Textile constructions with stabilized primary backings and related methods

• US 20030175474A1
• Filed: 03/13/2002
• Published: 09/18/2003
• Est. Priority Date: 03/13/2002
• Status: Active Grant

• Current Assignee: Milliken & Company
• Original Assignee: Milliken & Company
• Inventors: Morin, Brian G., Cowan, Martin E., Higgins, Kenneth B.
• Granted Patent: US 6,866,912 B2
• Time in Patent Office: Days
• US Class Current: 428/95
• CPC Class Codes: B32B 2307/734 Dimensional stability
• CPC Class Codes: B32B 2471/00 Floor coverings B32B2419/04 takes precedence
• CPC Class Codes: B32B 5/06 characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
• CPC Class Codes: B32B 5/26 another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: D06N 2201/02 Synthetic macromolecular fibres
• CPC Class Codes: D06N 2201/0254 Polyolefin fibres
• CPC Class Codes: D06N 2201/0263 Polyamide fibres
• CPC Class Codes: D06N 2201/082 Glass fibres
• CPC Class Codes: D06N 2201/12 Fibres being in the form of a tape, strip or ribbon
• CPC Class Codes: D06N 2203/068 Polyurethanes
• CPC Class Codes: D06N 2205/06 Melt
• CPC Class Codes: D06N 2205/20 Cured materials, e.g. vulcanised, cross-linked
• CPC Class Codes: D06N 2209/1628 Dimensional stability
• CPC Class Codes: D06N 7/0073 the back coating or pre-coat being applied as an aqueous dispersion or latex
• CPC Class Codes: D06N 7/0081 with at least one extra fibrous layer at the backing, e.g. stabilizing fibrous layer, fibrous secondary backing
• CPC Class Codes: D06N 7/0084 with at least one layer obtained by sintering or bonding granules together
• CPC Class Codes: D06N 7/0086 characterised by the cushion backing, e.g. foamed polyurethane
• CPC Class Codes: Y10T 428/23979 Particular backing structure or composition

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.

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.

2. The carpet as recited in claim 1, wherein the interwoven fiber elements are ribbon elements.

3. The carpet as recited in claim 2, wherein the ribbon elements comprise stabilized polypropylene containing a nucleating agent.

4. The carpet as recited in claim 3, wherein an adhesive covering extends across at least one side of the woven layer.

5. The carpet as recited in claim 4, wherein the adhesive is at least one of a latex and a hot melt adhesive.

6. The carpet as recited in claim 1, wherein the interwoven fiber elements are ribbon elements comprising stabilized polypropylene containing a nucleating agent and wherein a first portion of the ribbon elements extend in a warp direction within the woven structure at a predefined weave density and a second portion of the ribbon elements extend in a pick direction substantially transverse to the warp direction at a predefined weave density and the first portion of the ribbon elements is characterized by a linear density and/or weave density which is different from the second portion of the ribbon elements such that the woven structure is asymmetrical.

7. The carpet as recited in claim 6, wherein the first portion of the ribbon elements is characterized by a linear density which is greater than the linear density of the second portion of the ribbon elements.

8. The carpet as recited in claim 7, wherein the first portion of the ribbon elements is characterized by a linear density which is at least about 50% greater than the linear density of the second portion of the ribbon elements.

9. The carpet as recited in claim 6, wherein the first portion of the ribbon elements is characterized by a weave density which is greater than the weave density of the second portion of the ribbon elements.

115. The carpet as recited in claim 1, wherein said carpet composite or construction is at least one of a carpet, broadloom carpet, rug, area rug, decorator rug, runner, rugget, and carpet tile.

116. The carpet as recited in claim 115, wherein said carpet composite or construction is cushioned.

129. In a method of producing a carpet composite or construction, the improvement comprising the step of using a primary backing as set forth in claim 1.

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.

11. The carpet as recited in claim 10, wherein the nonwoven structure is selected from the group consisting of dry-laid material, a wet-laid material, a needle punched material, a hydroentangled material, and a spun bonded material.

12. The carpet as recited in claim 10, wherein the intermingled fiber elements comprise stabilized polypropylene elements containing a nucleating agent which fiber elements are spun bonded such that a plurality of fusion bonding points are present through the nonwoven structure.

13. The carpet as recited in claim 10, wherein an adhesive covering extends across at least one side of the nonwoven layer.

14. The carpet as recited in claim 13, wherein the adhesive is at least one of a latex and a hot melt adhesive.

117. The carpet as recited in claim 10, wherein said carpet composite or construction is at least one of a carpet, broadloom carpet, rug, area rug, decorator rug, runner, rugget, and carpet tile.

118. The carpet as recited in claim 117, wherein said carpet composite or construction is cushioned.

130. In a method of producing a carpet composite or construction, the improvement comprising the step of using a primary backing as set forth in claim 10.

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.

16. The carpet as recited in claim 15, wherein said at least one additional layer comprises woven glass.

17. The carpet as recited in claim 15, wherein at least a portion of the interwoven fiber elements in the first woven layer are ribbon elements.

18. The carpet as recited in claim 17, wherein at least a portion of the ribbon elements comprise stabilized polypropylene containing a nucleating agent.

19. The carpet as recited in claim 15, wherein said at least one additional layer comprises nonwoven glass.

20. The carpet as recited in claim 19, wherein at least a portion of the interwoven fiber elements in the first woven layer are ribbon elements.

21. The carpet as recited in claim 20, wherein at least a portion of the ribbon elements comprise stabilized polypropylene containing a nucleating agent.

22. The carpet as recited in claim 15, wherein said at least one additional layer comprises woven stabilized polypropylene fiber elements containing a nucleating agent.

23. The carpet as recited in claim 22, wherein at least one of the interwoven fiber elements in the first woven layer and the stabilized polypropylene fiber elements in said at least one additional stabilizing layer are ribbon elements.

24. The carpet as recited in claim 23, wherein both the interwoven fiber elements in the first woven layer and the stabilized polypropylene fiber elements in said at least one additional layer are ribbon elements.

25. The carpet as recited in claim 15, wherein said at least one additional layer comprises a nonwoven construction of stabilized polypropylene fiber elements containing a nucleating agent.

26. The carpet as recited in claim 25, wherein at least a portion of the interwoven fiber elements in the first woven layer are ribbon elements.

27. The carpet as recited in claim 26, wherein at least a portion of the ribbon elements comprise stabilized polypropylene containing a nucleating agent.

28. The carpet as recited in claim 15, wherein said at least one additional layer comprises a woven construction of polyester.

29. The carpet as recited in claim 28, wherein at least a portion of the interwoven fiber elements in the first woven layer are ribbon elements.

30. The carpet as recited in claim 29, wherein at least a portion of the ribbon elements comprise stabilized polypropylene containing a nucleating agent.

31. The carpet as recited in claim 15, wherein said at least one additional layer comprises a nonwoven construction of polyester.

32. The carpet as recited in claim 31, wherein at least a portion of the interwoven fiber elements in the first woven layer are ribbon elements.

33. The carpet as recited in claim 32, wherein at least a portion of the ribbon elements comprise stabilized polypropylene containing a nucleating agent.

34. The carpet as recited in claim 15, wherein said at least one additional layer comprises at least one of a woven and nonwoven construction of nylon, polyester, polypropylene, stabilized polypropylene, glass, and combinations thereof.

35. The carpet as recited in claim 34, wherein at least a portion of the interwoven fiber elements in the first woven layer are ribbon elements.

36. The carpet as recited in claim 35, wherein at least a portion of the ribbon elements comprise stabilized polypropylene containing a nucleating agent.

119. The carpet as recited in claim 15, wherein said carpet composite or construction is at least one of a carpet, broadloom carpet, rug, area rug, decorator rug, runner, rugget, and carpet tile.

120. The carpet as recited in claim 119, wherein said carpet composite or construction is cushioned.

131. In a method of producing a carpet composite or construction, the improvement comprising the step of using a primary backing as set forth in claim 15.

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.

38. The carpet as recited in claim 37, wherein said at least one additional layer comprises woven glass.

39. The carpet as recited in claim 38, wherein at least a portion of the intermingled fiber elements within the first nonwoven layer comprise stabilized polypropylene containing a nucleating agent.

40. The carpet as recited in claim 39, wherein the first nonwoven layer is a spun bonded nonwoven construction including a plurality of fusion bonding points between the intermingled fiber elements.

41. The carpet as recited in claim 37, wherein said at least one additional layer comprises nonwoven glass.

42. The carpet as recited in claim 41, wherein at least a portion of the intermingled fiber elements within the first nonwoven layer comprise stabilized polypropylene containing a nucleating agent.

43. The carpet as recited in claim 42, wherein the first nonwoven layer is a spun bonded nonwoven construction including a plurality of fusion bonding points between the intermingled fiber elements.

44. The carpet as recited in claim 37, wherein said at least one additional layer comprises woven stabilized polypropylene fiber elements containing a nucleating agent.

45. The carpet as recited in claim 44, wherein at least a portion of the stabilized polypropylene fiber elements in said at least one additional layer are ribbon elements.

46. The carpet as recited in claim 44, wherein at least a portion of the intermingled fiber elements within the first nonwoven layer comprise stabilized polypropylene containing a nucleating agent.

47. The carpet as recited in claim 46, wherein the first nonwoven layer is a spun bonded nonwoven construction including a plurality of fusion bonding points between the intermingled fiber elements.

48. The carpet as recited in claim 37, wherein said at least one additional layer comprises a nonwoven construction of stabilized polypropylene fiber elements containing a nucleating agent.

49. The carpet as recited in claim 48, wherein at least a portion of the intermingled fiber elements within the first nonwoven layer comprise stabilized polypropylene containing a nucleating agent.

50. The carpet as recited in claim 49, wherein the first nonwoven layer is a spun bonded nonwoven construction including a plurality of fusion bonding points between the intermingled fiber elements.

51. The carpet as recited in claim 37, wherein said at least one additional layer comprises a woven construction of polyester.

52. The carpet as recited in claim 51, wherein at least a portion of the intermingled fiber elements within the first nonwoven layer comprise stabilized polypropylene containing a nucleating agent.

53. The carpet as recited in claim 52, wherein the first nonwoven layer is a spun bonded nonwoven construction including a plurality of fusion bonding points between the intermingled fiber elements.

54. The carpet as recited in claim 37, wherein said at least one additional layer comprises a nonwoven construction of polyester.

55. The carpet as recited in claim 54, wherein at least a portion of the intermingled fiber elements within the first nonwoven layer comprise stabilized polypropylene containing a nucleating agent.

56. The carpet as recited in claim 55, wherein the first nonwoven layer is a spun bonded nonwoven construction including a plurality of fusion bonding points between the intermingled fiber elements.

57. The carpet as recited in claim 37, wherein said at least one additional layer comprises a woven construction of nylon.

58. The carpet as recited in claim 57, wherein at least a portion of the intermingled fiber elements within the first nonwoven layer comprise stabilized polypropylene containing a nucleating agent.

59. The carpet as recited in claim 58, wherein the first nonwoven layer is a spun bonded nonwoven construction including a plurality of fusion bonding points between the intermingled fiber elements.

60. The carpet as recited in claim 37, wherein said at least one additional layer comprises a nonwoven construction of nylon.

61. The carpet as recited in claim 60, wherein at least a portion of the intermingled fiber elements within the first nonwoven layer comprise stabilized polypropylene containing a nucleating agent.

62. The carpet as recited in claim 61, wherein the first nonwoven layer is a spun bonded nonwoven construction including a plurality of fusion bonding points between the intermingled fiber elements.

63. The carpet as recited in claim 37, wherein said at least one additional layer comprises at least one of a woven and a nonwoven construction of at least one of nylon, polyester, glass, polypropylene, stabilized polypropylene, and combinations thereof.

64. The carpet as recited in claim 63, wherein at least a portion of the interwoven fiber elements in the first woven layer are ribbon elements.

65. The carpet as recited in claim 64, wherein at least a portion of the ribbon elements comprise stabilized polypropylene containing a nucleating agent.

121. The carpet as recited in claim 37, wherein said carpet composite or construction is at least one of a carpet, broadloom carpet, rug, area rug, decorator rug, runner, rugget, and carpet tile.

122. The carpet as recited in claim 121, wherein said carpet composite or construction is cushioned.

132. In a method of producing a carpet composite or construction, the improvement comprising the step of using a primary backing as set forth in claim 37.

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.

67. The carpet as recited in claim 66, wherein said at least one additional layer comprises woven glass.

68. The carpet as recited in claim 67, wherein at least one of the opposing layers is a spun bonded nonwoven construction of intermingled fiber elements of polyester and including a plurality of fusion bonding points between the intermingled fiber elements.

69. The carpet as recited in claim 67, wherein at least one of the opposing layers is a spun bonded nonwoven construction of intermingled fiber elements of stabilized polypropylene containing a nucleating agent and including a plurality of fusion bonding points between the intermingled fiber elements.

70. The carpet as recited in claim 67, wherein said at least one additional layer further comprises a non-glass polymeric fiber constituent.

71. The carpet as recited in claim 66, wherein said at least one additional layer comprises nonwoven glass.

72. The carpet as recited in claim 71, wherein at least one of the opposing layers is a spun bonded nonwoven construction of intermingled fiber elements of polyester and including a plurality of fusion bonding points between the intermingled fiber elements.

73. The carpet as recited in claim 71, wherein at least one of the opposing layers is a spun bonded nonwoven construction of intermingled fiber elements of stabilized polypropylene containing a nucleating agent and including a plurality of fusion bonding points between the intermingled fiber elements.

74. The carpet as recited in claim 71, wherein said at least one additional layer further comprises a non-glass polymeric fiber constituent.

75. The carpet as recited in claim 66, wherein said at least one additional layer comprises woven stabilized polypropylene containing a nucleating agent.

76. The carpet as recited in claim 75, wherein at least one of the opposing layers is a spun bonded nonwoven construction of intermingled fiber elements of polyester and including a plurality of fusion bonding points between the intermingled fiber elements.

77. The carpet as recited in claim 75, wherein at least one of the opposing layers is a spun bonded nonwoven construction of intermingled fiber elements of stabilized polypropylene containing a nucleating agent and including a plurality of fusion bonding points between the intermingled fiber elements.

78. The carpet as recited in claim 75, wherein said at least one additional layer further comprises a non-glass polymeric fiber constituent.

79. The carpet as recited in claim 66, wherein said at least one additional layer comprises nonwoven stabilized polypropylene.

80. The carpet as recited in claim 79, wherein at least one of the opposing layers is a spun bonded nonwoven construction of intermingled fiber elements of polyester and including a plurality of fusion bonding points between the intermingled fiber elements.

81. The carpet as recited in claim 79, wherein at least one of the opposing layers is a spun bonded nonwoven construction of intermingled fiber elements of stabilized polypropylene containing a nucleating agent and including a plurality of fusion bonding points between the intermingled fiber elements.

82. The carpet as recited in claim 79, wherein said at least one additional layer further comprises a non-glass polymeric fiber constituent.

83. The carpet as recited in claim 66, wherein said at least one additional layer comprises woven polyester.

84. The carpet as recited in claim 83, wherein at least one of the opposing layers is a spun bonded nonwoven construction of intermingled fiber elements of polyester and including a plurality of fusion bonding points between the intermingled fiber elements.

85. The carpet as recited in claim 83, wherein at least one of the opposing layers is a spun bonded nonwoven construction of intermingled fiber elements of stabilized polypropylene containing a nucleating agent and including a plurality of fusion bonding points between the intermingled fiber elements.

86. The carpet as recited in claim 83, wherein said at least one additional layer further comprises a non-glass polymeric fiber constituent.

87. The carpet as recited in claim 66, wherein said at least one additional layer comprises nonwoven polyester.

88. The carpet as recited in claim 87, wherein at least one of the opposing layers is a spun bonded nonwoven construction of intermingled fiber elements of polyester and including a plurality of fusion bonding points between the intermingled fiber elements.

89. The carpet as recited in claim 87, wherein at least one of the opposing layers is a spun bonded nonwoven construction of intermingled fiber elements of stabilized polypropylene containing a nucleating agent and including a plurality of fusion bonding points between the intermingled fiber elements.

90. The carpet as recited in claim 87, wherein said at least one additional layer further comprises a non-glass polymeric fiber constituent.

91. The carpet as recited in claim 66, wherein said at least one additional layer comprises woven nylon.

92. The carpet as recited in claim 91, wherein at least one of the opposing layers is a spun bonded nonwoven construction of intermingled fiber elements of polyester and including a plurality of fusion bonding points between the intermingled fiber elements.

93. The carpet as recited in claim 91, wherein at least one of the opposing layers is a spun bonded nonwoven construction of intermingled fiber elements of stabilized polypropylene containing a nucleating agent and including a plurality of fusion bonding points between the intermingled fiber elements.

94. The carpet as recited in claim 91, wherein said at least one additional layer further comprises a non-glass polymeric fiber constituent.

95. The carpet as recited in claim 66, wherein said at least one additional layer comprises nonwoven nylon.

96. The carpet as recited in claim 95, wherein at least one of the opposing layers is a spun bonded nonwoven construction of intermingled fiber elements of polyester and including a plurality of fusion bonding points between the intermingled fiber elements.

97. The carpet as recited in claim 95, wherein at least one of the opposing layers is a spun bonded nonwoven construction of intermingled fiber elements of stabilized polypropylene containing a nucleating agent and including a plurality of fusion bonding points between the intermingled fiber elements.

98. The carpet as recited in claim 95, wherein said at least one additional layer further comprises a non-glass polymeric fiber constituent.

123. The carpet as recited in claim 66, wherein said carpet composite or construction is at least one of a carpet, broadloom carpet, rug, area rug, decorator rug, runner, rugget, and carpet tile.

124. The carpet as recited in claim 123, wherein said carpet composite or construction is cushioned.

133. In a method of producing a carpet composite or construction, the improvement comprising the step of using a primary backing as set forth in claim 66.

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.

100. The carpet as recited in claim 99, wherein the fibrous capping layer is selected from the group consisting of woven constructions, nonwoven constructions and semi-aligned carded fibers.

101. The carpet as recited in claim 99, wherein the fibrous capping layer comprises a multiplicity of intermingled staple fibers selected from the group consisting of polyester staple fibers, polypropylene staple fibers and mixtures thereof.

102. The carpet as recited in claim 99, wherein the fibrous capping layer comprises stabilized polypropylene fibers containing a nucleating agent.

103. The carpet as recited in claim 99, wherein the primary backing has at least three layers.

104. The carpet as recited in claim 99, wherein the primary backing has at least four layers.

105. The carpet as recited in claim 99, wherein said at least a first woven or nonwoven layer is in adjoined relation to at least a second fibrous capping layer disposed in substantially opposing relation to the first fibrous capping layer such that the primary backing has not less than three layers.

106. The carpet as recited in claim 105, wherein the primary backing has at least four layers.

107. The carpet as recited in claim 105, wherein the primary backing has at least five layers.

125. The carpet as recited in claim 99, wherein said carpet composite or construction is at least one of a carpet, broadloom carpet, rug, area rug, decorator rug, runner, rugget, and carpet tile.

126. The carpet as recited in claim 125, wherein said carpet composite or construction is cushioned.

134. In a method of producing a carpet composite or construction, the improvement comprising the step of using a primary backing as set forth in claim 99.

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.

109. The carpet as recited in claim 108, wherein the cushioning underlayer comprises a cellular foam.

110. The carpet as recited in claim 109, wherein the cellular foam is polyurethane.

111. The carpet as recited in claim 108, wherein the cushioning underlayer is a textile material.

112. The carpet as recited in claim 108, wherein the cushioning underlayer comprises a rebond foam.

113. The carpet as recited in claim 108, wherein said adhesive layer is at least one of a polymeric adhesive, resilient adhesive, hot melt adhesive, latex adhesive, and combinations thereof.

114. The carpet as recited in claim 108, wherein the carpet is free of any functional stabilizing layer between the primary backing and the cushioning underlayer.

127. The carpet as recited in claim 108, wherein said carpet composite or construction is at least one of a carpet, broadloom carpet, rug, area rug, decorator rug, runner, rugget, and carpet tile.

128. The carpet as recited in claim 127, wherein said carpet composite or construction is cushioned.

135. In a method of producing a carpet composite or construction, the improvement comprising the step of using a primary backing as set forth in claim 108.