Floor covering with universal backing and methods of making and recycling

A method of manufacturing a floor covering having a universal reinforcing backing layer which can be applied to both broadloom and modular floor coverings, the method comprising the steps of:

• providing a tufted textile substrate having a primary backing substrate extending in a first direction and a plurality of yarns tufted through the primary backing substrate, the primary backing substrate having a face side and a back side opposite the face side, a portion of each yarn forming a stitch portion having an end that is located on the back side of the primary backing substrate, and an interstitial space existing between the end of each stitch portion;
• moving the tufted textile substrate relative to an applicator;
• providing a pool having adhesive and reinforcement fibers;
• applying pressure in a controlled manner between the applicator and the tufted textile substrate for moving the adhesive and reinforcement fiber pool in a second direction that is toward the back side of the primary backing substrate;
• aligning the reinforcement fibers to lay predominantly in the first direction in a space between the stitch portions of the yarns and the applicator and separating the adhesive from the reinforcement fibers such that the reinforcement fibers form a reinforcement layer of fibers that is substantially parallel to the first direction and forming a layer of adhesive between the reinforcement layer of fibers and the primary backing substrate;
• applying a vacuum for assisting in the formation of the layer of adhesive between the reinforcement layer of fibers and the primary backing substrate;
• and
• curing the adhesive and the reinforcement layer of fibers.