Secondary carpet backing and buckling resistant carpet made therefrom
AssigneePropex Fabrics, Inc.
InventorsHugh Gardner, Carroll Yawn
Life of this patent
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Abstract
An improved secondary carpet backing fabric imparts increased resistance to buckling in carpets compared to conventional widely used secondary backings while providing the performance of conventional secondary carpet backings (e.g., similar peel strength, tuft bind, ease of handling). The improved backing is produced by a one-step weaving process and can be converted easily into carpet using current carpet making techniques. The inventive secondary carpet backing contains core-spun filling yarn with specific properties and is preferably woven in a leno or plain weave. Compared to carpets with conventional secondary backings, carpets with the inventive secondary backings display reduced growth in cyclic tensile testing.
Claims33
An improved secondary carpet backing, comprising a core-spun fill yarn, said core-spun fill yarn further comprising:
- a total denier, determined according to ASTM D-1907, of 800 to 3000;
- a tenacity, determined according to ASTM D-2256, of about 3 grams per denier to about 7 grams per denier;
- an elongation at peak load, determined according to ASTM D-2256, between 8% and 30%;
- a sheath;
- and
- a core component inside of the sheath, the core component comprising a yarn with a denier, determined according to ASTM D-1907, of 50% or less of the total denier for the core-spun fill yarn.
An improved carpet, comprising:
- a primary backing;
- a secondary carpet backing, said secondary carpet backing comprising a core-spun fill yarn, said core-spun fill yarn comprising:
- p2 a total denier, determined according to ASTM D-1907, of about 800 to 3000;
- a tenacity, determined according to ASTM D-2256, of about 3 grams per denier to about 7 grams per denier;
- and
- an elongation at peak load, determined according to ASTM D-2256, between 8% and 30%;
- a sheath;
- and
- a core component inside of the sheath, the core component comprising a yarn with a denier, determined according to ASTM D-1907, of 50% or less of the total denier for the core-spun fill yarn.
Dependencies are inferred from the claim text.