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

A soft-substrate carpet made from recycled yarns includes a carpet fiber layer and a recycled fiber layer in a top-to-bottom order, wherein the carpet fiber layer comprises carpet fibers and a first non-woven scrim, the carpet fibers being tufted on the first non-woven scrim, and the recycled fiber layer comprises recycled fibers and a second non-woven scrim, the recycled fibers being tufted on the second non-woven scrim; the carpet fiber layer and the recycled fiber layer are permanently bonded.

A dimensionally stable universal floor covering includes a tufted textile having stitches and a reinforcement layer operatively connected to the stitches to provide dimensional stability for the entire floor covering. The reinforcement layer is made of fibers that are initially contained within a composition of adhesive and fibers. Mixing of the adhesive/fibers composition and/or injection of compressed air, assists in preparing the adhesive and fiber composition to be in the preferred condition and position prior to the forming of the reinforcement layer. Multiple sources of pressure, including vacuum, are applied in a controlled manner for moving the adhesive and fiber composition to form a reinforcement layer of fibers that is operatively connected to the stitches and/or to form a layer of fibers and adhesive that is contained within the stitches. The universal floor covering is selectively cut and transported in a roll for installation, and it can be conveniently recycled if necessary.

Disclosed is composite comprising four layers, two of the layers is a polymer film and two of the layers are non-woven materials, that is suitable for use as a primary backing material and/or a secondary backing material in the manufacture of textile carpet compositions. Also disclosed is a method for making the disclosed composite.

A soft-substrate carpet made from recycled yarns includes a carpet fiber layer and a recycled fiber layer in a top-to-bottom order, wherein the carpet fiber layer comprises carpet fibers and a first non-woven scrim, the carpet fibers being tufted on the first non-woven scrim, and the recycled fiber layer comprises recycled fibers and a second non-woven scrim, the recycled fibers being tufted on the second non-woven scrim; the carpet fiber layer and the recycled fiber layer are permanently bonded.

A tufted carpet including a tufted primary carpet backing, pile yarns tufted into the primary carpet backing, a secondary carpet backing adjoining to the primary carpet backing on the side of the primary carpet backing which exhibits backstitches and optionally a precoat and/or a polymer coat, wherein the secondary carpet backing including at least a reinforcement layer of fibers and the secondary carpet backing has an air permeability of at least 1000 l/m.sup.2.Math.s, measured according to ISO 9237:1995.

A primary carpet backing including a structure of at least three layers, wherein a first layer and a third layer including a nonwoven layer of fibers, and wherein a second layer which includes a reinforcement layer of fibers and is located between the first and the third layer, wherein the nonwoven layer of fibers of the first layer has an air permeability of at most 8000 L/m.sup.2.Math.s and the nonwoven layer of fibers of the third layer has an air permeability of at least 1000 L/m.sup.2.Math.s measured according to ISO 9237:1995, wherein the nonwoven layer of fibers of the first layer has a lower air permeability as the nonwoven layer of fibers of the third layer.

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

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.