Carpet compositions having laminated film backings and methods for making same

Abstract

A carpet composition comprising a tufted yarn locked in place by a laminated film and methods of making same are disclosed.

1 . A carpet composition comprising:
 (a) a greige good comprising:
 i) a primary backing material having a face surface and a back surface; 
 ii) a plurality of fibers attached to the primary backing material, wherein a portion of the plurality of fibers extends from the face surface of the primary backing and wherein a second portion of the plurality of fibers are exposed on the back surface of the primary backing in a form of backstitches; and 
   (b) a film laminated on the backstitches to secure the plurality of fibers in place.   
     
     
         2 . The carpet composition of  claim 1 , wherein the carpet composition does not comprise a precoat. 
     
     
         3 . The carpet composition of  claim 1 , wherein the film comprises a first thermoplastic polymer. 
     
     
         4 . The carpet composition of  claim 3 , wherein the first thermoplastic polymer comprises a polyamide, a polyolefin, a polyester, or combinations thereof. 
     
     
         5 . The carpet composition of  claim 4 , wherein the primary backing comprises a second thermoplastic polymer. 
     
     
         6 . The carpet composition of  claim 5 , wherein the plurality of fibers comprises a third thermoplastic polymer. 
     
     
         7 . The carpet composition of  claim 6 , wherein the first thermoplastic polymer is substantially similar to the second and/or the third thermoplastic polymer. 
     
     
         8 . The carpet composition of  claim 6 , wherein the first thermoplastic polymer is the same as the second thermoplastic polymer. 
     
     
         9 . The carpet composition of  claim 6 , wherein the first thermoplastic polymer is the same as the third thermoplastic polymer. 
     
     
         10 . The carpet composition  claim 6 , wherein the first thermoplastic polymer is a blend of the second and the third thermoplastic polymers. 
     
     
         11 . The carpet composition of  claim 5 , wherein the second thermoplastic polymer comprises a polyamide, a polyolefin, a polyester, or combinations thereof. 
     
     
         12 . The carpet composition of  claim 6 , wherein the third thermoplastic polymer comprises a polyamide, a polyolefin, a polyester, or a combination thereof. 
     
     
         13 . The carpet composition of  claim 3 , wherein the first thermoplastic polymer composition comprises from 0 wt % to 100 wt % of a recycled polymer. 
     
     
         14 . The carpet composition of  claim 5 , wherein the second thermoplastic polymer composition comprises from 0 wt % to 100 wt % of a recycled polymer. 
     
     
         15 . The carpet composition of  claim 6 , wherein the third thermoplastic polymer composition comprises from 0 wt % to 100 wt % of a recycled polymer. 
     
     
         16 . The carpet composition of  claim 4 , wherein the polyolefin comprises a polyethylene and copolymers thereof, a polypropylene and copolymers thereof, or a combination thereof. 
     
     
         17 . The carpet composition of  claim 4 , wherein the polyolefin comprises, a low density polyethylene (LDPE), a linear low-density polyethylene (LLDPE), ultra low density polyethylene (ULDPE), very low density polyethylene (VLDPE), medium density polyethylene (MDPE), high density polyethylene (HDPE), a grafted polyethylene, heterogeneously branched ethylene polymer (HBEP), substantially linear ethylene polymer (SLEP), polypropylene, or a combination thereof. 
     
     
         18 . The carpet composition of  claim 4 , wherein the polyester comprises polyethylene terephthalate, polypropylene terephthalate, polybutylene terephthalate, copolymers thereof, or any combination thereof. 
     
     
         19 . The carpet composition of  claim 1 , wherein the film further comprises polyvinyl butyral (PVB), acrylic based materials, ethylene acrylic acetate (EAA), ethylene vinyl acetate (EVA), ethylene methyl acrylate (EMA), or a combination thereof. 
     
     
         20 . The carpet composition of  claim 1 , wherein the film has a thickness from about 0.001 inch to about 0.010 inch. 
     
     
         21 . The carpet composition of  claim 1 , wherein the carpet composition exhibits a tuft bind strength of at least 4 pounds as measured according to ASTM D1335. 
     
     
         22 . The carpet composition of  claim 1 , wherein the carpet composition exhibits a slip bind from 1 lb to 3 lb as measured according to ASTM D1335. 
     
     
         23 . The carpet composition of  claim 1 , wherein the carpet composition exhibits a grab/tear fill of 75 lb to 500 lb as measured according to ASTM D5034 at 150 min. 
     
     
         24 . The carpet composition of  claim 1 , wherein the carpet composition exhibits a grab/tear warp of 75 lb to 500 lb as measured according to ASTM D5034 at 150 min. 
     
     
         25 . The carpet composition of  claim 1 , wherein the carpet composition exhibits a load at 5% expansion of 30 lb to 250 lb in a machine direction as measured according to ASTM D5034. 
     
     
         26 . The carpet composition of  claim 1 , wherein the carpet composition exhibits a load at 5% expansion of 30 lb to 150 lb in a cross direction as measured according to ASTM D5034. 
     
     
         27 . The carpet composition of  claim 1 , wherein the carpet composition exhibits an elongation in a machine direction (fill) of 30 to 80 lbs as measured according to ASTM D5034. 
     
     
         28 . The carpet composition of  claim 1 , wherein the carpet composition exhibits an elongation in a cross direction (warp) of 30 to 80 lbs as measured according to ASTM D5034. 
     
     
         29 . The carpet composition of  claim 1 , wherein the carpet composition exhibits a maximum load at 45° of about 80 to about 500 lbs as measured according to ASTM D5034. 
     
     
         30 . The carpet composition of  claim 1 , wherein the carpet composition exhibits a maximum load at 45° at 5% expansion of about 30 to about 100 lbs as measured according to ASTM D5034. 
     
     
         31 . The carpet composition of  claim 1 , wherein the carpet composition further comprises a secondary backing. 
     
     
         32 . The carpet composition of  claim 31 , wherein the secondary backing comprises a tape-tape yarn, a tape-spun yarn, or a combination thereof. 
     
     
         33 . The carpet composition of  claim 31 , wherein the secondary backing further comprises a fiberglass. 
     
     
         34 . The carpet composition of  claim 1 , wherein the carpet composition is recyclable. 
     
     
         35 . The carpet composition of  claim 1 , wherein the carpet composition is an artificial turf. 
     
     
         36 . A method of making a carpet composition comprising:
 (a) providing a greige good composition comprising:
 i) a primary backing material having a face surface and a back surface; and 
 ii) a plurality of fibers attached to the primary backing material, wherein a portion of the plurality of fibers extends from the face surface of the primary backing and wherein a second portion of the plurality of fibers are exposed on the back surface of the primary backing in a form of backstitches; 
   (b) providing a film;   (c) laminating the film on the backstitches to secure the plurality of fibers in place.   
     
     
         37 . The method of  claim 36 , wherein the laminating is done at a temperature from about 300° F. to about 450° F. 
     
     
         38 . The method of  claim 36 , wherein the carpet composition is preheated prior to the step c) to a temperature from about 150° F. to about 200° F. 
     
     
         39 . The method of  claim 36 , wherein the film is integrally fused with the backstitches, so that substantially all of the plurality of fibers are secured in place.