Stitch-bonded split-film fabric

Claim 2

In a stitch-bonded fabric which includes a layer of nonwoven sheet and layers of split film of synthetic organic polymer, the split film providing one layer which forms a warp component and two layers arranged in zig-zag face-to-face relationship which form a weft component, the warp and weft components being held together by parallel rows of stitches formed by stitching yarn, the improvement comprising the nonwoven sheet being composed essentially of continuous filaments of synthetic organic polymer and being attached to warp layer to form an outer layer of the stitch-bonded fabric.

Claim 3

A stitch-bonded fabric of claim 1 wherein the nonwoven sheet and split film layers are held together by the stitching yarn stitches.

Claim 4

A stitch-bonded fabric of claim 1 or 2 wherein the parallel rows of stitches are chain-and-tricot two-bar stitches.

Claim 5

A stitch-bonded fabric of claim 1 or 2 wherein a carpet-backing tufting lubricant is included.

Claim 6

A stitch-bonded fabric of claim 1, wherein the fabric includes a carpet-backing tufting lubricant amounting to 1 to 5% by weight of the fabric, each split film layer is of a polymer consisting essentially of 60 to 100% polyethylene terephthalate and no more than 40% low density polyethylene and weighs in the range of 20 to 50 g/m 2 , the nonwoven sheet consists essentially of polyester filaments and weighs in the range of 15 to 45 g/m 2 , the stitching yarn is a multifilament polyester yarn having a dtex in the range of 60 to 200 and the stitch-bonded fabric weighs in the range of 100 to 250 g/m 2 .

Claim 7

A stitch-bonded fabric of claim 2 wherein the fabric includes a carpet-backing tufting lubricant amounting to 1 to 5% by weight of the fabric, each split film layer is of a polymer consisting essentially of 60 to 100% polyethylene terephthalate and no more than 40% low density polyethylene and weighs in the range of 20 to 50 g/m 2 , the nonwoven sheet consists essentially of polyester filaments and weighs in the range of 15 to 45 g/m 2 , the stitching yarn is a multifilament polyester yarn having a dtex in the range of 60 to 200 and the stitch-bonded fabric weighs in the range of 100 to 250 g/m 2 .

Claim 8

A tufted pile fabric wherein the stitch-bonded fabric of claim 2 or 6 is included as a primary backing.

Claim 9

A tufted pile fabric wherein the stitch-bonded fabric of claim 1 or 5 is included as a primary backing, the nonwoven sheet sheet of the fabric forming the back side of the backing and the tufted pile yarns attaching the nonwoven sheet to the stitch-bonded split-film layers.