The present invention pertains to carpet and method of making it. In one aspect, the carpet includes (a) a primary backing which has a face and a back surface, (b) a plurality of fibers attached to the primary backing and extending from the face of the primary backing and exposed at the back surface of the primary backing, (c) an adhesive backing, (d) an optional secondary backing adjacent to the adhesive backing, and (e) at least one homogeneously branched linear ethylene polymer. The method includes extrusion coating at least one homogeneously branched linear ethylene polymer onto the back surface of a primary backing to provide an adhesive backing. The method can include additional steps or procedures, either separately or in various combinations. Additional steps and procedures include preheating the primary backing prior the extrusion step, multilayer adhesive backings, washing or scouring the primary backing prior the extrusion step, and utilizing adhesive polymeric additives, high heat content fillers, blowing agents and/or implosion agents. The constructions and methods described herein are particularly suited for making carpet tile.

Carpet, carpet backings and methods

Lamination of a tufted, primary carpet backing to a secondary backing is conducted using a composite hot melt adhesive in sheet form. The composite adhesive overcomes the unfavorable temperature-viscosity gradient within the carpet structure during the lamination process, yielding tufted pile carpets with good tuft encapsulation, tuft bind strength and delamination strength. Also disclosed are hot melt adhesive compositions suitable for use in sheet form in such a process.

Method for preparing tufted pile carpet and adhesive therefor

Thermoplastic compositions are disclosed which are useful as backings for automotive carpets. The thermoplastic compositions contain a high filler content of at least 60 percent by weight, about 5 to 25 percent by weight of an ethylene homopolymer or copolymer, about 1 to 10 percent by weight of a non-vulcanized elastomeric resin and about 1 to 15 percent by weight of a plasticizer. Preferably a low viscosity precoat of polyethylene or ethylene/vinyl acetate copolymer is applied to the carpet prior to the application of the thermoplastic backing. The backet automotive carpet is moldable, withstands both high and low temperatures, possesses outstanding sound absorbing properties and can be produced economically.

Thermoplastic compositions and automotive carpeting backed therewith

The present invention pertains to foam cushion backings comprising at least one homogeneously branched ethylene polymer (HBEP) or a substantially linear ethylene polymer (SLEP). More particularly, the present invention pertains to foam cushion backings suitable for use in carpets and carpet tile products. The present invention further pertains to foam cushion-backed carpet and carpet tile products. The present invention further pertains to methods of making such foam cushion backings and carpet and carpet tiles as described herein.

Carpet structure with plastomeric foam backing

Sound absorbing/sound blocking products, including trim products formed from a porous fibrous layer backed by a sound absorbing layer and a sound blocking layer for use within vehicles, and methods of making same, are provided. A porous fibrous layer structure including a fibrous layer backing is heated to achieve a fluid or semi-fluid state and then subjected to vacuum to draw air through the fibrous layer backing to create a porous structure. A layer of sound absorbing and a layer of sound blocking material may be applied to the porous fibrous layer backing to provide improved acoustic properties. An underlayment may further be included to provide selected areas of increased thickness and provide tailoring of sound attenuation.

Sound absorbing/sound blocking automotive trim products

An aqueous ethylene copolymer dispersion, from which an improved water-repellent coating can be applied, is provided. The dispersion comprises a dispersion of an ethylene ionic copolymer and a paraffin wax held in dispersed phase by an amine soap surfactant and a terpolymer of vinyl acetate, ethylene and Nmethylol acrylamide. A fabric having thereon a coating of the dispersed phase of the dispersion and a process for preparing the coated fabric are also provided.

Ethylene copolymer dispersions as water repellent coatings

AUTOMOTIVE CARPET BACKSIZING COMOSITIONS ARE DISCLOSED WHICH HAVE SUPERIOR ADHEXIVE PROPERTIES AND CAN BE USED TO PREPARE CARPETS WITH IMPROVED SHAPE RETENTION. THE COMPOISTIONS CONTAIN BLENDS OF PARTICULAR ETHYLENE/ VINYL ESTER COPOLYMERS AND MICROCRYSTALLINE OR FISCHERTROPSCH WAXES HAVING MELTING POINTS OF AT LEAST 165*F. AND NEEDLE POINT PENETRATION VALUES OF LESS THAN 10. OPTIONALLY, THE COMPOSITIONS CAN CAONTAIN A POLYOLEFIN SUCH AS POLYETHYLENE.

Roland Edgar Stahl

Papers

Ethylene copolymer dispersions as water repellent coatings

Automotive carpet backsizing composition