Textile constructions with stabilized primary backings and related methods
First Claim
Patent Images
1. A carpet construction or composite including a surface forming pile fabric, wherein the pile fabric comprises:
- a pile surface formed from a plurality of outwardly projecting yarn elements; and
a primary backing disposed in underlying relation to the pile surface, wherein at least a portion of the yarn elements are tufted through the primary backing and wherein the primary backing comprises a woven structure having a single woven layer comprising a plurality of interwoven fiber elements and wherein the material forming the interwoven fiber elements is selected from the group consisting of polyester fiber elements, glass fiber elements, nylon fiber elements, polypropylene fiber elements, stabilized polypropylene elements containing a nucleating agent, and combinations thereof.
1 Assignment
0 Petitions
Accused Products
Abstract
A pile fabric suitable for use as a primary carpet fabric within a carpet construction or composite such as a cushioned carpet or tile. The primary carpet fabric includes a plurality of pile-forming yarns tufted through or adhered to a primary backing of integral dimensionally stable character. A cushioning layer of foam, felt, fabric, or other suitable cushioning material may be disposed at a position below the primary carpet fabric.
-
Citations
135 Claims
-
1. A carpet construction or composite including a surface forming pile fabric, wherein the pile fabric comprises:
-
a pile surface formed from a plurality of outwardly projecting yarn elements; and
a primary backing disposed in underlying relation to the pile surface, wherein at least a portion of the yarn elements are tufted through the primary backing and wherein the primary backing comprises a woven structure having a single woven layer comprising a plurality of interwoven fiber elements and wherein the material forming the interwoven fiber elements is selected from the group consisting of polyester fiber elements, glass fiber elements, nylon fiber elements, polypropylene fiber elements, stabilized polypropylene elements containing a nucleating agent, and combinations thereof. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 115, 116, 129)
-
-
10. A carpet construction or composite including a surface forming pile fabric, wherein the pile fabric comprises:
-
a pile surface formed from a plurality of yarn elements; and
a primary backing disposed in underlying relation to the pile surface, wherein at least a portion of the yarn elements are tufted through the primary backing and wherein the primary backing comprises a nonwoven structure having a single nonwoven layer comprising a plurality of intermingled fiber elements and wherein the material forming the intermingled fiber elements is selected from the group consisting of polyester fiber elements, glass fiber elements, nylon fiber elements, polypropylene fiber elements, stabilized polypropylene elements containing a nucleating agent, and combinations thereof. - View Dependent Claims (11, 12, 13, 14, 117, 118, 130)
-
-
15. A carpet construction or composite including a surface forming pile fabric, wherein the pile fabric comprises:
-
a pile surface formed from a plurality of yarn elements; and
a primary backing disposed in underlying relation to the pile surface, wherein at least a portion of the yarn elements are tufted through the primary backing and wherein the primary backing comprises a multi-layer composite structure having a first woven layer comprising a plurality of interwoven fiber elements disposed in laminate relation to at least one additional layer of woven or nonwoven construction, wherein the material forming the interwoven fiber elements within the first woven layer is selected from the group consisting of polyester fiber elements, glass fiber elements, nylon fiber elements, polypropylene fiber elements, stabilized polypropylene elements containing a nucleating agent, and combinations thereof. - View Dependent Claims (16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 119, 120, 131)
-
-
37. A carpet construction or composite including a surface forming pile fabric, wherein the pile fabric comprises:
-
a pile surface formed from a plurality of yarn elements; and
a primary backing disposed in underlying relation to the pile surface, wherein at least a portion of the yarn elements are tufted through the primary backing and wherein the primary backing comprises a multi-layer composite structure having a first nonwoven layer comprising a plurality of intermingled fiber elements disposed in laminate relation to at least one additional layer of woven or nonwoven construction, wherein the material forming the intermingled fiber elements within the first nonwoven layer is selected from the group consisting of polyester fiber elements, glass fiber elements, nylon fiber elements, polypropylene fiber elements, stabilized polypropylene elements containing a nucleating agent, and combinations thereof. - View Dependent Claims (38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 121, 122, 132)
-
-
66. A carpet construction or composite including a surface forming pile fabric, wherein the pile fabric comprises:
-
a pile surface formed from a plurality of yarn elements; and
a primary backing disposed in underlying relation to the pile surface, wherein at least a portion of the yarn elements are tufted through the primary backing and wherein the primary backing comprises a multi-layer composite structure of sandwich construction comprising a pair of opposing layers of woven or nonwoven construction and at least one additional layer of woven or nonwoven construction disposed intermediate the opposing layers wherein the material forming the opposing layers is selected from the group consisting of polyester fiber elements, glass fiber elements, nylon fiber elements, polypropylene fiber elements, stabilized polypropylene elements containing a nucleating agent, and combinations thereof. - View Dependent Claims (67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 123, 124, 133)
-
-
99. A carpet composite or construction including a surface forming pile fabric, wherein the pile fabric comprises:
-
a pile surface formed from a plurality of yarn elements; and
a primary backing disposed in underlying relation to the pile surface, wherein at least a portion of the yarn elements are tufted through the primary backing and wherein the primary backing comprises a multi-layer composite structure having at least a first woven or nonwoven layer comprising fibrous constituents selected from the group consisting of polyester fiber elements, glass fiber elements, nylon fiber elements, polypropylene fiber elements, stabilized polypropylene elements containing a nucleating agent, and combinations thereof, said at least a first woven or nonwoven layer being in adjoined relation to at least a first fibrous capping layer. - View Dependent Claims (100, 101, 102, 103, 104, 105, 106, 107, 125, 126, 134)
-
-
108. A carpet composite or construction comprising:
-
a pile surface formed from a plurality of yarn elements;
a primary backing disposed in underlying relation to the pile surface, wherein at least a portion of the yarn elements are tufted through the primary backing and wherein the primary backing comprises at least one layer of woven or nonwoven material selected from the group consisting of polyester fiber elements, glass fiber elements, nylon fiber elements, polypropylene fiber elements, stabilized polypropylene containing a nucleating agent and combinations thereof, the primary backing further comprising at least one additional layer selected from the group consisting of woven glass, nonwoven glass, woven polyester, nonwoven polyester, woven nylon, nonwoven nylon, woven stabilized polypropylene containing a nucleating agent, nonwoven stabilized polypropylene containing a nucleating agent, and combinations thereof;
a cushioning underlayer disposed at a position below the primary backing; and
,a layer of at least one adhesive extending between the primary backing and the cushioning underlayer. - View Dependent Claims (109, 110, 111, 112, 113, 114, 127, 128, 135)
-
Specification