US 11,746,467 B2
Polyester tufted carpet with polyester extrusion coating
Ernest Franklin Wilson, Alnemarie, NC (US); Timothy Joel Allison, Marion, NC (US); and Sean Bracken Simmons, Concord, NC (US)
Assigned to AURIA SOLUTIONS UK I LTD, London (GB)
Filed by AURIA SOLUTIONS UK I LTD., London (GB)
Filed on Jul. 28, 2021, as Appl. No. 17/387,151.
Claims priority of provisional application 63/062,648, filed on Aug. 7, 2020.
Prior Publication US 2022/0042239 A1, Feb. 10, 2022
Int. Cl. D06N 7/00 (2006.01); B32B 37/15 (2006.01); D05C 15/04 (2006.01); D05C 17/02 (2006.01)
CPC D06N 7/0076 (2013.01) [B32B 37/153 (2013.01); D05C 15/04 (2013.01); D05C 17/02 (2013.01); D06N 7/0068 (2013.01); D06N 7/0071 (2013.01); D06N 2201/02 (2013.01); D06N 2203/061 (2013.01); D06N 2205/06 (2013.01); D06N 2211/066 (2013.01); D06N 2213/02 (2013.01); D10B 2503/04 (2013.01); Y10T 428/23979 (2015.04); Y10T 428/23993 (2015.04)] 3 Claims
 
1. A method for manufacturing a carpet, where the method comprises:
providing polyester yarn comprising poly(ethylene terephthalate) (PET) at 800 denier to 2400 denier;
providing a primary polyester backing comprising poly(ethylene terephthalate) spunbond nonwoven, at a basis weight of 80 g/m2 to 160 g/m2 at a thickness of 0.25 mm to 1.00 mm having first and second sides;
tufting the polyester yarn into a first side of said primary polyester backing where said yarn extends from said second side of said primary backing;
extruding polyester directly onto said second side of said primary backing and forming a polyester extrudate on said second side of said primary backing wherein said polyester extrudate provides a secondary backing layer that engages said polyester yarn extending from said second side of said primary backing wherein the secondary polyester backing layer locks the polyester yarn in the polyester primary backing, wherein said polyester extrudate comprises a blend of branched PET and a copolymer of PET (coPET) having a melting temperature in the range of 120° C. to 200° C. and wherein said coPET is selected from the group consisting of poly(cyclohexylenedimethylene terephthalateglycol), poly(cyclohexylenedimethylene terephthalate/isophthalate glycol) and poly(cyclohexylenedimethylene terephthalate).