Primary carpet backing

Abstract

A primary carpet backing including a structure of at least three layers, wherein a first layer and a third layer including a nonwoven layer of fibers, and wherein a second layer which includes a reinforcement layer of fibers and is located between the first and the third layer, wherein the nonwoven layer of fibers of the first layer has an air permeability of at most 8000 L/m2·s and the nonwoven layer of fibers of the third layer has an air permeability of at least 1000 L/m2·s measured according to ISO 9237:1995, wherein the nonwoven layer of fibers of the first layer has a lower air permeability as the nonwoven layer of fibers of the third layer.

1 . A material for a primary carpet backing comprising a structure of at least three layers, wherein a first layer and a third layer comprise a nonwoven layer of fibers, and wherein a second layer comprises a reinforcement layer of fibers and is located between the first and the third layer, wherein the nonwoven layer of fibers of the first layer has an air permeability of at most 8000 l/m 2 ·s, and the nonwoven layer of fibers of the third layer has an air permeability of at least 3500 l/m 2 ·s measured according to ISO 9237:1995, wherein the nonwoven layer of fibers of the first layer has a lower air permeability than the nonwoven layer of fibers of the third layer. 
     
     
         2 . The material according to  claim 1 , wherein a weight ratio of the first layer and the second layer is at least 60:40. 
     
     
         3 . The material according to  claim 1 , wherein the fibers of the first layer have an average diameter, which is smaller than an average diameter of the fibers of the third layer. 
     
     
         4 . The material according to  claim 3 , wherein the fibers of the first layer have an average diameter of at most 50 μm and/or the fibers of the third layer have an average diameter of at least 30 μm. 
     
     
         5 . The material according to  claim 1 , wherein nonwoven layer of fibers of the first layer and/or the nonwoven layer of fibers of the third layer comprise mono-component fibers, two types of mono-component fibers and/or bicomponent fibers. 
     
     
         6 . The material according to  claim 1 , wherein the nonwoven layer of fibers of the first layer and/or the nonwoven layer of fibers of the third layer are made by a spun-laid process, wherein the fibers are made from a thermoplastic polymeric material. 
     
     
         7 . The material according to  claim 1 , wherein the reinforcement layer is a laid scrim, a woven scrim or a unidirectional layer of fibers, wherein the fibers of the unidirectional layer of fibers are aligned substantially parallel to each other in the machine direction. 
     
     
         8 . The material according to  claim 1 , wherein the reinforcement layer is made of high modulus fibers or filaments. 
     
     
         9 . The material according to  claim 1 , wherein the nonwoven layer of fibers of the first layer has an air permeability of at most 7000 l/m 2 ·s, measured according to ISO 9237:1995. 
     
     
         10 . The material according to  claim 1 , wherein the air permeability of the nonwoven layer of fibers of the third layer is of at least 5000 l/m 2 ·s, measured according to ISO 9237. 
     
     
         11 . A tufted carpet comprising material according to  claim 1 , comprising pile yarns tufted into the primary carpet backing, optionally a secondary carpet backing, adjoining on the side of the primary carpet backing which is not the carpet face, and/or optionally a precoat and/or a polymer coat. 
     
     
         12 . The tufted carpet according to  claim 11 , wherein the secondary carpet backing comprises a reinforcement layer. 
     
     
         13 . The tufted carpet according to  claim 12 , wherein the secondary carpet backing comprises a composite of at least three layers comprising two nonwoven layers of fibers and the reinforcement layer is located between the two spunbonded nonwoven layers of fibers, wherein the secondary carpet backing has an air permeability of at least 1000 l/m 2 ·s, measured according to ISO 9237:1995. 
     
     
         14 . The tufted carpet according to  claim 13 , wherein the fibers of the two nonwoven layer of fibers of the secondary carpet backing comprises have an average diameter of at least 30 μm. 
     
     
         15 . A process of producing a tufted carpet according  claim 11  by tufting a primary carpet backing, supplying a secondary carpet backing to the tufted primary carpet backing, on the side of the tufted primary carpet backing which is not the carpet face, and supplying a precoat into and/or onto the secondary backing from the side of the secondary carpet backing which is not facing the primary carpet backing, and optionally a polymer coating.