Method of manufacturing a carpet or carpet tile, carpet or carpet tile obtained by performing the manufacturing method, and support material for use in the method

Abstract

A carpet, such as a carpet tile, comprises a support material with yarns tufted therein. The support material comprises a first layer of a non-woven material, provided with a reinforcement, such as a second layer of a scrim adhered to the first layer. The yarns are thermally fused at one side of the tufted support material. One or more backing materials are applied to said one side of the tufted support material.

1 . A method of manufacturing a carpet, such as a carpet tile, the method comprising:
 providing an intermediate product comprising a support material having yarns tufted therein, the intermediate product having two opposite sides; and   thermally fusing the yarns at one of the sides of the intermediate product, for anchoring the tufted yarns to the support material,   wherein the support material comprises;   a first layer of a non-woven material, provided with a reinforcement.   
     
     
         2 . The method of  claim 1 , wherein the support material consists of a non-woven material and a reinforcement. 
     
     
         3 . The method of  claim 1 , wherein the support material comprises at least one layer of non-woven material. 
     
     
         4 . The method of  claim 1 , wherein the support material does not include a woven material. 
     
     
         5 . The method of  claim 1 , wherein the reinforcement comprises a reinforcement layer. 
     
     
         6 . The method of  claim 5 , wherein the reinforcement layer comprises a scrim. 
     
     
         7 . The method of  claim 6 , wherein the support material comprises any of:
 at least one layer of scrim;   a sandwiched structure of a first non-woven material, a scrim, and a non-woven material.   
     
     
         8 . The method of  claim 6 , wherein the support material comprises a sandwiched structure of a first scrim, a non-woven material, and a second scrim. 
     
     
         9 . The method of  claim 6 , wherein the scrim is a woven scrim. 
     
     
         10 . The method of  claim 5 , wherein the reinforcement layer comprises a fleece. 
     
     
         11 . The method of  claim 5 , wherein the reinforcement comprises separate parallel reinforcement threads. 
     
     
         12 . The method of  claim 1 , wherein the reinforcement is adhered to the first layer. 
     
     
         13 . The method of  claim 12 , wherein the reinforcement is glued to the first layer, in particular by a latex or a hot melt, or wherein the reinforcement is fused to the first layer. 
     
     
         14 . The method of  claim 6 , wherein the reinforcement is woven into the first layer. 
     
     
         15 . The of  claim 11 , wherein the reinforcement woven into the first layer. 
     
     
         16 . The method of  claim 1 , wherein the reinforcement and the non-woven material comprises polyester, PES, polypropylene, PP, glass, and/or polyamide, PA, in particular PA6 and/or PA6.6. 
     
     
         17 . The method of  claim 1 , wherein the reinforcement and the non-woven material comprises polyester, PES, polypropylene, PP, glass, and/or polyamide, PA, in particular PA6 and/or PA6.6. 
     
     
         18 . The method of  claim 5 , wherein the first layer of the support material is at a pile side of the intermediate product, and the reinforcement layer of the support material is at the opposite side of the intermediate product. 
     
     
         19 . The method of  claim 15 , wherein the step of fusing the yarns is carried out by contacting the yarns with a hot contact element and/or by radiating heat upon part of the yarns. 
     
     
         20 . The method of  claim 19 , wherein the contact element is a roller , and wherein the step of fusing the yarns is carried out by guiding the intermediate product along a surface of the roller. 
     
     
         21 . The method of  claim 1 , further comprising:
 applying one or more backing materials to said one of the sides of the intermediate product.   
     
     
         22 . The method of  claim 21 , wherein the step of applying one or more backing materials comprises applying a bitumen layer and for applying a latex layer. 
     
     
         23 . A carpet, such as a carpet tile, comprising:
 a support material with yarns tufted therein, the yarns being thermally fused at one side of the tufted support material,   wherein the support material comprises a first layer of a non-woven material, provided with a reinforcement.   
     
     
         24 . A support material for use in a method of manufacturing a carpet, such as a carpet tile, the method comprising:
 providing an intermediate product comprising a support material having yarns tufted therein, the intermediate product having two opposite sides; and   thermally fusing the yarns at one of the sides of the intermediate product, for anchoring the tufted yarns to the support material,   wherein the support material comprises a first layer of a non-woven material, provided with a reinforcement.   
     
     
         25 . A support material for use in a carpet, such as a carpet tile, comprising:
 a support material with yarns tufted therein, the yarns being thermally fused at one side of the tufted support material,   wherein the support material comprises a first layer of a non-woven material, provided with a reinforcement.