Primary carpet backing and tufted carpet comprising the same

Abstract

A primary carpet backing having at least a nonwoven layer of fibers, the nonwoven layer of fibers including fibers having a higher melting component and a lower melting component, wherein the fibers are 12 to 20 vol. % of the lower melting component. After tufting, a tufted carpet backing having the primary carpet backing exhibits improved stitch holding performance.

1 . A primary carpet backing comprising a nonwoven layer of fibers, wherein the nonwoven layer of fibers comprises fibers comprising two components, a first melting component and a second melting component that melts at a temperature lower than the first melting component, wherein the fibers are 12 to 20 vol. % of the second melting component. 
     
     
         2 . The primary carpet backing according to  claim 1  wherein the fibers are 14 to 18 vol. % of the second melting component. 
     
     
         3 . The primary carpet backing according to  claim 1  wherein the nonwoven layer of fibers has a uniform composition throughout the nonwoven layer of fibers. 
     
     
         4 . The primary carpet backing according to  claim 1  wherein the fibers are bicomponent fibers. 
     
     
         5 . The primary carpet backing according to  claim 4  wherein the bicomponent fibers are core/sheath bicomponent fibers. 
     
     
         6 . The primary carpet backing according to  claim 5  wherein the bicomponent fibers consist of a polyester core and a polypropylene sheath. 
     
     
         7 . The primary carpet backing according to  claim 5  wherein the bicomponent fibers consist of a polyester core and a polyamide sheath. 
     
     
         8 . The primary carpet backing according to  claim 4  any of the preceding claims wherein the primary carpet backing is thermally bonded by means of the second melting component of the bicomponent fibers. 
     
     
         9 . The primary carpet backing according to  claim 1  wherein the carpet backing comprises additional layers of fibers selected from a nonwoven layer of fibers, a woven layer of fibers or a scrim. 
     
     
         10 . A tufted carpet comprising the primary carpet backing according to  claim 1 . 
     
     
         11 . The primary carpet backing according to  claim 1  wherein the fibers are 15 to 17 vol. % of the second melting component. 
     
     
         12 . The primary carpet backing according to  claim 1  wherein the fibers are 16 vol. % of the second melting component. 
     
     
         13 . The primary carpet backing according to  claim 1  wherein the fibers have a linear density in the range of 1 to 25 dtex. 
     
     
         14 . The primary carpet backing according to  claim 1  wherein the fibers are filaments. 
     
     
         15 . The primary carpet backing according to  claim 1  wherein the second melting component has a melting temperature at least 5° C. lower than the melting temperature of the first melting component.