Secondary carpet backing and buckling resistant carpet made therefrom

Abstract

An improved secondary carpet backing fabric imparts increased resistance to buckling in carpets compared to conventional widely used secondary backings while providing the performance of conventional secondary carpet backings (e.g., similar peel strength, tuft bind, ease of handling). The improved backing is produced by a one-step weaving process and can be converted easily into carpet using current carpet making techniques. The inventive secondary carpet backing contains core-spun filling yarn with specific properties and is preferably woven in a leno or plain weave. Compared to carpets with conventional secondary backings, carpets with the inventive secondary backings display reduced growth in cyclic tensile testing.

1 . An improved secondary carpet backing, comprising a core-spun fill yarn, said core-spun fill yarn further comprising: 
 a total denier, determined according to ASTM D-1907, of 800 to 3000;    a tenacity, determined according to ASTM D-2256, of about 3 grams per denier to about 7 grams per denier;    an elongation at peak load, determined according to ASTM D-2256, between 8% and 30%;    a sheath; and    a core component inside of the sheath, the core component comprising a yarn with a denier, determined according to ASTM D-1907, of 50% or less of the total denier for the core-spun fill yarn.    
   
   
       2 . The improved secondary carpet backing according to  claim 1 , wherein said core component comprises a polyester yarn.  
   
   
       3 . The improved secondary carpet backing according to  claim 1 , wherein said core component comprises a polypropylene yarn.  
   
   
       4 . The improved secondary carpet backing according to  claim 1  wherein said core component comprises a high tenacity, low shrinkage continuous filament polyester yarn.  
   
   
       5 . The improved secondary carpet backing according to  claim 1  wherein said core component comprises a high tenacity, continuous filament polypropylene yarn.  
   
   
       6 . The improved secondary carpet backing according to  claim 1  wherein said core component comprises a fiberglass continuous filament yarn.  
   
   
       7 . The improved secondary carpet backing according to  claim 1  wherein said denier of the core component is between about 400 and 1500.  
   
   
       8 . The improved secondary carpet backing according to  claim 1 , wherein said sheath comprises staple fibers.  
   
   
       9 . The improved secondary carpet backing according to  claim 8 , wherein said sheath of staple fibers comprises polyester.  
   
   
       10 . The improved secondary carpet backing according to  claim 8 , wherein said sheath of staple fibers comprises polypropylene.  
   
   
       11 . The improved secondary carpet backing according to  claim 1 , wherein said secondary carpet backing further comprises a leno weave.  
   
   
       12 . The improved secondary carpet backing according to  claim 1 , wherein said core-spun fill yarn comprises friction spun yarn.  
   
   
       13 . The improved secondary carpet backing according to  claim 12 , wherein said core-spun fill yarn comprises DREF spun yarn.  
   
   
       14 . The improved secondary carpet backing according to  claim 1 , wherein said secondary carpet backing further comprises eight to thirty warp ends per inch and three to twenty picks per inch.  
   
   
       15 . The improved secondary carpet backing according to  claim 1 , wherein said secondary carpet backing further comprises sixteen warp ends per inch and five fill yarns per inch.  
   
   
       16 . The improved secondary carpet backing according to  claim 1 , wherein said secondary carpet backing comprises a plain weave.  
   
   
       17 . The improved secondary carpet backing according to  claim 1 , said secondary carpet backing further comprising a fill yarn that does not comprise a core-spun fill yarn.  
   
   
       18 . The improved secondary carpet backing according to  claim 1 , said secondary carpet backing further comprising a warp yarn, said warp yarn comprising a polypropylene tape yarn or a high strength, low shrinkage continuous filament PET yarn with a denier, determined according to ASTM D-1907, of about 200-800.  
   
   
       19 . An improved carpet, comprising: 
 a primary backing;    a secondary carpet backing, said secondary carpet backing comprising a core-spun fill yarn, said core-spun fill yarn comprising: p 2  a total denier, determined according to ASTM D-1907, of about 800 to 3000; 
 a tenacity, determined according to ASTM D-2256, of about 3 grams per denier to about 7 grams per denier; and  
 an elongation at peak load, determined according to ASTM D-2256, between 8% and 30%;  
 a sheath; and  
 a core component inside of the sheath, the core component comprising a yarn with a denier, determined according to ASTM D-1907, of 50% or less of the total denier for the core-spun fill yarn.  
   
   
   
       20 . The improved carpet according to  claim 19 , wherein said core component comprises a polyester yarn.  
   
   
       21 . The improved carpet according to  claim 19 , wherein said core component comprises a polypropylene yarn.  
   
   
       22 . The improved carpet according to  claim 19 , wherein said core component comprises a fiberglass yarn.  
   
   
       23 . The improved carpet according to  claim 19  through  claim 22 , wherein said core component has a denier between 400 and 1500.  
   
   
       24 . The improved carpet according to  claim 19 , wherein said sheath comprises staple fibers.  
   
   
       25 . The improved carpet according to  claim 19 , wherein said sheath of staple fibers comprises polypropylene.  
   
   
       26 . The improved carpet according to  claim 19 , wherein said sheath of staple fibers comprises polyester.  
   
   
       27 . The improved carpet according to  claim 19 , wherein said secondary carpet backing further comprises a leno weave.  
   
   
       28 . The improved carpet according to  claim 19 , wherein said core-spun fill yarn comprises friction spun yarn.  
   
   
       29 . The improved carpet according to  claim 28 , wherein said core-spun fill yarn comprises DREF spun yarn.  
   
   
       30 . The improved carpet according to  claim 19 , wherein said secondary carpet backing further comprises sixteen warp ends per inch and five fill yarns per inch.  
   
   
       31 . The improved carpet according to  claim 19 , wherein said secondary carpet backing further comprises a plain weave.  
   
   
       32 . The improved carpet according to  claim 19 , said secondary carpet backing further comprising a fill yarn that yarn that does not comprise a core-spun fill yarn.  
   
   
       33 . The improved carpet according to  claim 19 , said secondary carpet backing further comprising a warp yarn, said warp yarn comprising a polypropylene tape yarn or a high strength, low shrinkage continuous filament PET yarn with a denier, determined according to ASTM D-1907, of about 200-800.