Dual layer wet laid nonwoven mat

A dual-layer wet-laid nonwoven mat for a carpet tile, the dual-layer wet-laid nonwoven mat comprising:

• a glass fiber rich layer comprising a fiber mixture of glass fibers and synthetic fibers, the fiber mixture comprising at least 80 weight percent of the glass fibers;
• a synthetic fiber rich layer comprising a fiber mixture of glass fibers and synthetic fibers, the fiber mixture comprising at least 80 weight percent of the synthetic fibers;
• and
• an emulsion binder that is applied to the glass fiber rich layer and the synthetic fiber rich layer to bind the glass fibers and synthetic fibers in said layers together;
• wherein:
• the dual-layer wet-laid nonwoven mat includes at least 10 weight percent of the binder;
• the binder is curable at a maximum temperature of below 330 degrees Fahrenheit;
• and
• a total weight percent of glass fibers in the fiber mixture of the glass fiber rich layer and the fiber mixture of the synthetic fiber rich 17 layer is at least 48 percent.

A method of manufacturing a carpet tile, comprising:

• providing a pile fabric layer having a primary backing;
• applying a secondary backing to the primary backing;
• applying a dual-layer wet-laid nonwoven mat to an exposed surface of the secondary backing to form a carpet sheet, the dual-layer wet-laid nonwoven mat comprising:
• a glass fiber rich layer comprising a fiber mixture of glass fibers and synthetic fibers, the fiber mixture comprising at least 80 weight percent of the glass fibers;
• a synthetic fiber rich layer comprising a fiber mixture of glass fibers and synthetic fibers, the fiber mixture comprising at least 80 weight percent of the synthetic fibers;
• wherein a total weight percent of glass fibers in the fiber mixture of the glass fiber rich layer and the fiber mixture of the synthetic fiber rich layer is at least 48 percent;
• and
• an emulsion binder that is applied to the glass fiber rich layer and the synthetic fiber rich layer to bind the glass fibers and synthetic fibers in said layers together;
• wherein the dual-layer wet-laid nonwoven mat includes between about 10 and 50 weight percent of the binder and the binder is curable at a maximum temperature of below 330 degrees Fahrenheit;
• and
• cutting the carpet sheet into a plurality of carpet tiles.