US 6,475,592 B1 · Carpet backing that provides dimensional stability

Abstract

A tufted carpet is made by tufting yarn through a primary backing of at least two layers, including a first backing layer and a second backing layer. The first backing layer is formed of a woven material, a non-woven material, or a composite of a woven or non-woven material and a plastic sheet material. The second backing layer is formed of a woven material of ribbons of polypropylene, polyethylene or combinations of polypropylene and polyethylene, a woven fiber glass material, a leno weave material, an open weave material, a plastic net or a plastic sheet material. A plurality of tufts of yarn that are sewn through the primary backing are exposed on one side of the primary backing for forming face yarns, and also form a plurality of back stitches on the opposite side of the primary backing. At least a major portion of the back stitches secure each layer of the primary backing to each other layer.

Claims10

Dependent claims

A tufted carpet comprising:

(a) a primary backing comprised of at least two layers, including:
(i) a first backing layer which comprises a nylon-coated non-woven, spun-bonded polyester material;
(ii) a second backing layer which comprises a woven material comprised of ribbons of polypropylene, polypropylene or combinations of polypropylene and polyethylene;
(b) a plurality of tufts of yarn sewn through the primary backing, said tufts of yarn:
(i) being exposed on one side of the primary backing for forming face yarns;
and
(ii) forming a plurality of back stitches on the opposite side of the primary backing.

4 more elements

A tufted carpet comprising:

(a) a primary backing comprised of at least two layers, including:
(i) a first backing layer which comprises:
(1) a woven material,
(2) a non-woven material, or
(3) a composite of a woven or non-woven material and a plastic sheet material;
and
(ii) a second backing layer which comprises:
(1) a woven material comprised of ribbons of polypropylene, polyethylene or combinations of polypropylene and polyethylene,
(2) a woven fiber glass material,
(3) a leno weave material,
(4) an open weave material,
(5) a plastic net, or
(6) a plastic sheet material;
(b) a plurality of tufts of yarn sewn through the primary backing, said tufts of yarn:
(i) being exposed on one side of the primary backing for forming face yarns;
and
(ii) forming a plurality of back stitches on the opposite side of the primary backing;
(c) a back coating that covers and encapsulates the back stitches and locks in the fibers;
(d) a secondary backing material which is applied to the back of the back coating, said secondary backing material being comprised of a co-extruded polyethylene film comprised of a first component and a second component, wherein the first component of the co-extruded film has a lower melting point than the second component, and wherein the first component of the co-extruded film is applied to the back of the back coating on the primary backing.

16 more elements

Dependencies are inferred from the claim text.

Carpet backing that provides dimensional stability

Life of this patent

Carpet backing that provides dimensional stability

Life of this patent

Abstract

Claims10