, said substrate layer optionally comprising one or more reinforced thermoplastic layers. Said covering further comprises a backing layer on the bottom side of said substrate layer, opposite to said surface layer, and a textile layer attached to the bottom side of said backing layer, optionally through a contact layer. The covering further comprises a coating applied to the bottom of said textile layer. The invention also provides a method for producing a covering, such as a floor covering, wall covering or ceiling covering.

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.