MX2007010461A - Composite secondary carpet backing, method of manufacture thereof, and carpet made therefrom - Google Patents

Abstract

A two-layer secondary carpet backing including a woven scrim layer and a fibrous layer is described. The woven scrim layer is characterized as having a low open area and a flat weave. The two-layer secondary backing is capable of having a non-abrasive, textile back surface. The secondary carpet backing is also capable of having a construction that permits high carpet manufacturing speeds due to high air permeability and is capable of providing high dimensional stability, seam strength, and delamination strength to tufted carpets made therefrom.

Description

BACKING FOR COMPOUND SECONDARY CARPET, METHOD FOR DEVELOPING THE CARPET, AND CARPET PRODUCED FROM THE SAME FIELD OF THE INVENTION The present invention relates in general to materials for carpet backing, and more specifically cor. a backing for composite secondary carpet having two layers, wherein one layer comprises a layer of woven fabric having a planar weft construction and a low open area weft. The backing for composite secondary carpet is suitable for carpet manufacturing at high speeds and imparts dimensional stability and resilience to the removal of a carpet structure.

BACKGROUND OF THE INVENTION Carpets in general comprise a primary backing structure, front strand, a binder and, in many cases, a backing for secondary carpet. The front strand penetrates the primary backing structure to form tufts that project from one side, providing a hair surface, and stitches on an opposite side. The binder is present on the side with stitches, encapsulating and adhering the stitches to the anchor support structure: - the tufts. The backs for secondary carpet, usually adhere to the stitching with the binder. The binder typically comprises more than 80 weight percent of a milled inorganic solid such as, for example, calcium carbonate, in a styrene-butadiene or acetate-and-vinyl vinyl latex. Carpets are typically manufactured by tufting the front strand through a primary backing structure with alternate needles that carry the front strand back and forth through the structure to form the tufts and stitches, applying a binder formulation, usually as an aqueous latex for filling with inert macro-particles of an organic polymer, on the side with stitches, and curing the binder by heating for the extraction of water or other liquids. The backing for secondary carpet is usually rolled to the side with stitching, when producing it and the stitched side of the tufted structure together with the binder applied to the lacquer with stitches, or with the binder applied to both side with stitches of the structure primary backup as to the backing for secondary carpet, and cure the binder in contact with the side with stitches and the backing for secondary carpet. Curing, also commonly referred to as drying, typically involves heating the building with hot air, as in a carpet finishing oven. In the manufacture of carpets, the backing for secondary carpet, performs various functions. Typically, it imparts dimensional stability to the finished carpet and increases plume bonding. Dimensional stability is the capacity of the carpet to resist deformation in use after stretching. In general, the dimensional stability increases when the force required to separate (or detach) the backing for secondary carpet from the binder increases. Another problem with carpet performance is the ease of sewing them. The backing for secondary carpet, must allow the carpet to be joined with a sewing tape without distorting the appearance of the right side while forming strong bonds that can resist installation with a power draw. In addition to its contribution to carpet performance, the secondary carpet backing provides static and, in some cases, isolates the binder / filler abrasive mixture that is used to join the stitches on the underside of the carpet. The isolation of the binder / filler abrasive mix is important to minimize scratches to the walls and joinery during installation. For secondary, commercially viable carpet backings, fabrics must also meet critical requirements in the carpet manufacturing process. For example, the backs must have enough integrity so that they can be unrolled, coated and laminated to the back of the carpet without significant distortion of the spike line. They should also allow the carpet to be manufactured to. Online speeds that result in low rolling costs. A carpet backing property that correlates with faster in-line speeds is air permeability. Therefore, during the curing (or drying) of the binder / filler mixture, the backing should not act as a barrier to prevent the escape of volatilized liquids. Carpets that have incompletely cured binders have less resistance to delamination, less dimensional stability, and fewer plume joints, and less resistance to moisture than equivalent carpets with fully cured binders. These considerations determine that the ideal secondary carpet backing must meet many different requirements. Among others, it must be capable of imparting dimensional stability, forming a strong bond with the binder of the carpet and a tape in the seam of the carpet, which allows a rapid process of rolling the carpet, and prevent the abrasive binder mixture / filling causes damage. The design of secondary carpet backings that meet these requirements is complicated, since the structural characteristics that lead to good drying (ie, an open structure) may be in conflict with the characteristics to contain the filling and impart dimensional stability increased. Studies carried out by the inventors have shown that with the secondary carpet backings of cotton weave used today, it is not possible to predict with certainty the exact contribution of a secondary carpet backing to the dimensional stability of the finished carpets to the wide range of styles, weights and other characteristics of the carpets in which secondary backs are used for carpets. The inventors have also found the interactions of backings and binders within finished carpets when subjected to forces that are not well defined. In fact, studies of backs for common secondary carpets have shown a lack of correlation between the dimensional stability of the finished carpets and the properties of the carpet backing fabrics in them, which suggests that the capacity of these backs to impart stability dimensional is best calibrated from the performance of the carpet itself. The cotton weft is a weft in which the warp yarns are arranged in pairs that twist around the filling yarns. The most common secondary carpet backing that is currently used is an open weft fabric with a cotton weft construction in a warp count of 16 ends per inch (wpi) and a fill count of 5 peaks per inch (ppi, for its acronym in English). This product has polypropylene ribbon yarns in the warp direction and spun yarns in the fill direction. It combines low cost with the ability to provide adequate dimensional stability and resistance to delamination in the carpets that are manufactured. high online speeds ..

However, a disadvantage of using an open weave secondary carpet backing is that the binder / filler mixture is exposed on the underside of the finished carpet. This causes the underside of the carpet to have an unattractive appearance and an abrasive texture due to the exposed filler / binder mixture. This abrasive mixture of cured binder stiff, often causes scratching of the walls and carpentry when these carpets are installed. Figure 1 exemplifies a conventional cotton weft construction. This conventional technique does not constitute an admission of the priority of this figure being available as a reference against the technology of the applicants, or a waiver of any right that the applicant may have in accordance with the applicable statutes of the practice. As depicted, the construction 100 comprises warps 130 and wefts disposed 120 in a 16-warp-per-inch (wpi) cotton fabric construction per 5 po / inch (ppi) peaks · This provides a practically open construction that allows adequate air permeability for the drying of the binders applied during the construction of the carpet. For example, the open back area of the 16 x 5 cotton weft is approximately 34%. However, while allowing adequate air permeability, the open fabric design also allows the filling / binder mixture to breathe from the back of the carpet. This creates an abrasive surface that is often unsatisfactory, due to its appearance and tendency to scratch surfaces during installation. Various methods have been proposed to overcome the inadequate abrasive and aesthetic capacity in backing for secondary carpet of 16 x 5 conventional cotton / agglut system. na t fill. One procedure is to increase the warp count and the peak count of the cotton core of the v / pi by 5 ppi to approximately 18 wpi by 13 ppi. Although this procedure reduces the size of the open areas in the fabric, the open areas are still large enough for the binder filler blend to transpire through the backing of the secondary web during the manufacture of the carpet. Another aspect is that a backing for secondary carpet has a closed weave so that the filler / binder mixture is encapsulated between the side with stitches of the primary backing and the backing surface for secondary carpet that; it is opposite the side that comes in contact with the floor. A product of this type is a woven cloth with a flat weft of 24 wpi per 15 ppi of tapes of 127 thousandths per cm. (50 thousandths of an inch.) Wide in the direction of the warp and spun threads of 101.6 thousandths per cm. (40 thousandths of an inch) in diameter in the fill direction. These cloth weights about 124 grams. per meter2 (4 ounces per square yard (osy)) has practically no open area, that is, no space in the plane of the fabric that is not occupied, by a warp or transverse yarn. Since the fabric prevents the filler / binder mixture from transpiring to the underside of the carpet when cured, fast cure rates are not allowed for extended use. Therefore, it is not used commercially. A key measure related to curing speeds is the air permeability of the fabric. For the 24 x 15 flat web fabric described above, the air flow magnitude is 80 cfm / sq ft, as measured in accordance with ASTM D 737 with a 1.27 cm hydrostatic head. (0.5 inches). That figure is about one tenth of the air permeability of the secondary carpet backing of the 16 x 5 cotton weft described above. Other methods for improved secondary carpet backings have been proposed. A class of alternative backup constructions for secondary carpet, involves the preparation of compounds of two or more layers. One attempt is set forth in U.S. Patent No. 3,817,817 Pickens, Jr. et al., ("The '817 Pickens patent") wherein a secondary carpet backing sewn with a carpet needle comprises a carpet of closed weft, perforated with: needles with cut fiber. This composite backing provides a back surface similar to the textile that contains the filler / binder mixture, providing improved static and preventing the carpet from scratching the walls and the carpentry during installation. However, this construction has low air permeability, and is not suitable for the manufacture of carpets at the current high speeds in line because the water in the latex layer can not escape at a high enough speed, while the carpet it's in the oven. Figure 2 exemplifies Pickens' patent 817. As illustrated, the composite secondary carpet backing comprises warps 230 and wefts 220, where the warps 230 and wefts 220 comprise wide, thin ribbons or ribbon yarns. The furry side of the fabric is disposed against the foot side of the back / carpet construction, and the fibers that are drilled through the woven fabric are joined to the latex binder cap. However, the closeness and dimensions of these ribbon threads in the. Pickens patent 817, does not allow sufficient water removal during the curing process. Additionally, the patent? Pickens 817, does not show a relationship between the structure of the woven fabric layer and the subsequent performance on the carpets. Another support for composite secondary carpet is disclosed in U.S. Patent Nos. 6,060,145 and 6,344,254 to Smith et al. These patents disclose a backing for modified secondary carpet having a weft scrim in a cotton weft construction with a count of 16 wpi X 5 ppi (16 X 5), wherein the weft scrim is attached to a fibrous material sewn with needle The 16 x 5 open weft cotton fabric, described above, is practically the same as the commonly used 16 wpi by 5 ppi in the secondary carpet backings as described above. To create a less abrasive and more aesthetically pleasing carpet, the secondary carpet backing composites of the? 145 and? 254 patents combine the 16 x 5 cotton construction with a fibrous needle-sewn material. S: .milar to the construction of the '817 of Pickens, Jr. et al., this composite backing also provides a textile-like back surface that provides improved aesthetics and prevents carpet from scratching the walls and joinery during installation. In this way, patents 145 and 254, differ from the construction of 817 by Pickens, Jr. et al., Due to the nature of the woven fabrics. More specifically, the large open area in the screen weave of the patents? 145 and? 254, leads to a greater air flow through the composite backing. For example, with a layer of fiber sewn with a needle of 68.53 grams per meter2 (2.2 osy), the air flow is approximately half that of the fabric of 15 wpi per 5 ppi. This increased air permeability is cited as a key reason for faster curing speed with binder. However, while the patents' 145 and "254 of Smith et al., Provide enhanced air permeability with respect to the construction of 817 by Pickens, Jr. et al., A common industrial knowledge is that laminations of carpets built with secondary carpet backrests composed of? 145 and '254, they reduce in-line speeds, compared to laminations, where the 16 x 5 open-weave fabric is the backing for secondary carpet. , efforts to increase the speed in line to increase furnace temperatures have been very unsuccessful because the fibers in the fibrous nonwoven material melt at the highest temperatures.These melted sections of fibrous material lead to aesthetics?; deficient and to a non-uniform carpet appearance and can also lead to diminished properties of the carpet. Therefore, it is evident that there is currently a need for a technique for secondary carpet backings that allow for high speeds of carpet manufacture, to provide a surface similar to soft textile that prevents the filling / binder mixture from transpiring from the face lower carpet, and imparts high levels of dimensional stability, resistance to delamination, air permeability, and plume joints to carpets.

SUMMARY OF THE INVENTION Briefly described, in a preferred example embodiment, the backing for inventive secondary carpet and the carpet made cei. same can overcome the aforementioned disadvantages and meet the recognized needs for this invention by providing a backing for composite secondary carpet, wherein the backing for secondary carpet, provides increased dimensional stability, increased delamination resistance, and allows greater air permeability to facilitate faster carpet manufacturing speeds. The high air permeability can be obtained together with a similar appearance to the soft textile that prevents the filling / binder mixture from transpiring from the underside of the carpet. In a larger exemplary embodiment, the composite secondary carpet backing of this invention can comprise two layers, wherein the layer of the woven fabric is a flat weft with low aoreous area and a fibrous layer that weighs between about 15.57 up to 311.53 grams per m2 (0.5 to 10 osy) that is entangled with the woven fabric so that a portion of the fibers penetrate the fabric and extend outwards from the back. The secondary carpet backing composed of this invention can have an air flow of at least 220 cfm / sq ft in combination with a fabric that has an open area not greater than 15%. Preferred embodiments of the present invention may comprise flat screen constructions having, for example purposes only, 24 v / pi X 6 ppi, 28 wpi per 6 ppi ,. or 16 wpi per 10 ppi, where the flat web can provide no more than 15% open area. Notably, the present invention is neither a cotton weft, nor an open weft, and is therefore not limited to a construction of 16 wpi X 5 ppi. According to its main and widely-established aspects, the present invention in its preferred form is a set of secondary carpet backings having two layers, wherein the first layer may comprise a non-woven web or fabric that is pierced with needle or hydro-entanglement to a second layer, and wherein the second layer, may comprise a flat weft fabric having a ribbon-like yarn similarly woven in the warp direction and a coarse or woven yarn in the weft direction. The yarn-like yarn may comprise a strand of ribbon. The coarse strand may comprise a strand of multiple strands (spun-off strand ,. strand with coarse continuous filaments, core-spun yarn, or broken yarn by stretching. For example, yarns that can be used as the woven yarn include, but are not limited to, yarns as described in the DuPont publication entitled "Specialty Technologies: Uniplex ™ S Yarn Technology," which comprises polyolefin, (e.g., polyethylene, polypropylene). , and / or impact copolymers thereof), polyamide, or polyester (e.g., polytrimethylene terephthalate (PTT), polyethylene terephthalate (?,?), or terephthalate In addition, in one example embodiment, the woven yarn is at least three times thicker than the diameter of the ribbon yarn, both the yarn strands and the spun yarns may become entangled and may be penetrated by staple fibers. In the preferred embodiment, some of the fibers or filaments from the non-woven layer can be transferred through the woven layer and extended outwardly from the opposite side thereof. a backing for secondary carpet on a finished carpet, the side with most of the fibers, can be placed against the floor, and the opposite side, which have non-woven filaments that extend, all along, can be joined through of the latex or other binding agent on the side with stitches of the primary backing of the carpet. More specifically, an exemplary embodiment of "., backup for inventive secondary carpet in a preferred embodiment may comprise a secondary carpet backing having a flat weft construction of 24 wpi per 6 ppi, drilled with polypropylene fiber needle from 2.15 up to 46.73 grams per n2 (1 to 1.5 ounces per square yard (osy)) of 7.62 cm (3 inches) long, creating with this a uniform fibrous layer on one side of the flat weft fabric.The combination of 24 wpi of strands of ribbon and 6 ppi of spun yarn for filling in a flat weft construction can create an open area of less than 1% in the fabric weave The 6 ppi of the filling strand can comprise an isolated open end strand with a diameter between approximately 15 to 20 times the thickness of the strands of tape due to the differential thickness Separations can be formed at the intersections between the strands of tape and the spun threads, thus providing a permeability to l unexpected air for the seemingly closed fabric, and overcome the problem of tape-to-tape crossings, which may have very low permeabilities. In a preferred embodiment, the non-woven side of the composite backing can also be heated to lightly bond the surface fibers together, thereby creating a polished surface. The composite backing of this example embodiment can have a total weight between approximately 109 to 121.5 grams per m2 (3.5 to 3.9 osy) and an air permeability of 278 cfn / sq ft, according to ASTM D 737. Accordingly, a feature and advantage of the present composite secondary carpet backing can include its ability to impart high dimensional stability to the carpet. Another feature and advantage of the present composite secondary carpet backing can be its ability to impart high delamination resistance to a carpet. Another feature and advantage of the present support for composite secondary carpet may be its ability to impart high plume joints to a carpet. Another feature and advantage of the present invention may be its ability to impart high stitching resistance to a carpet. Another feature and advantage of the present invention can be its ability to impart to a carpet with a high resistance to unraveling. Yet another feature and advantage of the present invention may be that a non-abrasive back surface, similar to carpet textile, is provided. A further feature and advantage of the present invention may be that the filler / binder mixture is prevented from spilling. Yet a further feature and advantage of the secondary carpet backing composed of the present invention, may be its high air permeability, which allows increased production rates compared to prior art carpets with composite backs made from binder formulations with latex. A further feature and advantage of the present invention, may be that it has increased consistency to the melt of the fibrous layer compared to similar compounds with entangled? of open cotton weft. These and other features and advantages of the present invention will become more apparent to one skilled in the art from the following description and claims, when read in light of the accompanying drawings. The present invention will be better understood by reading the detailed description of the selected preferred and alternative embodiments, with reference to the accompanying drawings, in which similar reference numerals denote similar structures and refer to similar elements.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a photographic top view of an open screen weft in a construction of 16 wpi by 5 ppi according to the. conventional technique. Figure 2 is a top view of a secondary carpet backing of the prior art with low air permeability and low open area. Figures 3A through 3D illustrate a preferred embodiment of a woven fabric layer in the inventive composite secondary carpet backing, according to an exemplary embodiment of this invention. Figure 4 illustrates a side view of a system for manufacturing the secondary carpet backing composed in accordance with an exemplary embodiment of this invention. Figure 5 is a side profile of the inventive secondary carpet backing according to an example embodiment. Figure 6 is a flow chart describing an exemplary method for manufacturing the inventive secondary carpet backing according to an exemplary embodiment. Figure 7 illustrates a side view of an example embodiment of a carpet comprising the inventive secondary carpet backing.

DETAILED DESCRIPTION OF THE INVENTION The inventive system can provide a backing for inventive secondary carpet, comprising two layers, in addition to an inventive carpet. same. In addition, the secondary carpet backings of this invention can be used in wide loom carpet, carpet tiles, rugs, mats, and other floor coverings. Specific terminology is employed for better clarity in the description of the preferred embodiments of the present invention. The backing for inventive secondary carpet and the inventive carpet, however, are not intended to be limited to the specific terminology, and it should be understood by one skilled in the art that each specific element includes all the technical equivalents that function similarly to carry out similar functions. Figures 3A through 3C illustrate a still preferred embodiment of the woven fabric layer in the inventive inventive secondary carpet backing 300 of this invention. The knitted fabric comprises a flat weft of warp yarns 330 and weft yarns (ie, fill yarns) 320, which has a construction of 24 wpi per 6 ppi. As illustrated in Figure 3C, the frames 320 are practically thicker than the warps 330. According to one example embodiment, as illustrated in Figures 3B and 3C, the wefts 320 may be three times thicker than the warps. 330, where the thickness is denoted by the reference "X". This construction can create a low open area (<1%), however, allow the backing for secondary carpet to have an unexpectedly high permeability to the ai e (> 220 cfm / sq ft). As illustrated in Figure 3D, a warp yarn 330 and the wefts 320A-B form separations 350A and 350B at their junctions, where the spacing 350 provides air permeability of the inventive secondary carpet backing 300. In one embodiment yet For example, preferred, the backing for secondary carpet perforated with needle 3? 0 can be maintained on a laying frame and can be heated to illustrate the fibrous surface and compact the fibers together. Figure 4 illustrates a diagram of a system for needle puncturing a fiber fibrous material cut 410 to a woven fabric layer 405. The corded fiber fibrous material 410 and the woven fabric layer 405 are transported on a moving web. 415 to a cloth: 430 'needle to form a backing for composite secondary carpet 300A. The needles 440 consolidate the fibrous material of the staple fiber 410 by mechanical entanglement and slowly advance a portion of the fibers 410 through the can of woven cloth 4C5 to the opposite side 425. • 1 backing for secondary carpet 300A stitched composite can be used as is, or optionally it can be passed under a heated :: infrared 455 to create a secondary carpet backing 300B with a polished surface. Whether the backup for secondary carpet 300? or 300B will eventually become the underside of a carpet, depending on whether or not a polished surface is left. For the sewn process, individual tab needles 440 can be used as well as 440 needles with more tabs. A compaction band 420 can be used to press the fibrous material 410 before sewing, especially r? the weight of the fibrous material is greater than 62.30 grams per m2 (2 osy). At low weights of the fibrous material, a compaction band 420 is not needed. The fibers in the fibrous material 410 can be randomly distributed or with a preferred orientation depending on the process used to deposit them on the woven fabric. One requirement is that a portion of the fibers 410: .e should propel through the woven fabric 405 to the shape that the fibers 410 can become entangled in the filling / binder mixture when the secondary carpet backing 300 It is used to form a carpet. Specifically, the portion of fibers 410, which penetrate and extend to the front side of the woven fabric layer 405, should be at least about 5% by weight and not more than about 95% by weight, preferably about 20% by weight. % has "at 70%." The details for the fabrication of needle-punched composite fabrics are well known to those skilled in the art.In addition, U.S. Patent Nos. 4,069,361 and 6,344,254 address the principal considerations for perforated staple fibers with needle on woven fabric substrates Accordingly, US Pat Nos. 4,069,361 and 6,344,254 are hereby incorporated by reference.The entanglement of fibers 410 with nonwoven fabric 405 can be realized by any means known in the art, including, but not limited to, needle piercing and hydroentanglement.A requirement is that a portion of the fibers 410, be transferred to the cost. opposite 425 of woven fabric 405, as a result of the entanglement process. Figure 5 illustrates the manner in which a portion of the fibers 410 can be transferred to the opposite side of the woven fabric layer 405, according to an exemplary embodiment of the inventive secondary carpet backing 300. As illustrated, the fibers 410 on at least one face must extend outwardly in such a way that they can be bonded to the binder resin that is in contact with the opposite face. The optional step for fusing the surface of the fibers can be carried out on a heated roller instead of the application of infrared heat. Referring now to the Figure. 5, the inventive secondary carpet backing 300 of this invention, can comprise two layers - a woven fabric layer 405, comprising a special construction and a fibrous layer 510, which comprises ur weight from about 15.57 to 311.53 grams per m2 (0.5 to 10 osy) and also comprises cut fibers 410, which are entangled with the woven fabric layer 405, such that a portion of the fibers 410, penetrate the woven fabric layer 405 and extend outwardly from the reverse side of the fabric. woven fabric layer 405. More specifically, fibrous layer 510 can be formed by depositing the fibrous material of the fibers on woven fabric layer 405 and transporting (through hydroentanglement, needle piercing, or other known means by someone skilled in the art) a portion of the fibers 410 in the fibrous material towards the opposite side of the inventive secondary mat 300, during the manufacturing process of the former. 410 will come into contact with the binder, if the inventive secondary carpet backing 300 is attached to a primary backing to form an inventive carpet. As discussed previously, the distinctive features of woven fabric layer 405, are a flat weft and low open area. The term "planar weft" refers to planar wefts, woven wefts, and satin wefts, as well as their derivatives, which include panama ligaments and spike wefts. The flat weft constructions have a regular pattern of warp and fill yarns that alternate above and below each other. The panama ligaments are similar, except that the alternation above and below the warp and fill yarns involves more than one of either or both of the warp and fill yarns. Cotton wefts, which by definition require that pairs of warp yarns are twisted around the fill yarns, are distinct from planar wefts. An open area is a measurement of the area in the plane of the fabric that is not obstructed by the threads. An open area is reported as a percentage of the total area. The open areas are formed between adjacent warp threads and between adjacent fill threads. Stenciling of the woven ribbon-like strands, as in those in cotton weft fabrics, leads to an enlarged open area compared to a similar construction in which the strands are flat and parallel. The flat area was measured by taking a photograph of a representative area of the fabric (approximately 2.54 cm by 2.54 cm (1 inch by 1 inch)), using a low magnification microscope. A photograph of 20.32 cm was printed. by 25.4 cm. (8 inches by 10 inches), inspected, and the open areas were cut using a razor blade. To calculate the open area, the weight of the cut areas was compared with the weight of the photograph of the total area of the fabric. Alternatively, the photograph can be examined using computer software for image analysis. The open area of a fabric, c; e relates to its counts of warp and fill yarns and their dimensions. The open area is the opposite of coverage. The theoretical coverage of the warp / fill yarns can be calculated by multiplying the wpi or ppi by the width of the yarn. For example, for a warp yarn thread of 254 thousandths of an inch (100 thousandths of an inch) wide in a wpi construction, the theoretical warp coverage is (8 wpi X 0.254 cm (0.100 in) X 100 = 80%.) This leads to an open area in the warp direction of 100-80 = 20%. The fabric had 6 ppi of strands with an average diameter of 101.6 mils (0.1016 cm.) (40 mils, 0.040 inches)), the fabric could have a theoretical fill coverage of (6 X 0.1016 cm. 0.040 inches) X 100 = 24% Those strands could be removed at 241 from the open area in the warp direction, which leads to an open area in the cloth of 20% X (1-0.24) = 15.2%. woven fabrics of this invention, the open area is 15% or less and, preferably, 12% or less. It comes from someone with experience in the technique, the calculation above is just an example of an area calculation; therefore, also as understood, many combinations of warp and fill yarn counts can be used in a similar calculation until reaching the open area of a fabric. In addition, as recognized by someone skilled in the art, the warp and fill yarn counts and diameters can be altered in order to obtain varying degrees of open area on a secondary carpet backing. A feature of the strands in the woven fabric layer 405 of the inventive secondary carpet backing 300 of this invention is that the warp yarn 330 and the fill yarns 320 (ie, wefts) have different thicknesses. According to an example embodiment illustrated in Figure 3C, the diameter of the yarn, filling 320 is at least 3 to 30 times greater than the thickness of the warp yarn 333 and, preferably, at least five times larger. that the thickness of the warp yarn similar to woven tape 330 of such a shape that an air gap 35C can be formed at the crossing points. The air gap 350, which is formed at this junction according to an example embodiment, is illustrated in Figure 3D. It should be noted that the above example mode is for illustrative purposes only; therefore, one skilled in the art recognizes that an air space 350 can be formed in a secondary carpet backing, where the warp threads 330 are thicker than the fill threads 320. Other benefit and characteristic of the backrest for inventive secondary carpet 300 of this invention is that, when a secondary carpet backing is constructed, according to the single example embodiment, the structure has an open area virtually unexposed. However, the construction of the woven fabric in the inventive secondary carpet backing allows the passage of air through the separation 350 between the strands while maintaining the filling / binder mixture. This leads to a textile-like, soft appearance, which is less prone to scratching the woodwork and walls. The number of warp ends per inch and spikes per inch in the woven fabric is not decisive as long as the requirements for open area and air permeability are met. According to an example embodiment, the warp counts and peak counts can be in the variation of 7.62 hasra 101.6 cm. (3 nasta 40 per inch), preferably 25.4 to 76.2 cm. (10 to 30 per inch) for the warp counts and 10.16 to 38.1 cm. (4 to 15 per inch) for peak harvests. The specific preferred constructs are 24 wpi per 5 to 7 ppi; 28 wpi for 5 to 7 ppi, and 16 for 10 up to 14 ppi. The theoretical warp coverage with ribbon threads can be 50% up to 150%. In these preferred constructions, the warp threads 330 comprise, strand of ribbon, while the filling threads comprise spun yarn. The polymers used to make the ribbon and filler threads include polypropylene, polyester (PET and PTT), polyamide, polyethylene, polyamides, and acrylics. Polypropylene, PET, and PTT are preferred to a greater extent. Ribbon threads are usually similar to woven ribbon with a rectangular, ribbed, fibrillated, oval or other cross-sectional configuration. They are typically flat in the fabric or can be bent or twisted. Ribbons with low width to thickness ratios (eg, 1 to 2), or round cross sections can also be used. Ribbons are often used as warp threads, although in some secondary carpet backings, they can also be used as filler threads. The threads with thick filaments that are typically used as filler threads are spun yarns of open ends, ring spun yarns, threads with thick continuous filaments, core-spun yarns (i.e.or monofilaments that are rolled with cut fiber), and straight strands by stretching. Preferred strands are produced with polypropylene, polyester (PET and PTT), polyanide, and polyethylene. Preferred thread types are thread:? open-end courses, strands with thick, twisted continuous filaments, and core-spun threads with high tensile strength, low-shrink polyester continuous filament core strands, and polyester staple fibers. Typical deniers for the strands and strands of the filaments are from 200 to 5000, preferably from 350 to 3000. The staple fibers 410 that form the fibrous layer of Figure 4 can have deniers from about 1 to 100 and cut lengths approximately 1.27 haste. .1 .24 cm. (0.5 to 6 inches). The fibers may have a rounded, trilobal shape, or of any cross-sectional configuration. They can be produced from a material or bicomponent. Preferred fibers include polypropylene fibers, polyester (PET and PTT), polyamide, and polyethylene. The fibers may also have other "characteristics, such as flame resistance, antistatic, or antimicrobial properties." Fiber combinations may also be used Typical flame resistant fibers include modacrylic fibers such as Protex M from Kaneka c. rayon fiber modified with Visil by Kemira Oy Natural and synthetic fibers may be used Although the second composite backing layer has been described as a fibrous material of staple fibers, it is also contemplated that a non-woven fabric is preformed that joins the fabric layer "ejida by a process of needle piercing or hydro-entangling. An unexpected feature and benefit of the present invention is that the addition of a low fiber weight to a flat weft fabric such as, one with a construction of 24 wpi per 6 ppi, significantly increases the secondary backup strength to the distortion during the manufacture of carpets .. Without a fiber finish, without a fiber finish the line of peaks of a fabric of 24 wpi by 6 ppi, easily deforms when it unrolls and joins other fabrics. This characteristic makes it difficult for carpet mills to use these woven fabrics by themselves during the rolling process. It has been found that needle drilling from 3.15 to 46.73 grams per m2 ((1 to 1.5 osy) of a polypropylene fiber to the woven fabric makes the line of peaks much less prone to bending and twisting, allowing the composite Needle piercing maintains a straight line of peaks, perpendicular to the direction along the length of the carpet manufacturing.In a woven fabric, the curvature and twist are deviations of filling strands.The curvature occurs when the filling strands placed in the configuration of an arc instead of a straight confijuración through the fabric.The twist occurs when the filling strands are not perpendicular to the edge of the fabric but in their place they are diverted diagonally. A similar fabric - a 24 wpi by 6 ppi fabric with a cotton weft instead of a flat weft - does not need this fiber to achieve an acceptable level of fabric stability. The unexpected feature and benefit of the secondary composite backing of this invention is that it is more resistant to damage due to abrupt temperature increases during the manufacture of the carpets than a secondary backing composed of the prior art with a weft open weave cotton. As shown in the following examples, the secondary carpet backing composite of this invention was not damaged by passing it through a hot carpet oven, although an analog composite secondary carpet backing with an open weft of cotton weft . '. 6 wpi per b ppi, suffered a non-uniform fiber fusion. The unique construction of the woven fabric of this invention, which creates many small passages evenly distributed allowing moisture to escape, prevented the localized fusion of the finish, of fibers, leading to a carpet cor. an attractive, non-abrasive, and uniform backing surface. A still preferred embodiment of the backing for inventive secondary carpet in a preferred embodiment may comprise a backing for secondary carpet having a flat weft construction of 24 wpi per ß ppi, punched with needles with 3.15 to 46.73 grams per m2 ( 1 to 1.5 ounces per square yard (osy)) of polypropylene fiber of 7.62 cm. (3 inches) long, creating with this a uniform fibrous layer on one side of the flat woven fabric. The combination of 24 wpi of strands of tape and 6 ppi of strand for spun filler in a planar flat construction can create an open area of less than 1% in the fabric weave. The 6 ppi of the filling yarn may comprise an open-end spun yarn with a diameter of approximately 15-20 times the thickness of the ribbon strands. Also, the nonwoven side of the composite backrest can be; to heat to lightly join the fibers :; superficial joints, creating with this a polished surface. In addition, e "composite backing in this example embodiment can have a total weight of approximately 109 to 121.5 grams per m2 (3.5 to 3.9 osy) and an air permeability of 276 cfm / sq ft, when measured in accordance with ASTM D 737. Referring now to Figure 6, a method for preparing an exemplary embodiment of the inventive secondary carpet backing 300 of this invention is illustrated.In step 605, a woven fabric layer 405 is created by weaving strands for warp and flat tape 330, with yarns for core-spun filler 320. In step 610, a fiber fibrous material, cut 410, is entangled with the woven fabric layer 405. In step 615, a portion of staple fibers 410 are transported from one side of the woven fabric layer 405 to the other In step 620, the fibrous layer 510 of the inventive secondary carpet backing 300 can be polished by fusing the surface of the staple fibers 410 together under a infrared heater 4 55. However, the staple fibers 410 which extend to one side of the woven fabric layer 405, do not fuse together although they are still capable of bonding to the backing for inventive secondary carpet 300 with a binder layer and a tufted primary backing. so that an inventive carpet can be formed. In addition to the secondary composite carpet backings, the present invention also includes carpets 700 comprising the composite inventive secondary carpet backing 300. As illustrated in Figure 7, the carpets 700 of the present invention may comprise a primary ply backing layer. 705, a binder layer 710, and an inventive secondary carpet backing 300. As shown, the backing; for inventive secondary mat 300, comprises a fibrous layer 510 and a woven layer 405. Additionally, as illustrated, a portion of the fibers 410, of the fibrous layer 510 extend through the woven layer 405 to interact with the binder 710 In this way, the carpet 700, comprising the primary backing 705 and the inventive secondary carpet backing 300, can possess excellent touch and plume-joining resistances. With the present invention, a variety of carpet styles, binders or primary carpet backings can be used. For example, carpets may include, but are not limited to, cut pile, terry pile, or pile / terry pile carpets. The net value weight of the inventive carpet according to an exemplary embodiment of the invention is from about 217.07 grams / m2 to 2492.30 grams / n2 (7 ounces / square yard to 80 ounces / square yard). The matting thread of the carpet typically comprises synthetic threads, such as nylon, polyethylene terephthalate (FET), polytrimethylene terephthalate (PTT), and polypropylene, and natural fibers such as wool or cotton. Other types of fiber include, polylactic acid (PL7A, for its acronym in English). The primary backs can be in the form of woven fabrics from tapes, non-woven fabrics with continuous filaments or staple fibers, or composed of woven and non-woven fabrics. The polymers for the primary backings can be polypropylene, polyethylene, polyethylene terephthalate, polybutylene terephthalate, or polytrimethylene terephthalate. The tapes and fibers can all be of a polymorphic or bicomponent type. The inventive carpet is made using the same processes that are used for carpets made with secondary backings with conventional cotton weft, except that conventional backs are replaced by inventive secondary backs. For example, typical processes using latex binders for filling are described in R. L. Scott, Journal of Coated Fabrics, Volume 19, July 1989, pp. 35-52. In a common process, the tufted primary backing is contacted with approximately 623.8 to 872.3 grams per m2 (20 to 28 ounces per square yard) of latex for filling (ie, pre-coating), while the secondary backing is puts in contact with approximately 249.23 grams per m2 (8 ounces per square yard) of latex for filling. The binder layers are combined using a "bonding roller" at the entrance to a forced air oven. As the laminated structure moves through the furnace on laying pins, the edges are held in a laying frame to prevent the backs from tearing as the latex layer dries. 1 end of the kiln, the carpet is made to pass through a cooling box and then it is released from. ", Stretcher frame and rolled on a roller.The typical air temperatures in the furnace are 148,88 up 176.66 ° C (300 to 350 ° F), and residence times are up to three minutes, carpets can also be made with 100 percent of solids aglutinaac.es For example, the patent of the States No. 6,849,565 and British Patent 971,958, do they write these carpets with a polyethylene binder system, these are incorporated herein by reference, Carpets with hot melt adhesive binder systems are described in United States patents. Nos. 3,551,231; 3,684,600; 3,745,054 and 3,914,489, all are incorporated herein by reference. Fara binder systems that do not require the removal of volatiles for a cure or a drying step, the secondary carpet backings composites of this invention even provide many convenient features, including high resistance to delamination, high dimensional stability, high stitching resistances , and a back surface similar to the textile. The additional features and advantages of the inventive secondary carpet backing and carpet made thereof will be apparent to one of ordinary skill in the art from the following examples.

EXAMPLES To illustrate the inventive secondary carpet backings 300 and the carpets 700 made therefrom, a series of fabrics with a secondary backing of flat weave were woven and needle punched with approximately 3.15 to 52.96 grams per m (1 to 1.7). osy) of a polypropylene fiber. The carpet samples were then formed using the inventive secondary carpet backings 300 of this invention as well as other, different comparative secondary carpet backings.

Backing fabrics for exemplary and comparative secondary alphabeams Tables I and II illustrate comparative secondary mat backings and exemplary embodiments of the inventive composite secondary mat backing 300. The tests used to measure certain values of Table I are as follows. : 1. The thickness was measured in accordance with ASTM 1777-96 with a presser foot of 2.8 cm. (1.1 inches). 2. The airflow magnitude was determined in accordance with ASTM D-737 using a hydrostatic head pressure differential of 1.27 cm. (0.5 inches). 3. The grip stress properties were measured in accordance with ASTM D-4632. The secondary carpet backrests 31 through S9 are exemplary embodiments of the inventive secondary carpet backing 300. The secondary carpet backs Comp. 1 to Comp. 5, are shown for comparative purposes. Stop, compile the Table, a series of flat woven fabrics, of 386.03 cm. (152 inches) wide, they were woven on a projection loom using a variety of tape strands in the warp direction and spun threads in the fill direction. The threads of warp tape on all fabrics had dimensions of 4.31 X 122 thousandths of centimeters (1.7 X 48 thousandths of an inch) except as observed. The spun yarns are produced from 6.35 cm polypropylene cutting fiber. (2.5 inches) long by 4.6 denier, using an open end spinning process. The spun yarn of 1265 denier, had a diameter of approximately 91.44 thousandths of centimeters (36 thousandths of an inch), and the. The spun yarn of 1714 denier had a diameter of approximately 101.6 thousandths of an inch (40 thousandths of an inch). The sub-carpet backings of example SI, S3 through S9 and the comparative secondary carpet backings (Comp.) 1, 2, 3, and 5 were punched with a needle with a 7.62 cm polypropylene cut fiber web. (3 inches) and 7 denier, on a needle loom with needles with tongue type F-10-1 -26-5NK / LI / 1E 15 X 18 X 32 X 3 supplied by Foster Needle Company at a puncture density of approximately 450 penetrations per square inch (ppis, for its acronym in English). The backing for secondary carpet of example S2 was perforated with a needle with a denier polyethylene fiber fabric by 7.62 c. (3 inches) on a needle loom with six tongue needles supplied by Gros-Beckert USA (part number: C222 G 73012, type 15 x 16 x 36 x 3) at a puncture density of approximately 150 ppsi. For all needle-punched compounds, the penetration depth of the needle was 1.27 cm. (0.5 inches). Under these conditions, approximately 10% to 15% of the fibers in the fabric were forced through one side of the woven fabric and were visible on the opposite side. Table I summarizes the constructions of the example and comparative secondary carpet backings. Table II summarizes its properties.

Table I - SECONDARY SUPPORT A: = Dimensions of tape 4.57 X 127 thousandths of a centimeter (1.8 X 50 thousandths of an inch), denier 475 B == The filling thread was a strand of tape with dimensions of 5.33 X 292 thousandths per centimeter (2.1 X 115 thousandths per inch) As can be understood from Table I, all the woven fabrics of the carpet backs side effects of this invention S1-S9, had areas open 12% less, more frequently less than 1%.

Des of the comparative secondary backups; they had open areas of 2% less, while other three (Comp. 2, 3, and 4 in Table I) had fabrics with an open area of 34%.

The IR treatment applied to the backing for secondary carpet of example S2 and the backing for secondary carpet Comparative Comp. 3 and Comp. 5, comprised passing the needle punched compound after a bank of 91 in. (three feet) long infrared heaters at an in-line speed of approximately 6 to 15 meters / min. (20 to 50 ft / min.) The surface temperature of the fabric at a point of 30.5 cm. (twelve inches) passed to the end of the heater was between 82.22 ° and 99.89 ° C (180 ° and 210 ° F). The effect of the IR heat treatment was to fuse the fibrous tissue on the side of the compound with the majority of the fibers. 3 Under the IR heat treatment, used for the backing for example secondary carpet S2, there was little effect on the tensile strength or air permeability (compare the backing for example secondary carpet with the secondary backing for example carpet) S2). As illustrated in Table I above, Comp. 1 was equivalent to the backing for secondary carpet of example S5, except for the filler strand. In Comp. 1, a flat ribbon strand replaced the spun 1265 denier strand in the inventive secondary carpet backing S5. Comp. 2 contained a 16 x 5 cotton weft fabric described in the prior art. The fabric knitted in Comp. 2, differed from the woven fabric of the backs for example secondary carpet, since it had a cotton weave and a much larger open area. Comp. 3, was identical to Comp. 2, except that he had undergone IR treatment. Comp. 4, was the 16 x 5 of the prior art without a fibrous finish. Comp. ,. is commercially available as ActionBac®, backrest for secondary carpet style 3865 from Propex Fabrics Inc. Ccmp. 5, was similar to Comp. 1; the two woven fabrics had ribbon strands in the filling direction. In Comp. 5, the number of peaks / inch was greater than in Comp. 1, leading to a greater fill coverage.

TABLE II - SECONDARY BACKUP PROPERTIES Some woven fabrics were tested for tension properties prior to needle puncture with the fiber. For example, the tensile strength by grip of the woven fabric in the secondary backing composite backing of example S7 was 65.31 cm. (144 pounds) in the warp direction and 23.13 cm. (51 pounds) in the fill direction before needle piercing. The results in Table II, which measured after needle puncture, indicate that the strength of the fabrics of this invention did not radically degrade after needling with the fiber. As illustrated in Table II, the secondary carpet backings of SI to S9 of this invention had air flows greater than 250 cu ft / sq ft / min and open areas less than 15%, preferably less than 12%. Conversely, the backs for comparative secondary carpet Comp. 1 to Comp. 5, had either: a) high air flow with high open area, or b; Low air flows with ba to open area. However, as discussed above, a) is unsatisfactory due to poor aesthetics and abrasion ability of the finished carpet and b) is unsatisfactory because it leads to low carpet properties. Accordingly, it is surprising that the exemplary secondary carpet backings of this invention, which possess an unexpected combination of low open area and high air permeability, are capable of imparting both excellent carpet properties and attractive surfaces, similar to textiles. As illustrated in the following carpet examplesIt is also surprising, and unexpected, that the exemplary secondary carpet backings of this invention perform very well in the manufacture of carpets with excellent physical properties and an attractive, textile-like surface at high in-line speeds. As will be illustrated below, none of the comparative secondary carpet backings produced carpets that had fully satisfactory physical properties (eg, plume bonding, cyclic dimensional stability, and peel strength) in combination with an appearance similar to a uniform textile, abrasive Carpets The example and comparative secondary carpet backrests of Tables I and IT were subsequently used for the production of carpets. These results are illustrated in the following Tables I "I and IV The tests used to measure certain values in Tables III and IV are as follows: 1. The resistance to delamination (ie, resistance to peeling) of the carpet backing Secondary was measured in accordance with ASTM D-3936-00 2. Plume bonding on carpet samples was measured in accordance with ASTM D-1335 3. Dimensional stability was measured via a cyclic test described in the British standard 4682: Part 1, 1971. In this test, a strip of 5..06 cm (2 inches) of carpet was loaded with 0.453 kg up to 20.41 kg (1 pound up to 45 pounds) of tension and then discharged at 0.453 kg (1 lb.) The cycle was repeated ten times Various properties were diluted, including "extension without recovering", which is the difference in the stretch in the first load at 0.453 kg (1 lb) and the stretch in the tenth load to 0.453 kg (1 pound) and the "total extension", which is the difference between the stretch in the first load to 0.453 kg (1 lb) and the stretch in the tenth, load, to 20.41 kg (45 pounds). Publications such as, "Dimensional Stability of Carpets: Rucking of Carpets in Use," Sudnik, Z.. , Textile Inst. And Ind., 7, 278-281 (1969) and "The Dimensional Stability of Carpets in Installations, Part I: Stability to Mechanical Actions" Gentry, DR, Textile Research Journal 47 (1977) confirm that the sum of the extensions without recovering in the warp and fill directions should be less than 2% for carpets considered to have very good dimensional stability. The research of the present inventors also indicated that good dimensional stability also requires that the sum of the total extensions for the warp and fill directions be less than 8%.

Sample Carpet Cl To produce the carpet Cl e e.plo, a primary backrest tufted with. hair cut of 11.83 kcj per m2 (38 osy) with a hair height of 1.52 cm. (0.6 inches), 5/32 gauge, and 7 stitches per inch are laminated) for the secondary backing of example S2, - using a filler / binder mixture, which consisted of 450 parts by weight of carbonate filler of calcium with 100 portions of latex solids with styrene-butadiene. The rolling process was carried out at an in-line speed between approximately 15 meters (50 feet) per minute in a forced air oven 30.5 meters (100 feet) long with an internal air temperature of approximately 171.11 ° C ( 340 ° F). Several comparative secondary carpet backings were also laminated with a primary backing as previously described with the. Cl carpet. Specifically, the backs for comparative secondary carpet, Comp. 3rd Ccmp. 4 and Comp. 5, were used to make comparative carpets Comp. 1, Comp. 2, and Comp. 3, respectively. The tufted primary backing for all carpet samples had a nominal weight of 93.46 grams per cm2 (3.0 osy) and was similar to the 2200 PoliBac® primary backing sold by Propex Fabrics Inc. The primary backing fabric had a closed weft construction 24 X 11. Samples of the backing for secondary carpet were run reciprocally to reduce the differences in processing conditions. The results of the tests on the finished carpets appear in Table III.

Table IV - CARPET PROPERTIES The data in Table III, illustrate, that the example carpet Cl had better plume union than the carpets in comparative Comp carpets. 1, Cornp. 2, and Comp. 3. All carpets easily exceeded the plume union requirements for short pile carpets installed in homes that qualified for financing-through US Dep. Or :: Housing and Urban Development (HUD). The minimum requirement is 1.36 kg (3.0 pounds) per tuft attachment on short pile carpets. The cyclic dimensional stability of the carpet Cl was essentially the same as that of the carpet in Comparative Example 2 in Table III. The last carpet was made with the backing for the most common secondary carpet used for making carpets nowadays. All the carpets of Table III, had satisfactory cyclical dimensional stability performance as measured by both the uncoated extension and the total extension. The carpets in the exemplary carpets Cl and the comparative carpets 1 and 2 of Table III, had peel strengths (ie, resistance to delamination) exceeding the minimum requirement for HUD financing (1.13 kg / cm (2.5 lbs. /inch)). In fact, the Cl carpet example, had a remarkable resistance to descent - greater than any of the comparative carpets. In addition, the carpet in comparative carpet 3, had a resistance to very low delamination (0.40 kg (0.9 pounds)). This level of performance is lower than the minimum requirement for households financed by HUD and below industry standards. The other two comparative carpets of Table III, had deficiencies that were not observed in the carpets of this invention. Comparative carpet Comp. 2, I had a backrest for secondary carpet that includes an open mesh 16 x 5 without fiber finish.

The back of this rug was abrasive and did not have a textile-like appearance. Comparative carpet Comp. 1, had a backing for secondary carpet with the same open mesh scrim than the secondary carpet backing of comparative carpet 2. However, in Comp. 1, a layer of polypropylene fiber had been sewn into the underlay to produce a backing for composite secondary carpet. Despite this, the appearance and abrasive capacity of the reverse Comparative carpet Comp. 1 was very similar to that of Comp. 2, because the fibers melted almost completely when the latex was dried in the oven. Subsequently, the appearance of the backrest for secondary carpet in the comparative carpet Comp. 1, was not satisfactory. The example rugs of this invention had a combination of excellent physical properties (plume bonding, cyclic dimensional stability, and peel strength) and a textile-like and non-abrasive backing surface. It was unexpected that the secondary carpet backings of this invention were more tolerant to high temperatures in the carpet curing ovens than the secondary composite carpet backings of the prior art, which had a 16 x 5 open cotton weft pattern.

Carpets C2, C3, and C4 of example To produce carpets C2, C3, and C4, for example, a primary backing tufted hair cut with nylon 9.03 kg per m2 (29 osy) with hair height of 1.27 cm. (0.5 inch), 3/16 gauge, and 7 stitches per inch was laminated to a secondary carpet backing using a filler / binder mixture that consisted of 425 parts by weight of calcium carbonate filler with 100 parts of latex solids with styrene-butadiene. The rolling process was carried out at an in-line speed of approximately 19.76 m (65 ft) per minute in an air oven for 20.66 m (67 ft) long with an internal air temperature of approximately 182.22 °. C (360 ° F) Several comparative secondary carpet backings were also laminated with the primary backing tufted as described above with the example C2, C3, and C4 carpets. Specifically, the backs for comparative secondary carpet Comp. 1 and Comp. 2, were used to make comparative carpets Comp. 4 and Comp. 5, respectively. The primary backing for all carpet samples had a nominal weight of 1.2 kg per m2 (3.3 osy) and was similar to the 2205 PoliBac® primary backing sold by Propex Fabrics Inc. The primary backing fabric had a closed weft construction 24 x 13. Backup samples for secondary carpet were run reciprocally to minimize differences in processing conditions. The results of these tests on finished carpets are shown in Table IV.

All of the carpets C2, C3, and C4 of example in Table IV, exceeded the minimum requirements for physical properties (plume union > 1.36 kg (3.0 pounds); cyclical dimensional stability, full extension (warp + padding) and extension without recover (warp + padding); <2%; and peel strength> 1.13 kg / cm (2.5 lb./in.) In some cases, for example, with the example C4 mat, the peel strength 2.7S kg / cm (6.1 pounds / inch) was higher than all the other carpets made during this test, similarly, the C3 carpet, for example, had the best performance in the cyclic dimensional stability test of all the carpets, and the Example C4 carpet tuft union (2.63 kg (5.8 pounds)) was superior to that of both comparative example carpets These results are unexpected, especially since the prior art teachings that relate to backs for alfo Secondary materials indicate that an open weft pattern is required for the good properties of the carpet. Comparative carpet Comp. 4 in Table IV, did not meet all of the physical property requirements. Specifically, the peel strength ranged from zero pounds / inch to 1.90 kg / cm (4.2 pounds / inch). The reading of zero pounds / inch fne due to the fact that large sections of the secondary carpet backing were stiffened when the carpet was cured in the oven. These non-uniform properties were not acceptable on carpets that were sold to residential or commercial customers. Comparative carpet Comp. 5 in Table IV also did not meet all the requirements. Although the plume junction, the cyclic dimensional stability, and the peel strength were satisfactory, reverse of the carpet was rough and open because the fiber cut into the backing for composite secondary carpet melted when the latex of the carpet was cured. . In contrast, the fibrous layers on the secondary carpet backings of the example C2, C3, and C4 carpets did not melt to any significant degree during the curing of the latex. This result was unexpected, since these fibers had the same chemical composition as those on the back of the comparative mat 5 of Table IV. Notably,. The minimal open area construction of the example carpets created unexpected air flow allowing removal of water at a sufficient rate to prevent the fibrous layers from melting, despite the fact that similar fibrous layers were used in the comparative carpets. Accordingly, the high air flow despite the low open area in the fabric weaves of the secondary backs of carpets C2, C3 ,. and example C4, led to other unexpected results, such as, the ability to withstand the rigorous curing of latex without causing the fibrous layer to melt. The foregoing deption and drawings comprise illustrative embodiments of the present invention. Having thus debed the exemplary embodiments of the present invention, it should be noted by those skilled in the art that the exposures are exemplary only, and that various other alternatives, adaptations, and modifications may be made to the scope of the present invention. List or number simply the steps of a method in a certain order, does not constitute any limitation in the order of the steps of that method. Many modifications and other embodiments of the invention will become apparent to those skilled in the art, having the benefit of the teachings presented herein. Although specific terms may be used herein, they are used in a generic and deptive sense only and not for purposes of limitation. Accordingly, the present invention is not limited to the specific embodiments illustrated herein, but rather is limited only by the following claims.

Claims (16)

1. NOVELTY OF THE INVENTION Having described the present invention, it is considered as a novelty and, therefore, the content of the following CLAIMS is claimed as property: 1. A backing for secondary carpet, comprising: a layer of woven fabric characterized by a flat plot and having an open area of less than 15%; and a fibrous layer, wherein the layer weighs between 15.57 g. per m2 and 311.53 g. per m2 (0.5 osy and 10 osy), and wherein at least a portion of the fibers has penetrated through the woven fabric layer and extends outward from one side thereof; and where the backing for secondary carpet has a permeability, to air greater than 220 cfm / sq ft. The backing for secondary carpet according to claim 1, the woven fabric layer characterized in that it comprises: a warp thread having a first thickness, and a filling thread having a second thickness. 3. The backing for secondary carpet according to claim 2, characterized in that the second thickness is greater than the first thickness. 4. The secondary carpet backing according to claim 2, characterized in that the second thickness is less than the first thickness. 5. The secondary carpet backing according to claim 2, characterized in that the second one is at least three times thicker than the first thickness. The backing for secondary carpet according to claim 2, characterized in that the filling threads comprise one of the following group of threads: spun yarn of open end, spun yarn ring, spun yarn, continuous thick, a core-spun yarn and one strand challenges by stretching. 7. The secondary carpet backing according to claim 2, characterized in that the filler yarn and p > A warp comprises at least one of the following materials: polypropylene, polyester, peliamide, and polyethylene. The backing for secondary carpet according to claim 1, characterized in that the portion of the fibers that penetrate the layer of woven fabric and extend outwardly from a side thereof comprises at least 5% by weight and no more 95% by weight. 9. A backing for secondary carpet, comprising: a layer of woven flat fabric of? A wpi X 6 ppi, characterized in that it comprises: a warp thread; and a filler strand; and a tangled layer of polypropylene fiber, wherein a portion of the fiber extends from a first side of the woven fabric layer and extends from a second side of the woven fabric layer. 10. The backup for secondary carpet according to claim 9, characterized in that: the warp thread comprises strands of tape; and the filler strands comprise spun yarn. 11. A method for making a backing for secondary carpet, the method characterized in that it comprises the steps of: weaving selected strands of the group consisting of spun-off spun threads, thick continuous filaments, spun-core and broken by stretching through a plurality of tapes in a planar weft construction to form a woven toid layer; entangling staple fibers with the woven fabric layer, wherein at least a portion of the staple fibers is present on both sides of the finished fabric layer; heating the staple fibers on one side to lightly fuse the surfaces of the staple fibers together while the staple fibers on the other side remain without fusing; and wherein the woven fabric layer comprises a planar web and has an open area of less than 15%; a fibrous layer, where the layer weighs between 15.57 g. per m2 and 311.53 g. per m2 (0.5 osy and 10 osy); and an air permeability greater than 220 cf: n / sq ft. The backing for secondary carpet according to claim 11, the layer of the woven fabric characterized in that it further comprises: a warp thread having a first thickness, and a filling thread having a second thickness. 13. The secondary carpet backing according to claim 12, characterized in that the second thickness is greater than the first thickness. 14. An inventive carpet, comprising: a primary backup; and a second backing, the secondary backing comprises: a woven fabric characterized by a flat web and having an open area of less than 15%; and a fibrous layer, wherein the layer weighs between 15.57 g. per m2 and 311.53 g. per m2 (0.5 osy and 10 osy), and wherein at least a portion of the fibers have penetrated through the woven fabric layer and extend outward from one side thereof; and where the backing for secondary carpet has an air permeability greater than 220 cfm / sq ft. 15. The inventive carpet according to claim 14, the layer of the woven fabric characterized in that it comprises: a warp yarn having a prime :: thickness, and a filling yarn having a second thickness. 16. The inventive carpet according to claim 15, characterized in that the second thickness is greater than the first thickness.