Applications in the Carpet Industry

Peter R. J. Blanpain, Richard L Scott, Onno Craalmann, and J. Arthur Smith 

This chapter covers the use of synthetic polymer dispersions in the carpet industry. In 1999, carpet accounted for approximately 60 % [1] of the volume of aU floor coverings (soft and hard) sold in the USA, with an estimated [2] sales volume and value of 1.6 billion m and 11.7 biUion respectively. Of this volume, the tufted carpet and rug segment, the largest user of polymer dispersions, is dominant with an estimated 1.4 biUion m, with broadloom s share accounting for approximately 1.3 billion m. Europe and the Asia-Padfic countries produced during the same period an estimated 1.13 billion [3] and 284 milHon m soft floor covering respectively. 

Synthetic polymer dispersions have been used as binders for the backing of carpet since the late nineteen-forties. The function of the polymeric binder in carpet backings is primarily to anchor the pile fibers in place, give improved dimensional stability, hand, and resistance to fraying or tuft loss at cut edges of the carpet. 

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Blanpain, P. (2002) Applications in the carpet industry. In Urban and Takamura (eds). Polymer Dispersions and Their Industrial Applications. WUey-VCH, Weinheim. 

Applications in the Carpet Industry Tab. 9-3 1999 European carpet production (in million). 

Nylons have a variety of uses ranging from tire cord to carpet to hosiery. The most important application is cord followed by apparel. Nylon staple and filaments are extensively used in the carpet industry. Nylon fiber is also used for a variety of other articles such as seat belts, monofilament finishes, and knitwear. Because of its high tenacity and elasticity, it is a valuable fiber for ropes, parachutes, and underwear. 

Natural mbber latex is also used in adhesives for tape, packaging, envelopes, and in the footwear industry. It is used in the carpet industry as a binder for backing compounds, but this is another area in which synthetic SBR latex has competed effectively. There are a number of relatively small and specialized applications for natural mbber latex including rubberized coir or hair and cast products such as toys. Latex sheeting which is used in dental dams and for numerous other purposes can be made by dipping or casting onto a continuous belt. 

Being a general-purpose plastic, polypropylene has found applications in almost every field in which plastics are used. Polypropylene has found wide use in the textile industry, where it is successfully competing with rayon and other synthetic fibers as well as the natural fibers. This is particularly true in the carpet industry. The largest use of extruded polypropylene is in thin-film packaging. 

The main uses for both nylon 6,6 and nylon-6 are in apparel, carpets, and industrial applications. In the area of general apparel, polyester has gained considerably in significant market segments at the expense of polyamides because of its easy-care characteristics. Polyamide textile fibers, however, will expectedly continue to be the principal materials for women s hosiery, intimate apparel, and certain stretch fabrics. It seems safe to conclude that the price to performance ratio will continue to secure a firm market position for polyamide fibers, even at increased feedstock prices. Primarily tire yarns in the developing countries will drive polyamide industrial fibers. 

Polypropylene (PP) fibre is one of the most widely used synthetic fibres in the textile industry. PP has some advantages it is cheaper and stronger than many other synthetic fibres and it has been applied widely in various fields, e.g., carpets, automotive interior trim, films, packaging, protective cover, and cables. In particular, it is used for healthcare applications such as surgical masks, babies nappies, and filters, which need to display antibacterial effects. 

The combination of properties for SPS/nylon blends described above has led to substantial amounts of these blends being used in under-the-hood connectors in the automotive industry. These blends have also received much interest in the carpet fiber industry. There are a great number of patents where SPS/ nylon blends are a candidate material for the application being patented. In some patents, SPS/nylon is the required material. These applications are described in more detail below. 

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