Abstract A tufted carpet coated with a fused thermoplastic resin on the underside of a tufted primary backing is formed by impregnating the primary backing with a liquid plasticizer either undiluted or diluted with a solvent for the plasticizer, coating the underside of the primary backing with a solid resin powder capable of being plasticized by the plasticizer and fusing the resin coating by heating. The primary backing can be tufted subsequent to impregnation and preferably prior to impregnation with the plasticizer. In one embodiment a secondary backing, either impregnated with plasticizer or containing no plasticizer is applied to the resin coating either prior to or during the time the resin is fused to adhere the primary backing to the secondary backing.
The process of claim 1 wherein the pile and bundle wraps are formed into the primary backing prior to impregnating the primary backing with the plasticizer.
Claim 2
Dependent Claim
39 words
The process of claim 1 wherein a secondary backing is applied to the resin coating on said primary backing either prior to or during the time the resin is fused to adhere said primary backing to said secondary backing.
Claim 3
Dependent Claim
39 words
The process of claim 2 wherein a secondary backing is applied to the resin coating on said primary backing either prior to or during the time the resin is fused to adhere said primary backing to said secondary backing.
Claim 4
Dependent Claim
12 words
The process of claim 1 wherein the resin comprises poly (vinyl chloride).
Claim 5
Dependent Claim
25 words
The process of claim 2 wherein the resin comprises poly (vinyl chloride). 7. The process of claim 3 wherein the resin comprises poly (vinyl chloride).
Claim 6
Dependent Claim
12 words
The process of claim 4 wherein the resin comprises poly (vinyl chloride).
Claim 7
Dependent Claim
47 words
A carpet comprising a primary backing having a yarn pile on one surface and bundle wraps on the other surface, said surface having bundle wraps being coated with a fused thermoplastic resin composition containing a plasticizer for said resin, said yarn pile being substantially free of resin.
Claim 8
Dependent Claim
18 words
The carpet of claim 9 having a secondary backing adhered to said primary backing with said fused resin.
Claim 9
Dependent Claim
12 words
The carpet of claim 9 wherein the resin is poly (vinyl chloride).
Claim 10
Dependent Claim
12 words
The carpet of claim 10 wherein the resin is poly (vinyl chloride).
Claim 11
Dependent Claim
42 words
The process of claim 1 which comprises applying to the solid resin powder a coating comprising a mixture of a solid resin powder capable of being plasticized by said plasticizer and a filler prior to heating the resin to fuse the resin.
Claim 12
Dependent Claim
28 words
The carpet of claim 9 having an additional coating on said fused thermo plastic resin composition which additional coating comprises a fused thermo plastic resin and a filler.