Carpets with improved fuzz-resistance

Abstract

Tufted carpets bonded with thermoplastic binders and having improved resistance to fuzz formation due to removal of pile yarn filaments from tuft bundles comprise one or more backings, face yarn that forms a pile on one side and stitches on an opposite side, a thermoplastic binder that binds stitches and the backing or backings, and an organic polymer that bonds filaments of the stitches. Processes for making carpets comprise applying to a stitched side of a tufted backing a liquid stitch bind composition comprising an organic polymer component, removing a liquid component of the composition to bond filaments of the stitches and bonding stitches and one or more backings with a thermoplastic binder that is melted or applied as a melt in contact with the stitched side and the backing or backings and solidified.

1 - 27 . (canceled)  
   
   
       28 . A tufted carpet comprising: 
 a backing;    face yarn comprising a plurality of filaments;    an organic polymer component;    a thermoplastic binder, wherein the face yarn penetrates the backing such that a plurality of tufts of the face yarn project from a surface of the backing, wherein the thermoplastic binder consists entirely or essentially of a thermoplastic polyethylene-having flow properties corresponding to an MI of about 2.2 to about 105 g/10 min. as measured in accordance with ASTM D 1238; and a viscosity between approximately 230,000 and 4,881,000 cps at about 270° F. with a shear rate of about 10 sec −1  as measured in accordance with ASTM D 3835;    a plurality of face yarn stitches are disposed on an opposite surface of the backing;    a plurality of filaments of the face yarn stitches are bonded by the organic polymer component; and    a plurality of stitches are bonded within the tufted carpet with the thermoplastic binder.    
   
   
       29 . The carpet of  claim 28 , further comprising a secondary backing that is bonded to a stitched surface of the backing with the thermoplastic binder.  
   
   
       30 . The carpet of  claim 28 , having a Fuzz Rating of 4 or less.  
   
   
       31 . The carpet according to  claim 28 , having a tuft bind strength of at least about 2 pounds.  
   
   
       32 . The carpet according to  claim 28 , having a tuft bind strength of at least about 5 pounds.  
   
   
       33 . The carpet according to  claim 28 , containing less than 3 osy crosslinked polymer solids.  
   
   
       34 . The carpet according to  claim 28 , wherein the organic polymer has a weight of 0.2 to 3 ounces per square yard of stitched surface of the tufted carpet.  
   
   
       35 . The carpet of  claim 28 , wherein the backing comprises a woven polypropylene fabric tufted with face yarn.  
   
   
       37 . The carpet of  claim 28 , wherein the face yarn comprises nylon filaments.  
   
   
       38 . The carpet of  claim 28 , wherein the face yarn comprises polyester filaments.  
   
   
       39 . A carpet comprising: 
 a backing comprising a stitched side;    face yarn comprising a plurality of filaments;    a stitch bind composition comprising an organic polymer component, the stitch bind composition joined with the stitched side of the backing;    a thermoplastic binder, wherein the face yarn penetrates the backing such that a plurality of tufts of the face yarn project from a surface of the backing opposite to the stitched side of the backing, wherein the thermoplastic binder consists entirely or essentially of a thermoplastic polyethylene-having flow properties corresponding to an MI of about 2.2 to about 105 g/10 min. as measured in accordance with ASTM D 1238; and a viscosity between approximately 230,000 and 4,881,000 cps at about 270° F. with a shear rate of about 10 sec −1  as measured in accordance with ASTM D 3835;    a plurality of filaments of face yarn stitches are bonded by stitch bind composition on the stitched side of the backing; and    a plurality of stitches are bonded within the carpet with the thermoplastic binder.    
   
   
       40 . The carpet of  claim 39 , wherein the thermoplastic binder comprises a nonwoven fabric needled to the backing.  
   
   
       41 . The carpet of  claim 39 , wherein the organic polymer component comprises a film-forming organic polymer.  
   
   
       42 . The carpet of  claim 39 , wherein the organic polymer component comprises a thermoplastic polymer.  
   
   
       43 . The carpet of  claim 39 , wherein the organic polymer component comprises a crosslinkable organic polymer.  
   
   
       44 . The carpet of  claim 39 , wherein the stitch bind composition comprises a crosslinking agent for the organic polymer.  
   
   
       45 . The carpet of  claim 39 , wherein the organic polymer component comprises an olefin-unsaturated acid, olefin-unsaturated acid ester or olefin-diene copolymer.  
   
   
       46 . The carpet of  claim 39 , wherein the organic polymer component comprises an ethylene acrylic acid copolymer.  
   
   
       47 . The carpet of  claim 39 , wherein the organic polymer component comprises a styrene acrylate copolymer.  
   
   
       48 . The carpet of  claim 39 , wherein the organic polymer component comprises a carboxylated styrene butadiene copolymer.