MXPA98005886A - Modified fabric of secondary backrest, metodopara the manufacture of the same and carpet quecontain the mi - Google Patents

Abstract

A modified secondary backing fabric 20 for carpet 50 comprises a secondary backing base fabric and a fibrous material 21 integrated with the secondary backing fabric to form the modified fabric, providing a smooth face 51 opposite the face 52 presented by the fabric base, uninterrupted by the base fabric. A carpet 50 comprises a strand of view 11, a primary backing cloth 12, the strand of view is tufted into the primary backing fabric, a modified secondary backing fabric 20 is attached to the primary backing fabric, and an adhesive material 14 joins the strand of view to the primary backing fabric and the primary backing fabric with the secondary backing fabric. The modified secondary backing fabric 20 comprises a secondary backing base fabric 15 and an integrated fibrous material 21 as a unitary base, which provides a soft face 51 formed on the underside of the carpet, the soft face forming a uninterrupted barrier by a base fabric and blocks the exudation of any adhesive material from the underside of the carpet. One method for manufacturing a modified secondary carpet backing 20 consists of selecting a secondary backing base fabric 15 and a fibrous material 21, joining the two fabrics to form the secondary modified carpet backing 20, providing an opposite smooth face 51. to the face 52 presented by the base fabric, uninterrupted by the base fabric, and subjecting the modified fabric to sufficient heat to remove substantially all of the loose fibers projecting from the smooth surface. The present invention also provides a method for the manufacture of the carpet

Description

MODIFIED FABRIC OF SECONDARY BACKREST, METHOD FOR THE MANUFACTURE OF THE SAME AND CARPET THAT CONTAINS THE SAME CROSS REFERENCE WITH RELATED APPLICATION The present invention is a continuation in part of United States document Serial No. 08 / 898,667 issued July 22, 1997.

FIELD OF THE INVENTION The present invention is broadly related to a modified secondary backing material or base fabric. This modified base is both novel and improved and is particularly suitable for carpets. More particularly, the present invention relates to a carpet containing the improved base fabric and to the manufacture thereof. Carpets typically include view fibers, in the form of plushs, backup members, primary and secondary, and latexes or adhesives, or both, to bond the components together. A modified secondary or base backing member has been developed for the carpets, imparting useful properties to form a novel and improved carpet. The present invention also provides an easy method for manufacturing the modified secondary backup members and their use in the manufacture of the carpet.

P11 6 / 98MX BACKGROUND OF THE INVENTION Plush carpets are widely used today in the United States and abroad. These carpets are produced by tufting machines that are sewing machines with multiple needles. The tufting machines push, or more specifically, sew the strands of view of the carpet (also called strands of hair) through the primary backing fabric, forming loops in the strands of view. The machines also hold the view strands in place while the needles move. The loops that are formed by the strands of view are either released to form a plush carpet with hair in loops or are cut to form the plush carpets of shaved hair. A secondary backing fabric, attached to the stitched side of the primary backing fabric, that is, the side opposite the overhanging strands of view, is used to keep the strands of view tucked in place and is typically attached to the backing fabric. primary backing by a latex or an adhesive binder applied to the stitched side of the primary backing fabric. Although the combination of the secondary backing fabric and the adhesive binder combine to provide the necessary rigidity for the carpet, allowing it to P1146 / 98MX remains flat and resists coiling or usage traffic, the back surface of the carpet becomes very rough, in fact abrasive. The carpets are delivered to the installation site in rolls, with the strands of view internally, and in sections taken from the loom that are usually 12 to 15 feet wide. Because the roll is heavy and in some way unmanageable, it often creeps around the corners of walls and through narrow aisles and doorways, which causes the rough back surface of the carpet to cause some damage to the room. , house or building in which it will be installed. Although there are some carpets that have a soft backing, such as the foam backing that is used for indoor / outdoor carpets, better quality terry rugs have been produced using a secondary backing and adhesives as described above. It is expected that the current production of plush carpets for the year of 1997, in the United States alone, will reach more than 4 billion square yards in addition to the 1.6 billion in 1994. However, despite the damage that results constantly from the delivery and installation of the carpet, very little has been done to change the construction of the plush carpets. A review of patent literature P1146 / 98MX during the last three decades reveals many variations of carpets. For example, U.S. Pat. No. 3it is. , 497,414, discovers a nonwoven carpet and a method for making the same. The non-woven carpet of the patent is produced by sewing a block of polyolefin fiber fibrous material to compress and partially strengthen the block of fibrous material and to create a smooth face and a hair face from which the ends of the fiber slightly protrude. of polyolefin. The hair face of the block of fibrous material is heated to melt the ends of the fibers to form balls at the ends of the fibers. This combination can be used alone as a carpet or as a carpet finish in combination with a backing that can consist of a laminate sewn of fibrous material with foam fiber. Preferably, the laminate is composed of polyolefin fiber and a layer of flexible polyurethane foam and is bonded to the carpet finish by lamination. U.S. Patent No. 3,510,386 discloses a structure of an antistatic mat having a fibrous layer, an antistatic conductive coating and a polymeric backing. The structure discovered includes a fibrous hair that extends upwards from the primary backrest that was initially supported by an antistatic layer. The backup layerPolymeric P1146 / 98MX keeps the antistatic coating layer in place and can help the antistatic coating layer to disperse loads to the ground. The polymeric backing layer is preferably applied in the form of an aqueous latex dispersion although other polymer coatings such as polystyrene, vinylidene chloride, polyacrylates, styrene and butadiene rubbers and their like can be used. The patent also discovers that a secondary backup to the polymeric backing can optionally be applied. U.S. Patent No. 3,922,454 discloses a secondary backing for carpets comprising a synthetic base woven with a layer of strand fibers stitched onto the upper surface of the base with portions of fibers projecting across the surface bottom of the base. Then, a latex coating is applied to adhere the fibers to the lower surface of the base and the lower surface then ironed. The secondary backup is connected to the back side of the primary backrest by a layer of adhesive. Once applied, the secondary backing provides an anti-slip coating that allows the carpet to better bond to the floor. U.S. Patent No. 4,112,161, discloses the structure of a plush pile fabric for P11 6 / 98MX interior / exterior that is intended to be a substantially permanent floor covering. The plush pile fabric includes a primary synthetic plastic backing and a secondary synthetic plastic backing which are laminated together by a hot melt adhesive, to form a relatively rigid impermeable sheet. Then, the structure is provided with a plurality of perforations to give the fabric a soft feel and respiration. The patent intends for the fabric to be secured to the floor with adhesive. U.S. Patent No. 4,153,749 discloses an antistatic mat that includes a primary backing that carries the strands. A secondary backing includes a base formed of woven or non-woven jute or polypropylene or polyester and a conductive polymeric layer that attaches to the upper side of the base. The secondary backing is bonded to the primary backing by a conventional non-conductive latex coating. U.S. Patent No. 4,305,986 discloses a plush carpet composed of strands of hair that are attached to a primary backing that can be either a non-woven or woven fabric attached thereto. A secondary backup is a nonwoven fabric composed of P1146 / 98MX individual filaments that are arranged randomly, in such a way that they intersect and that they are united on their crossing points, with the help of the application of a secondary binder. The secondary backing is adhered to the primary backing by a rubber or PVC latex coating. The patent discovers that the purpose of the secondary backing is to provide not only greater stability to the plush carpet, but also to provide easy sliding on other surfaces. U.S. Patent No. 4,522,857 discloses a carpet plate consisting of a primary carpet base and a foam layer. The base of the carpet is laminated to the foam layer by an adhesive layer which is embedded with a glass base layer to provide dimensional stability to the carpet plate. The foam layer consists of a backing with woven polypropylene fibrous carrier coated with a high density urethane foam having an integral surface of rough skin on its lower side. The patent discloses that the carrier backing can be woven or non-woven and composed of other materials such as nylon, polyester or glass fiber. The carrier backing makes contact with the adhesive that joins the foam layer with the primary base of the carpet. U.S. Patent No. 4,702,950 P1146 / 98MX discovers a carpet plate having a primary backing sheet composed of a non-woven polyester or a polypropylene tape. The carpet plate includes a first precoating composition and a second precoating or an intermediate coating composition that includes a limestone load, a bitumen, petroleum resin and an ethylene vinyl acetate polymer. A second layer of backing composition includes a bitumen with a polymeric rubber thermoplastic material that adheres to the secondary backing sheet that includes a glass fiber base material bonded to the secondary backing sheet, which forms the surface exposed back of the carpet. The secondary backsheet may consist, for example, of a nonwoven polyester sheet material. The secondary backing coating is hot melted onto the secondary backing sheet and the combination is laminated with the top layers. United States Patent no. 4,871,603 is directed to a carpet plate with a cushioned backrest. The backing material is described as non-woven and laminated to the base of the carpet by an adhesive layer, polyolefin, modified polyolefin, polyamide or other suitable thermoplastic material, which is embedded with a glass base layer to provide stability of the backing.

P1146 / 98MX dimension. The non-woven layer is about 3/16"to" thick and consists of substantially all synthetic fibers, such as polyester, nylon and their like. The patent discloses that synthetic fibers are held together in the layer by conventional needle puncture or air layers. U.S. Patent No. 4,988,551 discloses a carpet having a nonwoven hair fabric adhered to the secondary backrest by embossing. The nonwoven hair fabric is embossed on a secondary backing which is attached in a conventional manner to a primary backing. The relief roll makes contact with the nonwoven hairy fabric and forms high and low areas. The undersurface of the non-woven layer is then coated with a layer of pressure-sensitive adhesive and used to securely secure the floor covering to the underlying floor. The low areas extend into the secondary backrest and serve to unify the hairy fabric with the secondary backing. U.S. Patent No. 5,030,497 is directed to a carpet plate having a backing layer of hot melt composition having a secondary backing of a glass fiber fabric sheet material directly adjacent to the sheet material fibrous nonwoven as a sheet material P1146 / 98MX polypropylene. The secondary backing includes a lightweight, fiberglass fabric sheet material and a spunbond nonwoven sheet material adhered with polypropylene attached thereto. The patent discloses that the back surface of the nonwoven sheet material is not saturated with hot melt composition to keep the nonwoven sheet layer bonded to the sheet layer of glass fiber fabric. U.S. Patent No. 5,104,712, discloses a material for covering a surface that includes an outer layer consisting of a preformed fabric, a lower layer consisting of a sheet material impervious to liquids, rigid and adhered to the underside of the outer layer by means of a layer of bonding adhesive, and a lower layer of a hydrophobic closed cell foam, relatively more flexible, which is attached to the lower surface of the lower layer by a hot melt adhesive or by sintering. U.S. Patent No. 5,204,155, discloses a floor covering, such as a carpet or a carpet plate that includes a primary backing layer composed of a fabric having a fluffy, fibrous face and a fibrous back surface that is coated with a pre-coating layer, a first layer, a non-woven glass fiber base sheet, P1146 / 98MX porous, a layer of foam and a layer of modified bitumen. A second secondary backing layer includes a nonwoven, porous fiberglass fabric sheet material that is directly bonded by the bitumen layer to the secondary backing layer of polypropylene or nonwoven polyester, such that the backing layer Bitumen does not extend through the secondary backup layer. U.S. Patent No. 5,470,648, refers to a composite fabric having two layers of non-woven fabric consisting of non-bonded nylon filaments entangled and a reinforcing layer of base with glass fiber bonded by adhesives to each of the non-woven layers. The composite fabric is useful as a backing in a carpet arrangement. The patent discovers that the composite fabric is especially useful in environments where changes of season with respect to humidity and temperature can cause the carpets to loosen and wrinkle. The non-woven nylon layers are bonded to the glass fiber base by means of an adhesive applied to the surface of the base. U.S. Patent No. 5,540,968 discloses a padded backing carpet plate with a nonwoven stabilized backing. The backing material is preferably a non-woven material with needle puncture that has been subjected to a treatment of P1146 / 98MX heat to impart a smooth surface finish. The backing material consists of between about 30 percent and about 70 percent polypropylene and between about 70 percent and about 30 percent polyester. The thickness of the backing material can vary within the range of 0.03 inches to about 0.07 inches. A polymer layer is kneaded into the backing material and made at a predetermined height with a blade. A primary carpet fabric is joined with a reinforcing material that is placed directly on the polymer layer made to laminate the layers. U.S. Patent No. 5,558,916 discloses a method for manufacturing a carpet having a secondary backing substantially impervious to liquids. The method involves applying a repellent finish on the secondary backing material and drying the finish. The finish can be applied as a foam to the secondary backing material, which is found to be one of the backing materials known in the art, such as jute, woven polypropylene tapes, plain woven polypropylene fabrics, felts and thermoplastic films of polymer. The secondary backup is connected to the primary backup with any adhesive polymer latex.

P1146 / 98MX U.S. Patent No. 5,578,357 discloses a carpet having a primary backing with felts of synthetic carpet fibers protruding from a top surface and, optionally, a secondary backing. The secondary backing is discovered as a woven or non-woven fiber construction. The secondary backing is joined with an iso-static polyolefin sheet that melts to the primary backing. The patent also discloses that the lower layer of the carpet may be formed to be a co-extruded layer of thermal plastic polyolefin elastomer bonded to the bottom surface of an extruded sheet that is bonded to the primary backing. Finally, U.S. Patent No. 5,604,009 discloses a bonded, non-stick carpet, consisting of a carpet with secondary and primary backing that is made of non-woven fabrics. The eye strands are embellished inside the primary nonwoven fabric and then the primary and secondary fabrics are combined without adhesive. While the art is saturated with examples of carpet plates having a variety of backing materials, the manufacture of a wide range of plush carpets has remained relatively unchanged until this present invention.

P1146 / 98MX SUMMARY OF THE INVENTION It is, therefore, an object of the present invention is to provide a modified secondary carpet backing that will increase the delamination resistance and the dimensional stability of the carpet. It is another object of the present invention to provide a modified secondary carpet backing that provides a physical barrier that blocks the exudation of latex or other adhesive out of the backing of the carpet. It is still another object of the present invention to provide a modified secondary carpet backing that provides a non-abrasive surface to minimize surface damage to walls, skirting boards, wood, floors of commercial buildings and residences, as well as physical damage to The installer. It is another object of the present invention to provide a secondary modified backing that improves the perception of the surface or "feel" of the finished system of the carpet. It is another object of the present invention to provide a modified secondary carpet backing that facilitates the installation of the carpet using it by providing a surface with reduced friction, allowing both the carpet and the P1146 / 98MX cushioned slide together. It is another object of the present invention to provide a modified secondary carpet backing that functions to provide additional or unique cushioning for the carpet system. It is another object of the present invention to provide a modified secondary carpet backing that can be employed as a separate cushion for the carpet. It is another object of the present invention to provide a modular or wide-width carpet that has greater flexibility, which improves the installation process by providing a carpet with superior flexibility that allows the carpet installers to bend, twist and manipulate the carpet. carpet in narrow aisles, as well as accommodate unusual floor strokes, providing the potential to remove up to 33 percent of the normal seam required. It is another object of the present invention to provide a carpet in modules or wide width that provides a carpet of superior flexibility in which the coefficient of flexibility is increased up to 20 percent at 40 ° F unlike the prior art and up to a 35 percent increase at 70 ° F unlike the previous technique.

P114S / 98MX It is another object of the present invention to provide a carpet in modules or wide width that provides a carpet with superior flexibility that reduces installation time up to 20 percent, therefore, provides substantial cost savings during the installation process It is another object of the present invention to provide a modified secondary carpet backing, which functions to provide greater comfort when walking on it. It is another object of the present invention to provide a modified secondary carpet backing that provides antimicrobial properties to carpets made therefrom. It is another object of the present invention to provide a modified secondary carpet backing that provides anti-static properties to the carpets that are made therefrom. It is another object of the present invention to provide a carpet of modules or wide width having antimicrobial properties. It is another object of the present invention to provide a carpet in modules or wide width having antistatic properties. It is another object of the present invention to P1146 / 98MX provide a method for manufacturing a modified secondary carpet backing that provides a smooth backing surface. It is another object of the present invention to provide a method for manufacturing a carpet using the secondary modified carpet of the present invention to provide a smooth backing surface. At least one or more of the above objects, together with the advantages thereof, are known in the art relating to carpets and the manufacture thereof, and which will be apparent from the specification that follows, are achieved by the invention as described and claimed hereafter. In general, the present invention provides a secondary modified backing fabric for the carpets, consisting of a secondary backing base fabric and a fibrous material integrated with the secondary backing fabric which forms a modified fabric, providing a smooth face opposite to the backing fabric. the face presented by the base fabric, uninterrupted by the base fabric. The present invention also includes a carpet consisting of a strand of view, a primary backing fabric, the strand of view is tucked inside the primary backing fabric; a modified fabric of P1146 / 98MX secondary backup attached to the primary backup fabric; an adhesive material joins the strand of view to the primary backing fabric and the primary backing fabric to the secondary backing fabric. The modified secondary backup fabric consists of a secondary backing base fabric and the integrated fibrous material as a unitary baseBy providing a smooth face that forms the underside of the carpet, the soft face forms an uninterrupted barrier by the base fabric and blocks the exudation of any adhesive material from the underside of the carpet. The present invention also provides a method for manufacturing a secondary modified backing base for carpet, which consists of selecting a secondary backing base fabric and a fibrous material.; joining the two fabrics to form the secondary modified backing base for carpet and providing a smooth face opposite the face presented by the base fabric, uninterrupted by the base fabric; and subjecting the modified fabric to sufficient heat to substantially remove all loose fibers projecting from the smooth surface. The present invention also provides a method for manufacturing a carpet consisting of providing the viewing strands in a backing fabric.

P1146 / 98MX primary; providing a modified secondary backing for carpet, formed from a secondary backing base fabric and a fibrous material, the modified backing provides a smooth face opposite to the face presented by the base fabric, uninterrupted by the base fabric; attaching the modified backing to the primary backing fabric with an adhesive material; and heat the modified backing, the primary backing cloth and the adhesive material together at a sufficient temperature to adhere the backs together and produce a carpet, which has a smooth face that forms the underside of the carpet, the soft face forms a barrier uninterrupted by the secondary backing base fabric and blocks the exudation of any adhesive material from the underside of the carpet.

BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is an isometric view of a section of a plush carpet according to the prior art, showing the different stages of the construction; Fig. 2 is a schematic side elevation of an apparatus used for manufacturing a secondary modified backing carpet base of the present invention; P1146 / 98MX Fig. 3 is a side elevation of a section of a modified secondary backup base of the present invention; Fig. 4 is a fragmented top plane with a progressive cut showing the different layers of a plush carpet, according to the present invention, as illustrated in Fig. 6; Fig. 5 is a lower floor elevation of a modified secondary carpet backing base illustrated in Fig. 3; Fig. 6 is an isometric view of a section of the plush carpet utilizing the modified secondary carpet backing base of the present invention, showing the different layers of the construction; FIG. 7 is the sectional view of a plush carpet according to the prior art illustrating the separation of the primary and secondary backing fabrics in delamination; FIG. 8 is a sectional view of a plush carpet utilizing the modified secondary carpet backing base and illustrating the separation of the primary and secondary backing fabrics in delamination; Figs. 9-11 are bar graphs that illustrate P114S / 98MX the delamination values and the seam strengths by comparing the carpet of the present invention with the carpet of the prior art; Figs. 12A-B are two comparison areas over which a type of carpet was evaluated for rest, each one reporting the statistical results of the evaluations; and Figs. 13A-B are two additional areas of comparison on which another kind of carpet for rest was evaluated, each of which reports the statistical results of the evaluations.

DETAILED DESCRIPTION OF THE INVENTION The known construction of the carpets is apparent from the section illustrated in Fig. 1, where some of the layers have been peeled to reveal their components. As used herein, the term "carpet" refers to all forms of types of plush, woven and sewn carpets, because the practice of the present invention is not based on the type of carpet, but on the use of a carpet. modified base fabric in place of the conventional secondary base or carpet backing, as will be explained hereinafter. A typical carpet, designated generally with the number 10 in the drawing, includes a plurality of strands P1146 / 98MX 11 are typically felted, knitted or needle punched in and through a primary backing cloth 12, providing loops 13 that are secured within the primary backing. These, in turn, are held more securely in place by a conventional latex and a binder adhesive 14. The most common method for finishing a carpet 10 is to laminate a polypropylene woven secondary backing or a base 15 to the primary fabric 12 by the use of latex 14. It is attached to the primary backing by virtue of the adhesive layer 14 and adhesives by separated, applied to the base. The adhesive binder (s) surround the warp and weft threads 16 and 18 respectively, of the base and occupy a portion of the interstitial areas 19, formed by the warp and weft threads and often encapsulate the threads. After the binder materials are hardened or cured, an abrasive, rough surface is produced by the charge added to the binder which is often ground marble, inherently abrasive. This lamination step is an important part to make a carpet more stable, resistant to moisture, shrink-proof and non-fraying at the edges. More obvious is the fact that without any kind of rolling step, the plush or the face of the carpet will P1146 / 98MX could easily pull the carpet. In addition to the mechanical characteristics, this step of lamination also helps the aesthetics, so that it improves its thickness or volume and provides a more consistent and pleasant appearance and sensation. The lamination of a polypropylene secondary carpet backing is achieved by a multi-step process, which uses an oven that is often greater than 200 feet in length. First, the back of a carpet is coated with approximately 22 to 28 ounces / yard of latex and the application is softened with a "scraper blade". This scraper blade is necessary to put the latex inside the fluted thread to secure the strand in the primary backing. Simultaneously, the second part of the multi-step process is performed, covering the secondary backup. This coating is much lighter than the carpet application, approximately 4 to 10 oz / yd. The third step is the "marriage" of these two pieces in a single unit. The secondary backrest must be placed very carefully so that the edges coincide with the plush product and the two are pulled through a pressure roller (called link roller) to laminate or stick them together.

Thereafter, the carpet is processed in an oven at approximately 300 ° F to dry or "set" the latex. The P1146 / 98MX finished carpet is cooled and rolled up before storage for final shipment to the customer. The strands 11 of view of the carpet 10 can be made of any material known in the art as being suitable for use as eye strands and, preferably, are made of polymers selected from the group comprising polyolefins, polyamides, polyesters, teraphthalate of polyethylene (PET) and polytrimethylene teraphthalate (PTT) and mixtures thereof. Most preferred are polypropylene, polyester and nylon. Of course, the practice of the present invention is not limited to the selection of any specific kind of fiber for the strands of view and this includes the use of natural fibers. The viewing strands 11 may be prepared by any means known in the art. Preferably, the conventional equipment and method are used to make the rolled strands or continuous filament strands in bulk consisting of a plurality of polymer fibers produced by conventional extrusion methods with conventional equipment. Thus, the term eye strands is intended to include all forms of threads that can be used for carpet manufacture, either rolled strands or continuous filament strands of continuous filament or other forms of strands.

P1146 / 98MX The primary backup fabric 12 can be produced by using industry accepted methods. Typically, the primary backing fabric 12, as well as the secondary backing fabric 15, are made of polyamides and polyolefins, particularly polypropylene. As it is known primary and secondary backing fabrics are prepared from fibers, typically synthetic fibers that have replaced natural or wool or cotton fibers. However, the fibrous components can be derived from natural as well as synthetic fibers and the synthetic materials can be derived from natural materials as well as from recycled materials, and thus, the practice of the present invention is intended to include all forms of fibers in the manufacture (weaving) of the primary and secondary backing fabrics and the selection thereof is not critical to the practice. With respect to adhesive binders, typical materials used include styrene-butadiene rubbers (SBRs), PVC, EVA, polyesters, polyurethanes, polyolefins, emulsified polymers and their like. In accordance with this, the practice of the present invention includes all the known sight strands and backing materials, as well as the adhesive binders, none of which constitute P114S / 98MX a limitation for practice. In addition, other methods for joining the primary and secondary backup members include extrusion coating, blow molding, thermal bonding including ultrasonic, infrared, microwave, radio frequencies and their like. As can be seen from the foregoing, the present invention provides a secondary modified backing material for carpet, indicated generally with the numeral 20 in Fig. 3. The modified secondary backing consists of an integrated, novel base formed by the union of a conventional woven secondary backing fabric 15, with a layer of fibrous material 21 or with a nonwoven material (fabric) made of fibrous material. Notwithstanding the reference of the conventional woven secondary backing fabric, it should be appreciated that the practice of the present invention is not limited to any particular kind of secondary fabric, since the woven, basted, dot-stitched fiber can be employed, thermally melted with the use of low melting fibers and other processes, to manufacture an appropriate secondary modified backing. As is known, fibrous and non-woven materials can be manufactured from fibers, including natural as well as synthetic fibers, and materials Synthetic P114S / 98MX can be derived from natural as well as from recycled materials. With respect to natural fibers, cotton can be particularly useful although other wool fibers can not be excluded. With respect to synthetic fibers, polyolefins, particularly polypropylene, are preferred. Synthetic fibers are advantageous because of their physical and chemical properties and also because natural and recycled materials can be employed, and thus, the practice of the present invention is intended to include all forms of fibers in the manufacture of materials fibrous and non-woven and the selection of them is not critical to the practice. In the manufacture of a non-woven material, it is also possible to use fibers that have been treated or manufactured with separate properties such as antimicrobial or antistatic, and in addition the usefulness of a modified secondary backup for carpet and the carpet made therefrom is improved. A product that has antimicrobial properties will be useful for "clean" environments such as hospitals, food handling / processing areas, health societies, locker rooms and the like. Similarly, products that have antistatic properties will be useful in the electronics industry where control over the static of the P1146 / 98MX electricity is vital. Thus, although the following description of the secondary modified carpet backing of the present invention is exemplified by the use of polypropylene fibers for nonwovens, it should be understood that fibers having additional chemical properties can be easily employed. Nonwovens are produced by many different processes, but all have three steps in common: formed of the canvas, union of the canvas and finished of the canvas. By using the variations of these steps, a non-woven fabric can be accredited for many different applications in textile and industrial use. The following description is a generalization of each of the steps used to produce a non-woven fabric and does not mean including all possible variations. The formation of the canvas can be divided into three different methods; wet fixation, dry fixation and direct fixation. The wet setting process is very similar to that of papermaking. Manipulate short fibers with a water solution through a mesh where the water is removed and a sheet or canvas is formed. Generally, the canvas has some kind of chemical applied as a binder before moving on to the next process. The method of dry fixation is also known as carding (carding wool). The carding is a P114G / 98MX process that arranges fibers in arrays of parallel lines when using rotating drums covered with fine wires and teeth. Due to the relatively high thickness of the canvas, some kind of canvas layers (transverse overlap) are usually employed in the non-woven card. The direct fixation method can be classified as spinning or melting by blow. In spun bonding, fibers are formed by forcing the melted polymer out of small holes and depositing the filaments on a moving band that forms the canvas. The filaments stick together at the crossing points created by the movement of the extrusion dies and the air flow. In the melt blown the molten polymer is blown with hot air on the face of the rows causing the filaments to fracture into small fibers. These fibers are blown into a mesh where it joins with one another as it cools to form a canvas. A fourth means for the formation of the canvas includes the grouping that is a method of ornamentation of clothes, in which a fabric is printed or covered with an adhesive and crushed fibers are applied by various means, such as dusting, air blowing or attraction. electrostatics. In grouping printing, the fibers adhere only to the printing areas P1146 / 98MX and are removed from the non-printed areas by mechanical action. This technique can be used to form useful canvases for bonding with the secondary fabric, as will be described later. The adhesion of the canvas can be achieved by chemical adhesion, mechanical adhesion or thermal adhesion. The chemical adhesion is simply to use latex or in some cases a solvent, to stick the formed canvas. Other adhesion chemicals are known and can be used for the practice of the present invention. Sometimes coloring or printing is achieved in this step. Mechanical adhesion can be either needle puncture, hydroentangling or adhesion by sewing. The needle puncture consists of forcing the needles barbed vertically through the formed canvas and entangling the fibers as the needles pass multiple times through the canvas. In this process the type of barbed needles and the speeds of the needle and the fabric are critical for the development of adhesion. The hydroentangling uses water jets at high speeds to achieve adhesion of the fiber canvas. These jets of high pressure water are directed towards a perforated cylinder to allow an aesthetically pleasing appearance. The adhesion by stitching uses a continuous filament stitched inside the formed canvas to keep the fabric together with P1146 / 98MX her. Thermal adhesion can be achieved by forcing hot air through the canvas or by transferring the canvas through a set of hot, embossed rollers. In any method the adhesion is aided by having low temperature melting fibers in the canvas, or by applying the low melting point additives (powder or grain) to the canvas before the heating stage. The finishing of the fabric is determined by the properties required for the final use of the fabric. If a softer fabric with more volume is desired, slip and emboss are used to change the texture and feel of the non-woven fabric to meet the needs of the end use. In order to form fabrics with complex properties, the laminate is used. For example, two softer and weaker fabrics can "sandwich" a stronger fabric, in order to obtain a strong fabric with the characteristic of softness. Some of the properties that are achieved by the finishing process are respiration, repellency, porosity, absorbency, softness to the touch and combinations thereof. In a preferred embodiment, the fibrous material 21 is a needle punched canvas material that lies transversely and consists of polypropylene fiber. When using polypropylene fiber, fibers of about 4 denier are preferred P1146 / 98 X filament by 4 inches in length, with the weight of the fiber varying from about 0.5 to about 40 ounces per square yard, and being more preferred with about 1.75 to 2.25 ounces per square yard. The higher weights of the fibrous material will provide greater rest cushion, greater noise absorption and greater insulating properties. The fibrous material 21 adheres to the secondary backing fabric 15 by mechanical adhesion, particularly by needle puncture. With reference to Fig. 2, a segment of apparatus, generally 25, used for mechanical adhesion is illustrated schematically. A continuous layer of the secondary backing 15 is delivered on a mobile band 26 where it is joined from above by a fibrous material 21. A roller mechanism 28 is juxtaposed on the moving fibrous material to compress some of the individual layers consisting of fibrous material, such as 29. Then, the two adjacent components are fed into the loom, generally 30. As they enter the loom, the fibrous material 21 rides on the upper part of the secondary fabric 15 and is then further compressed between two plates, base and release 31 and 32, respectively, where sewing actually occurs. The two plates are mirror images of each other and contain small holes 33 for P1146 / 98MX the penetration of the needles. Needle looms, when used with fibrous materials, such as individual layers of fibrous material, urge needles through the fibers to form a tangle. However, for the present invention, the barbed needles carry fibers of the fibrous material 21 through the secondary base 15, to provide lamination between the two. While there are many configurations of looms, the preferred loom for the manufacture of the modified base 20 uses the technology of a single downward puncture. This means that the needles 34 carried by the needle board 35 are moved by a reciprocal mechanism 36 to penetrate the fabrics from the top downwards, or through the fibers of the fibrous material within the base. Other needle looms provide both upper and lower penetration and / or multiple needle panels in series within the same loom. The single needle board has a needle density of approximately 75 to 150 needles per inch of working width. In typical use, the penetration speed of a puncture needle line will be approximately 20-25 feet per minute with needle boards sewing at approximately 600 to 1200 strokes per minute, resulting in 350 to 450 penetrations of P1146 / 98MX needle per square inch (PPSI) with an advance of approximately 0.31 inches per stroke. The inches of advance per stroke depend on the needles per inch with respect to the width of the work, or density of needles. A stretch or elongation of 4-8 percent is required in the needle loom to provide the correct tension during sewing. It is believed that the invention works best by providing approximately 400 PPSI in order to provide the stability of desired dimension, adhesive blocking ability, desired aesthetics (smoothness, uniformity), securing the fibers to avoid draping, lamination of the secondary base and fibers and the cushioning effect. Significant changes in the PPSI may increase some of the listed effects while sacrificing others (i.e. the increased PPSI would increase the securing of the fibers to avoid draping, but would decrease the cushioning effect). The needles used in the needle puncture process can be of any type (eg barbed) suitable for integrating the fiber into the secondary backing fabrics, but the preferred needles are the standard Foster type, triangular knife needles 15x18x36x3 RBA or its equivalent . These needles consist of a triangular shaped arrow, 6 harpoons (2 at each apex), a depth of P114ß / 98MX arrow of 0.0003 ', an arrow angle of 20 °, a spacing of arrow RBA and a length of 3.5 inches. These needles penetrate the secondary fabric and the fibrous material to a depth of approximately 12 mm. This depth is defined as the distance in which the tip of the needle penetrates the lower plate (bed). With the aforementioned needles, this depth is preferred and is believed to provide maximum integration of the fibers of the fibrous material with the secondary fabric. The needles must penetrate through the fiber first and then into the base. A reverse in the direction of the needle would not produce an equal product. A deeper penetration would adversely affect the desired characteristics such as the uniformity of the fabric (aesthetics) and the cushioning effect on the final carpet product. Less penetration would not achieve sufficient mechanical adhesion between the fibers and the base. During the sewing process it is important that approximately 70 percent of the fibers remain on one side of the base, which is referred to as the side of the needle or upper side, which is the side that will eventually make contact with the floor. The remaining 30 percent of the fibers to be directed towards the latex binder, allows the base to have an intimate contact with the binder during the manufacture of the carpet; for the P1146 / 98MX therefore increases the rolling resistance and adds stability to the carpet. While the above proportions of the fibers residing on the floor side of the modified base 20 are larger than on the latex side for most of the carpets, there are examples where it may be useful to have other proportions, approaching the same or where the amount of the side of the floor is less than that of the adhesive side. In the manufacture of carpet plates, as an example, a higher concentration of fibers e. g. 70 percent on the latex side, will produce improved products on existing carpet plates that do not employ the modified base of the present invention. Returning to the manufacture of the modified base, it will be appreciated that the above-specified operation is only a preferred process for joining a secondary backing fabric with the fibrous material. Furthermore, with respect to the needle puncture process described above, it can be appreciated that alternative operations of the needle loom can be used. For example, lower penetration speeds and the reduction of punches per minute of the needle panels would still allow the needle loom to provide the required number of punches per square inch through the fibrous material and the backing fabrics.

P1146 / 98MX secondary. After passing through the needle loom 30, the resulting bonded matted fabrics are pulled from the loom by opposite drive rollers 38, 39, to pass through an infrared heater 40. The infrared heater 40 is used to melt the errant fibers hanging upwards on the surface 41 of the modified base, originated in the fibrous material that is now integrated into the base. The melting of the protruding fibers serves to prevent them from breaking and loosening in subsequent processes and to improve the adhesive blocking characteristic of the product, while providing a slippery surface which facilitates installation. During the subsequent manufacture of the carpet, a modified base 20 is adhered to the primary back 12 and to the loops 13 of plush strands with an adhesive. The casting of the foreign fibers eliminates any undesired formation of masses consisting of loose fibers and adhesives that can be formed and deposited in the smooth application of the layers in the final stages of the manufacture of the carpet. The heating step is conducted at a temperature sufficient to melt the foreign protruding fibers, without melting the fibers in the P1146 / 98MX fabric body. The temperature that is required will depend on the polymer used, with polypropylene, the temperatures vary from 138 ° C to 171 ° C. The residence time within the heating area varies from about 6 to 15 seconds. These parameters of heat and time depend on the distance between the heat source and the surface of the fabric. In practice the fabric has been placed about 4 inches from the surface of the fabric and infrared heat is applied only on the side of the fabric that does not have the secondary base exposed. With reference to Figs. 3 and 5, it is apparent that a portion of the fibers 45 of the fibrous material 21 penetrate and become entangled with the secondary base 15. On the opposite side of the fibrous material 21, the leftover fibers 46 are attached to the surface of the floor. The union of the fibrous material with that of secondary base imparts the physical properties that neither a non-woven fabric i.e. a fibrous material sewn into a fabric without secondary base, nor a secondary base product can impart individually. In addition, a simple layer of the two fabrics or the joining of the two in a way that does not provide an integrated product can not duplicate the desired physical characteristics. These facts are supported by the values reported in Table I below.

P1146 / 98MX • or H M TABLE 1 COMPARISON OF PHYSICAL PROPERTIES WEIGHT (%) ENCOGÍ - LBS. (%) SIZE FLOW RIGIDITY FLOW (OZ / YD2) LENGTH TENSION AIR LENGTH (APPARENT FEET OF WATER PULG-LBS URDIMBRE X URDIMBRE XU URRDDIIMMBBRREE XX CUBIC OPENING (GALLONS TRAMA T TRRAAMMAA / MIN) / MIS) BASE 4.3 1.7 x 1.1 52 x 72 18 x 36 456 100 178 50.37 MODIFIED FABRIC 2.0 3.3 x 4.9 78 x 31 23 x 34 1242 open N / A 6.53 BASE FABRIC NO 2.3 2.4 x 0.4 65 x 100 60 x 55 312 140 202. 9 20.58 I? J TISSUE The values reported in Table 1 were determined as follows: 1. Mass per Area Unit - ASTM D-5261 - The mass per unit area of a fabric is determined by weighing the test samples of known dimensions, cutting them in several places over the total width of the laboratory sample. The calculated values are averaged to obtain the average mass per unit area of the fabric in question. The mass is expressed in ounces per square yard. 2. Shrinking the fabric - ASTM D-2646 - A measured sample is taken from a laboratory sample and exposed to dry heat for a prescribed time, cooled and remeasured to determine the dimensional changes. The shrinkage is expressed as% change. 3. Grip tension and elongation - ASTM D-4632 - A continuously increasing load is applied longitudinally to the sample and the rupture test is carried out. The values for the breaking load and elongation of the test sample are obtained from the machine or interface computer brands. The values obtained are averaged to obtain the breaking load and the P1146 / 98MX elongation of the given fabric. The tension is expressed in pounds of applied force and the elongation is expressed as a percentage. Air Permeability - ASTM D-737- The velocity of air flow through a known area of the fabric is adjusted to ensure a prescribed pressure difference between the two surfaces of the fabric in the test area and this velocity of flow determines the air permeability of the fabric. The air permeability is expressed as the air flow in cubic feet per minute. Apparent size of opening - ASTM D-4751 - A cloth sample is placed on a mesh frame, and glass beads are placed on the surface of the fabric. The fabric and the frame are shaken laterally so that the percussion movement induces the beads to pass through the fabric sample. The procedure is repeated in the same sample with several different sizes of glass beads until the apparent size of opening is determined. The openings are expressed as Mesh Size E.U. or millimeter size of opening. Water permeability - ASTM D-4991 - A head with 50 mm (2 in.) Of water is maintained in the fabric sample throughout the test. The amount of flow is measured against time. The velocity of the water flow through the fabric is measured under the pressure differential. Water permeability is expressed as gallons per minute per square foot. 7. Rigidity - ASTM D-1388 - A strip of cloth slides in a direction parallel to its length dimension, so that its end projects from the edge of a horizontal surface. The length of the flight is measured when the tip of the test sample is depressed by its own weight to the point where the line joining the tip to the edge of the platform makes an angle of 41.5 degrees with respect to the horizontal. One half of its length is the length of bend of the sample. The cube of this quantity multiplied by the weight per unit area of the fabric is the flexural stiffness. Stiffness is expressed in inches-pounds. By integrating the secondary base 15 and the material 21 fibrous in one, i.e. the modified base 20 of the present invention, a synergistic effect is obtained that can not be achieved by any base fabric or the nonwoven fabric of the prior art, or by layering these two PX146 / 98MX components together. The properties of shrinkage, elongation and rigidity of the modified base according to the present invention are all superior while the air flow, the size of the opening and other characteristics are within the limit not detrimental to the final product. Shrinkage and minor elongation prevent the modified base fabric from shrinking or distorting as it passes through the carpet finishing process, so that a more rigid fabric 20 allows easier handling during the process. The unique properties of the integrated base 20 allow the use of regular equipment for the manufacture of carpets currently in practice, while creating a novel carpet product. Unexpectedly, although the integrated base fabric 20 is rigid, a more flexible and softer carpet is produced by the use of the fabric 20. The particular physical properties of the modified base depend somewhat on the physical characteristics of the base. secondary and selected fibrous material 21, however, as can be seen from the data recorded in Table 1, the physical characteristics generally also improve with the combination of two individual components. A photomicrographic review of the carpet produced using the modified base 20 of the present P114S / 98MX invention discloses the unique mesh of carpet view fibers with the filaments sewn into the base 20 from the fibrous material and that both are entangled together during bonding of the components with adhesive. The end result is a superior composite product with a delamination resistance increased up to 141 percent over conventional secondary woven wood backs. Additionally, it can be seen that the surface area available for the purposes of adhesion is increased up to 300 percent by the introduction of the filaments 45 sewn into the secondary backing fabric 15. As an example of the manufacture of a modified base within the scope of the present invention, a secondary base fabric consisting of 16 ends / inches of warp direction by 5 peaks / inch in the weft direction of the woven cloth it was selected as the substrate or fabric 15 substrate. This base fabric was placed on a track platform e. g. transport device 26 and a canvas or fibrous material of non-woven fibers were placed on the upper part of the fabric 15. The weight of the nonwoven selected was 2-3 oz / yd2. The fiber cloth and the base cloth were sewn together on the loom 30 of the needle, with critical parameters being the penetration depth of the needle and the punctures / in2.

P1146 / 98MX The resulting fabric was maintained to a specific thickness by a stretch frame while passing through a series of heaters 40, to provide the desired surface characteristics, as explained above. The finished modified base fabric 20 was wound around a core to a specific length determined by the carpet manufacturer. Although the exemplary base fabric 15 comprised 16 ends per inch (warp) per 5 peaks per inch (raster), this does not constitute any limitation for the practice of the invention, since less than 5 peaks per inch can be used as well like more than 5 peaks per inch. Also, while the fabric 15 was woven wood, any type of fabric can be used e. g. flat, satin, twill as desired to manufacture a secondary carpet backing, in the present or in the future. What is important to practice of the invention is that the base fabric and the fibrous material are integrated to form the modified base 20. The specific amount of sewing is necessary to provide e.1 adequate air flow and moisture escape during the coating / lamination process, as well as to provide a thermal barrier from the same heat source used during the coating process /lamination. View threads, backing Primary P1146 / 98MX and secondary backup are all heat sensitive and, therefore, subject to reorientation of the molecular structure during extreme heat exposure. The use of a modified base backing, in accordance with the present invention, is designed to absorb heat at a controlled level to prevent reorientation of the molecules in the carpet components. The total effect of this reorientation of molecules results in a carpet that is 20-25 percent more rigid or less flexible than the carpets made with the modified base 20 of the present invention. This thermal barrier is also provided for the underside and composite temperatures of 75 ° F to 125 ° F and results in less shrinkage of the fiber components, which results in higher face values, greater cushioning for the foot, as will be described with respect to the drawings of Figs. 12A-B, 13A-B below. In Figs. 4 and 6, the carpet according to the present invention is generally indicated by the number 50. It includes a plurality of strands 11 of view that are fluffed, knitted or needle punched into and through the primary backing fabric 12, providing loops 13 that are insured within the primary backup. A conventional latex or adhesive binder 14 is used as P1146 / 98MX above, which also laminates the modified base 20 of the present invention with the primary backing fabric. With the notable exception of the modified base 20, the construction of the carpet 50 is otherwise the same as that of the carpet 10. In this way, several parameters for the manufacture of the carpet may be different depending on the type of carpet. The carpet to be produced and the equipment used, such as speeds, temperatures and their like, remain essentially the same as the modified base 20 of the invention. Until now, it is generally known by those skilled in carpet manufacturing technology, they do not constitute a limitation to the practice of the method and have not been studied here. The flexibility of the carpet 50 is enhanced by the use of a modified base 20 of the present invention, to a degree that the flexibility coefficient for the carpet is improved to about 20 percent, at 40 ° F and up to about 30 percent. percent at 70 ° F on the prior art carpet. With greater flexibility also decreases the installation time up to about 20 percent on conventional carpets. As can be seen from the above, the greater flexibility imparted to the carpet 50 is totally unexpected given the rigidity of the base 20. Another advantage P1146 / 98MX imparted to the carpet 50 by virtue of using a modified base 20, is that the R value of the carpet is increased. As a result of using a modified base 20 of the present invention in the manufacture of the carpet, the resistance to delamination between the primary backing and the modified base is significantly improved over current carpets in which the primary and secondary backing fabrics are They laminate together with the use of an adhesive or a latex binder. In order to appreciate this difference, reference should be made to Figs. 7 and 8. Fig. 7 characterizes the prior art eg, carpet 10 of Fig. 1. In Fig. 7, the secondary backing is pulled away from the secondary backing 12 and after that the cohesion value of the binder 14 of latex has been exceeded, the two fabrics are separated, in a manner indicative of delamination. Fig. 8 characterizes the present invention e. g. the carpet 50 of Fig. 6, which uses a modified base. In Fig. 8, the modified base 20 is also pulled away from the primary backing 12 and after the cohesion value of the latex binder 14 has been exceeded, the two fabrics are separated in a manner indicative of delamination. However, in distinction to the separation in Fig. 7, which appears "clean", the separation of the base 20 from the backing 12 is prevented due to the vast plurality of fibers 45 that P1146 / 98MX have become entangled in the latex binder 14 as well as around the primary backrest 12 to make contact with the loops 13 of the viewing strands 11, which protrude through the primary backrest 12. The result is a greater resistance to delamination With reference to Fig. 9, it is evident that the resistance to delamination was significantly improved in a variety of carpet types by the use of the modified base 20 of the present invention, compared to the carpet using a conventional secondary base fabric 15. In Fig. 9, four rugs of hair were evaluated in loops - A = Classicweave; B = Hatteras II; C = Foothills; and D = Homeweave. Two shaved pile Saxony carpets -E = Versatile and F = Softmelody were also evaluated. Each carpet type A-F was provided in two ways; the bar on the left of each pair of values in Fig. 9 represents the carpets manufactured with a conventional secondary backing, while the bar on the right of each pair of values in Fig. 9 represents the carpet manufactured with the base 20 modified of the present invention. The delamination resistances of 2 to 3 times, unlike conventional carpet, can be observed by comparing the values. For a quick comparison, percentage increases have been noted above each of P1146 / 98MX the right-hand values. The delamination values were determined according to ASTM D-3936. With reference to Figs. 10 and 11, a remarkable increase in sewing quality is also evident when the modified base 20 of the present invention is employed compared to a carpet using a conventional secondary backing fabric. In Fig. 10, the breaking resistance of sewing has been reported for C (Foothills) and B (Hatteras II) carpets. Again, the bar on the left of each pair of values in Fig. 10 represents the carpet manufactured with a conventional secondary backing 15, while the bar on the right of each pair of values in Fig. 10 represents the manufactured carpet. with a modified base 20 of the present invention. The sewing pull resistance was greatly improved due to the increase in the total surface area provided by the modified base. This increase over 50 percent in pull strength of sewn. It provides less product failures caused by poor adhesion quality of conventional backings as used in current technology. The breaking strength of the sewing pull was determined according to ASTM D-2646. In the same way, the seam spikes were also improved as is evident in Fig. 11. The types of P1146 / 98MX carpets C (Foothills), B (Hatteras II), D (Homeweave) and A (Classicweave) were evaluated, the prior art is illustrated in the bar on the left of each pair and the invention is illustrated in the bar the right of each pair. To interpret the values reported in FIG. 11, the seam spikes were evaluated on a scale of 0 to 4 with a value of 2 which is indicative of an average or acceptable seam; 0 is poor and unacceptable; 1 is less than average and 3 is higher than average. A difference of 1.5 is remarkable and carpet C (Foothills) showed a difference of 0.75. Generally, a sewing speed of 3 provides a seam that can not be easily seen. Considering the four evaluations in Fig. 11, it is apparent that the carpet 50 provided better seams than the conventional carpet. Also noted above, the carpet 50 of the present invention provides a smooth or expensive backing 51 opposite the face 52 provided by the base material 15. The soft backing forms an uninterrupted barrier through the base fabric 15 and subsequently blocks the migration of latex binders or adhesives containing abrasive fillers that are actually exposed on the interior walls, wood flooring and all interior surfaces of personal residences. In conformity with this, unlike most of the P1146 / 98MX carpets produced today, the carpet 50 does not have a rough bottom surface, on the contrary it is a smooth and smooth surface to minimize the damage on the surfaces of the walls, wooden works, plinth plinths, floors and other surfaces of houses and offices. The use of the modified secondary backing for carpet also facilitates the installation of the carpet using it to provide a surface with reduced friction, allowing both the carpet and the cushion to slide together and improve the surface feel of the "touch" of the carpet 50 finished. The modified secondary carpet backing also functions to provide a cushion only or additional to the carpet system. The increasing foot rest and value are both substantial and are measured as reported by a series of test subjects when the carpet of the present invention is tested in comparison with the carpet made with the conventional woven secondary backing. The level of resting of the carpet according to the present invention was evaluated subjectively with a group of eight people, adult men and women. For this test, four carpeted areas of approximately 8 x 10 were arranged, each in eight separate series as follows. First, two strips of cushioning feet P1146 / 98MX urethane with different densities were placed on a concrete floor surface. The first strip had a density of 1.8 pounds; the second strip had a density of 2.2 pounds; the third strip had a density of 2.7 pounds; and the fourth strip had a density of 5.3 pounds. Each strip was approximately 10 feet in length and the strips were arranged in continuous rows. On the top of the first five feet of cushioned strips, from the left side, was placed a conventional carpet panel (10), type of shaved hair Creative, which covered all four strips (approximately eight feet in length). Immediately after the first carpet segment was a second carpet segment (50), also a type of Creative shaved hair, which covered the four strips, approximately eight feet in length. However, this panel was made using a modified base 20 according to the present invention. The result was a carpeted area with eight different zones or cells. With respect to the surplus drawings, the results of these evaluations have been illustrated schematically. In Figs. 12A and 12B the shaved pile carpet Creative was reported in Fig. 12A, the subjects wore shoes on the carpet while in Fig. 12B, the subjects removed their shoes. With reference P114S / 98MX first to Fig. 12A, the eight cells were labeled: A1-A2; B1-B2; C1-C2 and D1-D2. The left hand side (1) of each of the cells was of the prior art carpet, while the immediate right side (2 = of each pair of cells was of the carpet 50, according to the present invention. one of the subjects walked on cell A1 to develop a "sensation" and then they proceeded to cell A2 and did the same thing.From cell A2, each proceeded to cell Bl, then to cell B2, then to cell Cl and so on.The results of each test were recorded in each cell for a quick comparison.For example, 50% of the subjects felt that the Al cell was more comfortable than the A2 cell and 50% were in favor of the cell A2 When moving from cell A2 directly to cell Bl (carpet of the prior art with thicker cushioning) 85% of subjects reported better feeling than on cell A2, however, when cell Bl was compared directly with cell B2, 85% of the subjects preferred cell B2, and 15% of subjects did not express preference. Then, and totally unexpected, after the movement between cell B2 (carpet 50) and cell Cl (carpet 10), 75% of the subjects reported that they preferred cell B2 over cell C1.

P1146 / 98MX words, walking on a carpet with thicker cushioning did not represent an improvement in feeling for most subjects. At this point it can be noted that the arrow between cells Bl and A2 points to cell Bl, revealing a preference of 85%, while the arrow between cells Cl and B2 points to cell B2, revealing the preference of 75 %, and so on. Following this scheme it can be seen that in the last comparisons, cell C2 was preferred over cell DI by 85% and cell D2 was preferred over cell DI by 60%. In Fig. 12B, the same interpretation results can be applied for subjects who walk on the same rugs as in Fig. 12A, but without shoes. Again, the preferences reported for each cell and the trends between the adjacent cells was B3 preferred over A4, but then B4 was preferred over C3 and C4 preferred over D3. In other words, moving a step over a level of cushioning of the carpet 10 does not always provide a better feeling on the lower level of cushioning of the carpet 50 in most cases. Then, in Figs. 13A and B, the same type of carpeted areas was tested and reported but in these pairs of tests, a Homeweave Berber carpet was used. In the P1146 / 98MX Fig. 13A, cells El, Fl, Gl and Hl were conventional carpets and cells E2, F2, G2 and H2 were carpets 50 of the present invention, where the subjects wore shoes. In Fig. 13B, cells E3, F3, G3 and H3 were conventional carpets and cells E4, F4, G4 and H4 were rugs 50 of the present invention where the subjects removed their shoes. Statistical results and trends were recorded in these figures as described above. Based on the combined results, two conclusions can be reached. First, the use of a modified base imparts a better feel to the carpet 50 and may allow it to be used with a lesser degree of cushioning in most cases, except for the least degree of cushioning and still, for the same degree of padding, carpet 50 was generally considered better than carpet 10. Second, modified base 20 is not sensitive to any particular kind of carpet to impart the improvements proclaimed here. In this way, it is evident that the carpet of the present invention is provided with a smooth backing surface even if it retains another conventional assembly of components, i.e. primary and secondary backup materials and latex binder or adhesives. In other words, it must be understood that the practice of P114S / 98MX present invention includes the use of all known sight strands, primary and secondary backup members and fibrous materials or non-woven fabrics with secondary backing. The fibrous components can be derived from synthetics as well as natural fibers and the synthetic materials can be derived from natural as well as from recycled materials. The soft backing is obtained through the use of the modified secondary base of the present invention which provides a fibrous material integrated with the secondary backing fabric. The modified or base fabric, in turn, provides a smooth face opposite the face presented by the base or secondary fabric, which is uninterrupted by the base fabric, and within the carpet, provides a barrier to the flow of binder latex or adhesive. The carpet is particularly useful for use in residential as well as commercial applications or in any place where walls or wood work could be damaged by contact with the carpet backing during delivery and installation. Furthermore, it will be appreciated that the carpet 10 of the present invention can be manufactured with the equipment and methods other than those mentioned herein, it should be understood that the equipment and method for producing the modified base has been provided for demonstration purposes only.

P1146 / 98MX Furthermore, while the present invention has been described in conjunction with the use of a single modified base layer or component, it is not within the scope of the present invention to provide more than one modified base layer within the carpet product. , when a further increase in the improved properties is desired. Further, while the modified base has been described in conjunction with the use as a carpet component, one also has the vision that the base material may have other uses such as that of a separate cushion for the carpet. Based on the previous discovery, it should be apparent that the modified base and carpet described here will meet the objectives set forth above. Therefore, it should be understood that any variation obviously falls within the scope of the claimed invention and therefore, the selection of the specific component elements can be determined without departing from the spirit of the invention discovered and described herein. In particular, the methods of making the view strands, primary backing fabric and secondary backing fabric employed in the manufacture of the carpet, do not constitute a limitation for the practice of the present invention. In addition, as noted above, other means for joining the non-woven layer, or the fibrous material to P1146 / 98MX secondary backup fabric and other means for treating the non-woven side of the modified base can be replaced by needle puncture or infrared heating steps. Thus, the scope of the invention should include all modifications and variations that may fall within the scope of the appended claims.

P1146 / 98MX

Claims (50)

1. CLAIMS: 1. A modified secondary backing fabric comprising: a secondary backing base fabric and a fibrous material integrated with the secondary backing fabric forming the modified secondary backing fabric, which provides a smooth face opposite to the face presented by the base fabric, uninterrupted by the base fabric.
2. 2. A modified secondary backing fabric, as set forth in claim 1, wherein the primary backing fabric is selected from the group consisting of polyolefins, polyamides, natural fibers and mixtures thereof.
3. 3. A modified secondary backing fabric, as set forth in claim 3, wherein the primary backing fabric consists of polypropylene fibers.
4. 4. A modified secondary backing fabric, as set forth in claim 1, wherein the secondary backing fabric is selected from the group consisting of polyolefins, polyamides, natural fibers and mixtures thereof.
5. 5. A modified secondary backing fabric, as set forth in claim 4, wherein the secondary backing fabric consists of polypropylene fibers. P1146 / 98 X
6. 6. A modified secondary backing fabric, as set forth in claim 1, wherein the fibrous material is a cross cloth of carded cloth.
7. 7. A modified secondary backing fabric, as set forth in claim 6, wherein the fibrous material employs fibers of 4 denier X 4 inches.
8. 8. A modified secondary backing fabric, as set forth in claim 7, wherein the fibrous material has a fabric weight of about 0.5 to about 40 ounces per square yard.
9. 9. A modified secondary backing fabric, as set forth in claim 1, wherein the fibrous material provides antimicrobial properties.
10. 10. A modified secondary backing fabric, as set forth in claim 1, wherein the fibrous material provides antistatic properties.
11. 11. A modified secondary backup fabric, as set forth in claim 1, and used as a carpet cushion.
12. 12. A carpet comprising: a strand of view; a primary backing fabric, the strand of view is afelpated on the primary backing fabric; a modified secondary backup fabric attached to the primary backing fabric: P1146 / 98MX an adhesive material that joins the strand of view with the primary backing fabric, and the primary backing fabric with the secondary backing fabric, the modified secondary backing fabric consists of a secondary backing base fabric and a material fibrous integrated as a unitary base, providing a smooth face that forms the underside of the carpet, the smooth face forms an uninterrupted barrier through the base fabric and blocks the exudation of any adhesive material from the underside of the carpet. A carpet, as set forth in claim 12, wherein the strand of view is selected from the group consisting of polyolefins, polyamides, polyesters, polyethylene teraphthalate (PET) and polytrimethylene teraphthalate, natural fibers and mixtures thereof. same. 14. A carpet, as set forth in claim 12, wherein the primary backing fabric is selected from the group consisting of polyolefins, polyamides, natural fibers and mixtures thereof. 15. A carpet, as set forth in claim 14, wherein the primary backing fabric consists of polypropylene fibers. 16. A carpet, as set forth in claim 12, wherein the secondary backing fabric P1146 / 98MX is selected from the group consisting of polyolefins, polyamides, natural fibers and mixtures thereof. 17. A carpet, as set forth in claim 16, wherein the secondary backing fabric consists of polypropylene fibers. 18. A rug, as set forth in claim 12, where the fibrous material is a cross cloth of carded canvas. 19. A carpet, as set forth in claim 18, wherein the fibrous material employs fibers of 4 denier x 4 inches. 20. A carpet, as set forth in claim 19, wherein the fibrous material has a fabric weight of from about 0.5 to about 40 ounces per square yard. 21. A carpet, as set forth in claim 12, wherein the fibrous material provides antimicrobial properties. 22. A carpet, as set forth in claim 12, wherein the fibrous material provides antistatic properties. A carpet, as set forth in claim 12, wherein the adhesive material is selected from the group consisting of styrene-butadiene rubbers, EVA, polyesters, polyurethanes, polyolefins, P1146 / 98MX emulsified polymers and mixtures thereof. 24. A method for manufacturing a modified secondary backing base for carpet comprising: selecting a secondary backing base fabric and a fibrous material; joining the two fabrics to form the modified secondary backing for carpet that provides a smooth face opposite the face presented by the base fabric, uninterrupted by the base fabric; and subjecting the modified fabric to sufficient heat to remove substantially all of the loose fibers projecting from the smooth face. 25. A method as set forth in claim 24, wherein the joining step includes needle puncturing the fibrous material with the secondary backing fabric. 26. A method as set forth in claim 24, wherein the heating step includes using infrared heat to partially melt the fibers that form the fibrous material. 27. A method as set forth in claim 24, wherein the step of heating is carried out to obtain a cloth temperature of about 157 ° C to 163 ° C for the fabrics of P1146 / 98MX polyolefins. 28. A method as set forth in claim 24, which includes the step of selecting the primary backing fabric from the group constituting polyolefins, polyamides, natural fibers and mixtures thereof. 29. A method as set forth in claim 28, wherein the primary backing fabric is a polypropylene fiber. 30. A method as set forth in claim 24, including the step of selecting the secondary backing fabric from the group consisting of polyolefins, polyamides, natural fibers and mixtures thereof. 31. A method as set forth in claim 30, including the step of selecting the secondary backing fabric from the group consisting of polypropylene fibers. 32. A method as set forth in claim 24, which includes the step of selecting a cross cloth of carded cloth as the fibrous material. 33. A method as set forth in claim 24, which includes the step of selecting fibers of 4 denier x 4 inches to form the material P1146 / 98MX fibrous. 34. A method as set forth in claim 24, which includes the step of selecting the weight of the fabric from about 0.5 to about 40 ounces per square yard to form the fibrous material. 35. A method as set forth in claim 24, wherein the fibrous material provides antimicrobial properties. 36. A method as set forth in claim 24, wherein the fibrous material provides antistatic properties. 37. A carpet cushion produced by the method of claim 24. 38. A method for manufacturing a carpet comprising: providing strands of view on a primary backing fabric; providing a secondary modified backing base for carpet, formed of a secondary backing base fabric and a fibrous material, the modified backing provides a smooth face opposite to the face presented by the base fabric, uninterrupted by the base fabric; attaching the modified backing to the primary backing fabric with an adhesive material; Y P1146 / 98MX heat the modified backing, the primary backing fabric and the adhesive material together, at a temperature sufficient to adhere the backs together and produce a carpet that has a smooth face that forms the underside of the carpet, the soft side forms an uninterrupted barrier through the secondary backing base fabric and blocks the exudation of any adhesive material from the underside of the carpet. 39. A method as set forth in claim 38, which includes the step of selecting the strand of view of the group constituting polyolefins, polyamides, polyesters, polyethylene teraphthalate (PET) and polytrimethylene teraphthalate (PTT), natural fibers and mixtures thereof. 40. A method as set forth in claim 38, including the step of selecting the primary backing fabric from the group consisting of polyolefins, polyamides, natural fibers and mixtures thereof. 41. A method as set forth in claim 40, wherein the primary backing fabric consists of polypropylene fibers. 42. A method as set forth in claim 38, which includes the step of selecting the secondary backup fabric of the group constituting the P1146 / 98MX polyolefins, polyamides, natural fibers and mixtures thereof. 43. A method as set forth in claim 38, including the step of selecting the secondary backing fabric from the group consisting of polypropylene fibers. 44. A method as set forth in claim 38, which includes the step of selecting a cross cloth of carded cloth as a fibrous material. 45. A method as set forth in claim 38, including the step of selecting 4 denier x 4 inch fibers as fibrous material. 46. A method as set forth in claim 38, which includes the step of selecting the weight of the fabric from about 0.5 to about 40 ounces per square yard to form the fibrous material. 47. A method as set forth in claim 38, wherein the fibrous material provides antimicrobial properties. 48. A method as set forth in claim 38, wherein the fibrous material provides antistatic properties. 49. A method as set forth in claim 38, which includes the step of selecting the adhesive material consisting of styrene-rubbers. P1146 / 98MX butadiene, EVA, polyesters, polyurethanes, polyolefins, emulsified polymers and mixtures thereof. 50. A carpet produced by the method of claim 38. P1146 / 98MX SUMMARY OF THE INVENTION A modified secondary backing fabric 20 for carpet 50 comprises a secondary backing base fabric and a fibrous material 21 integrated with the secondary backing fabric to form the modified fabric, providing a smooth face 51 opposite to the face 52 presented by the base fabric, uninterrupted by the base fabric. A carpet 50 comprises a strand of view 11; a primary backing fabric 12, the eye strand fills inside the primary backing fabric; a modified secondary backup fabric 20 is attached to the primary backing fabric; and an adhesive material 14 joins the strand of view to the primary backing fabric and the primary backing fabric with the secondary backing fabric. The modified secondary backing fabric 20 comprises a secondary backing base fabric 15 and an integrated fibrous material 21 as a unitary base, which provides a soft face 51 formed on the underside of the carpet, the soft face forming a uninterrupted barrier by a base fabric and blocks the exudation of any adhesive material from the underside of the carpet. A method for manufacturing a modified secondary carpet backing 20 consists of selecting a secondary backing base fabric 15 and a fibrous material 21; join the two fabrics to form the P1146 / 98 X secondary modified backing 20 for carpet, providing a smooth face 51 opposite the face 52 presented by the base fabric; uninterrupted by the base fabric; and subjecting the modified fabric to sufficient heat to remove substantially all of the loose fibers projecting from the smooth surface. The present invention also provides a method for the manufacture of the carpet. P1146 / 98MX