Carpet Comprising A Propylene-Based Elastomer and Methods of Making the Same

Abstract

Provided are carpets comprising at least one propylene-based elastomer. The presence of the propylene-based elastomer provides the carpet with improved properties, including good tuft bind strength and tuft lock strength, and reliable construction.

What is claimed is: 
     
         1 . A carpet comprising:
 (a) a primary backing layer having a face side and a back side;   (b) a plurality of fibers attached to the primary backing layer and extending from both the face side and the back side of the primary backing layer; and   (c) a second layer attached to the back side of the primary backing layer, comprising at least one propylene-based elastomer comprising at least about 60 wt% propylene-derived units and about 5 to about 25 wt% ethylene-derived units, by weight of the propylene-based elastomer, wherein the propylene-based elastomer has a heat of fusion of less than about 75 J/g,   wherein the second layer substantially locks in the plurality of fibers extending from the back side of the primary backing layer.   
     
     
         2 . The carpet of  claim 1 , wherein the carpet comprises no more than 150 g/m 2  of latex. 
     
     
         3 . The carpet of  claim 1 , wherein the carpet comprises no more than 100 g/m 2  of latex. 
     
     
         4 . The carpet of  claim 1 , wherein the carpet comprises no more than 50 g/m 2  of latex. 
     
     
         5 . The carpet of  claim 1 , wherein the carpet comprises no more than 20 g/m 2  of latex. 
     
     
         6 . The carpet of  claim 1 , wherein the carpet comprises 0 g/m 2  of latex. 
     
     
         7 . The carpet of  claim 1 , wherein the fibers comprise at least one of polypropylene, nylon, wool, cotton, acrylic, polyester, and polyethylene terephthalate. 
     
     
         8 . The carpet of  claim 1 , wherein the primary backing layer comprises at least one thermoplastic polyolefin. 
     
     
         9 . The carpet of  claim 1 , wherein the second layer further comprises a filler. 
     
     
         10 . The carpet of  claim 9 , wherein the filler is a flame retardant. 
     
     
         11 . The carpet of  claim 9 , wherein the filler is aluminum trihydrate or calcium carbonate. 
     
     
         12 . The carpet of  claim 1 , further comprising a third layer attached to the second layer opposite to the primary backing layer. 
     
     
         13 . The carpet of  claim 12 , wherein the third layer comprises at least one thermoplastic polyolefin. 
     
     
         14 . The carpet of  claim 13 , wherein the third layer further comprises a filler. 
     
     
         15 . The carpet of  claim 12 , wherein a reinforcement layer is present between the second layer and the third layer. 
     
     
         16 . The carpet of  claim 15 , wherein the reinforcement layer comprises at least one of thermoplastic fabrics and fiberglass. 
     
     
         17 . The carpet of  claim 15 , wherein a middle layer is present between the second layer and the reinforcement layer. 
     
     
         18 . The carpet of  claim 17 , wherein the middle layer comprises at least one thermoplastic polyolefin. 
     
     
         19 . A method for making a carpet comprising the steps of:
 (a) providing a primary backing layer having a face side and a back side, with a plurality of fibers attached to the primary backing layer and extending from both the face side and the back side of the primary backing layer;   (b) applying a second layer to the back side of the primary backing layer, wherein the layer comprises at least one propylene-based elastomer comprising at least about 60 wt% propylene-derived units and about 5 to about 25 wt% ethylene-derived units, by weight of the propylene-based elastomer, wherein the propylene-based elastomer has a heat of fusion of less than about 75 J/g; and   (c) forming a carpet,   wherein the second layer substantially locks in the plurality of fibers extending from the back side of the primary backing layer.   
     
     
         20 . The method of  claim 19 , wherein in (b) the second layer is applied to the back side of the primary backing layer by extrusion coating or sheet lamination. 
     
     
         21 . A carpet comprising:
 (a) a primary backing layer having a face side and a back side, wherein the primary backing layer comprises at least one thermoplastic polyolefin;   (b) a plurality of fibers tufted into the primary backing layer and extending from both the face side and the back side of the primary backing layer;   (c) a second layer attached to the back side of the primary backing layer, comprising at least one propylene-based elastomer, wherein the propylene-based elastomer comprises at least about 60 wt % propylene-derived units and about 5 to about 25 wt % ethylene-derived units, by weight of the propylene-based elastomer, and wherein the propylene-based elastomer has a heat of fusion of less than about 75 J/g;   (d) a third layer attached to the second layer opposite to the primary backing layer, wherein the third layer comprises at least one thermoplastic polyolefin; and   (e) a reinforcement layer between the second layer and the third layer, wherein the reinforcement layer comprises at least one of thermoplastic fabrics and fiberglass,   wherein the second layer substantially locks in the plurality of fibers extending from the back side of the primary backing layer, and wherein the carpet comprises 0 g/m 2  of latex.