Pattern-tufted, fusion-bonded carpet and carpet tile and method of preparation

A pattern-tufted, fusion-bonded carpet tile having a fibrous pile face wear surface with a fibrous, tufted pile pattern thereon, wherein the carpet tile comprises:

• a) a primary adhesive layer formed from a water-based ethylene vinyl acetate latex material;
• b) a plurality of fibrous yarns bonded to and extending generally upright from the adhesive layer to form a fibrous face wear surface;
• c) a woven polyester fibrous sheet material;
• d) a porous, glass fiber fleece sheet material adjacent to the woven polyester sheet material, the woven polyester sheet material and the adjacent glass fiber fleece sheet material bonded to the primary adhesive layer;
• e) a plurality of tufted yarns extending through the primary adhesive layer, the polyester woven sheet material and the glass fiber fleece sheet material, the tufted yarns forming a selected, sheared, tufted pattern on the face wear surface of the carpet tile, the tufted yarns having a different color, type, style, texture or properties than the fibrous face wear surface, the tufted yarns sheared to about the same height as the height of the fibrous face surface, and the other ends of the tufted yarns cut and extending to the back surface of the glass fiber fleece sheet material;
• and
• f) a solid, thermoplastic backing layer bonded to the back surface of the glass fiber fleece sheet material.