Stable Synthetic Carpet Backing Material

Abstract

A dimensionally stable and non-raveling synthetic primary carpet backing material is provided by applying to the carpet backing material an amount of adhesive material sufficient to bind adjacent and crossing strands of material to one another without necessarily providing a continuous coat for the backing material. After application of the adhesive material, the backing may be subjected to a conventional tufting operation wherein carpet yarn is interlaced through the carpet backing to provide a pile surface and an undersurface. If desirable a conventional secondary backing may be adhered to the undersurface of carpet yarn and synthetic primary carpet backing material.

Parent Case Text

This application is a division of Ser. No. 221,166, filed Jan. 27, 1972 which is a continuation-in-part of Ser. No. 877,777, filed Nov. 18, 1969, now abandoned.

Description

This invention relates to a primary carpet backing material and to an adhesive formulation which when applied to the backing material will reduce the raveling capability of the material without an undesirable increase in the needle resistance provided by the backing material during a tufting operation and will increase the adhesion capability of the synthetic backing material.

Conventionally tufted carpet is prepared in a tufting operation in which carpet yarn is interlaced through a primary backing (conventionally a jute material) to produce a pile surface and an undersurface. After the tufting operation is completed, a rubber or resinous coating is applied to the undersurface of the tufted product or an adhesive material and a secondary backing are applied to the undersurface. Both operations secure the carpet yarn in place and increase the dimensional stability of the carpet product.

Recently a new carpet backing material has come into use. This material is woven from flat strands of synthetic material which are substantially uniform in thickness and width. U.S. Pat. No. 3,110,905 discloses such a product and the inherent advantages provided thereby. Since the product has been adopted for use, certain disadvantages have become apparent. Most significantly, the woven material tends to ravel at the edges due to the inherently slipping characteristics of the flat strands. Consequently, during installation of the tufted product, the backing material pulls apart under lateral tension and fails to withstand normal use.

In addition it has been found that the flat woven synthetic material exhibits little or no adhesion for a conventional latex secondary backing adhesive. Because of this poor adhesion performance, the woven material has been usable to date only as a primary backing substrate, and even in that application a secondary backing of jute or other conventional backing material adheres only to the backs of the yarn tufts and does not bond to the primary backing itself. Consequently, the pile loops are not as securely locked into the synthetic primary backing material as with more commonly used jute to which conventional latex laminating adhesives bond securely.

It is an object of the present invention therefore to provide an adhesive material which may be used to increase the adhesion capability and secure in place the synthetic strands of a woven synthetic carpet backing material and provide thereby a carpet product which may be installed and used in conventional fashion. These and other objects, features and advantages of the present invention will become apparent from a review of the following detailed description and the accompanying drawings wherein:

FIG. 1 is an end, or edge, view of the present backing material used as a primary backing for a tufted pile fabric, showing only one row of pile loops or stitches;

FIG. 2 is a bottom view of the primary backing shown in end view in FIG. 1;

FIG. 3 is a bottom view similar to FIG. 2 showing a conventional synthetic backing material with characteristic fraying and unraveling of its edges and instability of weave in central portions of the material; and

FIG. 4 is an end view of a tufted pile fabric having attached thereto a secondary backing which is of the same or similar construction and material as that of the primary backing material.

According to the present invention an adhesive material is provided for application to a woven synthetic primary carpet backing material to enhance the dimensional stability of the backing material, reduce or substantially eliminate the tendency of the carpet backing material to ravel at the edges, enhance bonding between the synthetic material and the adhesive employed in the application of a secondary backing material to the undersurface of the tufted primary backing material, and increase the overall usefulness of the synethetic backing material. The invention is directed specifically to solving problems created by the use of a synthetic woven backing material and the invention therefore is limited in that respect. In addition it should be understood that the carpet backing material must remain susceptible to an efficient tufting operation. If the adhesive material successfully reduces raveling but produces a carpet backing that clogs the tufting needles with adhesive material or slows the tufting operation, the adhesive is unacceptable. Consequently, it may be seen that the problem is not one of simply adhering strands of carpet backing together but it is one of accomplishing adherence without reducing the tuftability of the backing or detrimentally effecting the other physical properties of the backing material.

In order to clearly understand the nature of the present invention, a discussion of the woven synthetic carpet backing material is initially provided. Such a carpet backing material is composed of a woven fabric of flat synthetic strands having substantially uniform thickness and width. Suitable synthetic materials are penetrable by a tufting needle but are sufficiently strong to provide an adequate carpet backing. Preferred synthetic materials include polyolefins, and particularly preferred materials consist of polyethylene and polypropylene. These synthetic materials are fashioned into solid ribbons or strands by either direct extrusion into a desired width and thickness or by slitting a sheet of material at a desirable width. Optionally these strands of synthetic material may be fashioned to a width wider than the desired width. The wider strand may then be folded to provide either a U or Z-shaped cross-section.

The even width and thickness of the strands of synthetic material yields a uniform sheet of woven fabric having a thickness equivalent to two strands at every point in the fabric. This form of construction automatically eliminates the irregularities and interstices which are inherent in conventional jute or burlap backing material. Furthermore, it is possible to control the thickness and width of the synthetic strands with much greater precision than is the case with jute and burlap-type backing yarns so that irregularities due to the interweaving of thin backing yarns and thick backing yarns are eliminated.

Since the strands of the present backing material are substantially flat and penetrable by a tufting needle, it is possible for the tufting machine to interlace substantially uniform and parallel rows of tufting yarn. When using conventional jute or burlap backing material, the tufting needles often slide off the arcuate yarn face and the rows of tufted yarn show areas of uneveness and irregularity. Consequently, with the present carpet backing material the longitudinal spacing between each of the stitches of carpet yarn is approximately the same regardless of whether the stitch happens to fall in the middle of one of the synthetic backing strands, inbetween two adjacent backing strands, or near the edge of one of the backing strands. This characteristic illustrates the beneficial results achieved when the carpet yarn carrying tufting needles always penetrate a homogeneous and relatively uniform woven backing material.

The flat strands of synthetic material have a smooth surface rather than the textured surface presented by twisted yarn such as conventionally found in jute and burlap backing. The smooth surface of the strands causes the weave of the present backing material to be easily separated and the edges thereof to become ravelled.

In order to improve the dimensional stability of the present woven backing material, enhance adherence of conventional laminating adhesives to the synthetic backing material and reduce or substantially eliminate raveling of the edges of the fabric, an adhesive is applied to the backing prior to the tufting of carpet yarn therethrough. The adhesive binds adjacent and crossing strands of plastic material to one another. The adhesive is one of the following four groups of compositions: (A) An aqueous dispersion of a styrenebutadiene latex compound modified with a melamine formaldehyde resin additive; (B) An aqueous dispersion of carboxylated styrene-butadiene latex compound modified with a melamine formaldehyde resin additive; (C) An ethylene vinyl acetate hot-melt adhesive; and (D) A polyurethane adhesive. Of these groups, A and B are preferred and A is most preferred. As additional additives each group of adhesives may also include thickeners, curing agents, synthetic wax lubricants, antifoams, stabilizers, emulsifiers, antioxidants, accelerators, surfactants, and mineral fillers.

The most preferred form of adhesive is a styrenebutadiene copolymer latex compound modified by a melamine formaldehyde resin additive. The preferred styrene-butadiene latex compound is a hot-polymerized type having the following properties:

Total Solids 53.3% Residual Styrene 0.04% PH 11.1 Mooney, ML.sub.4 at 212.degree.F 65 Coagulum, 80 mesh 0.01% Bound Styrene 46.0% Specific Gravity of Latex 25.degree./25.degree. 0.99

The styrene-butadiene copolymer latex compound is modified by the addition of a melamine formaldehyde resin thereto. The properties of this resin are as follows:

Physical Form Clear, viscous syrup at room temperature Solids Content 80%, Approximately Weight Per Gallon 10 pounds PH of Aqueous Solution 8.6-9.6 Solubility In water

When preparing this adhesive formulation it is preferred that from 1 to 10 parts of melamine formaldehyde resin per 100 parts of styrene butadiene latex be employed. In a particularly preferred embodiment of the present invention 3 to 5 parts of resin per 100 parts of latex compound are employed.

In addition to the melamine formaldehyde resin additive, additional additives such as thickeners, curing agents, synthetic wax lubricants, antifoams, stabilizers, emulsifiers, antioxidants, accelerators, silicon surfactants and mineral fillers may also be added. A preferred quantity for these additives is from 5 to 20 parts per 100 parts of latex compound.

A preferred group of additional additives include a thickener of carboxymethylcellulose having the following physical properties:

Powder Methoxyl 27.0-30.0% Hydroxypropoxyl 4.0-7.5% Sulphated Ash Max 2.0% Moisture Max 3.0% Chemical Iron Max 150 ppm Sodium Chloride Max 1.0%;

A lubricant of silicone wax emulsion in water having the following physical properties:

Appearance white liquid at room temperature Solids 50% Melting Point 122.degree.F-125.degree.F PH 8-9 Pounds per Gallon 7.9;

An additional thickener of sodium polyacrylate; an accelerator of zinc oxide; a curing and vulcanizing agent of sulfur; and an optional silicon surfactant having the following properties:

Color White Total Solids 51-53% Silicone Solids 50% Emulsifier Anionic Density 8.2-8.3 No./gal.

The second adhesive composition (Group B) employs a carboxylated styrene butadiene latex compound rather than the styrene butadiene latex compound. Otherwise the adhesive material is similar to Group A. The carboxylated sytrenebutadiene latex compound has the following properties:

Solids 49-51% Surface Tension 40-45 dynes/cm Brookfield Viscosity at 25.degree.C 100-150 No./at 20 RPM Color White Styrene 48.5% Butadiene 48.5% Carboxyl Groups 3.0% PH 8.8-9.2

A preferred group of additives in addition to the melamine formaldehyde resin additive includes a water dilutable silicone emulsion containing 30% silicone in a nonionic emulsion as an antifoam agent; a surfactant of sodium tetradecyl sulfate; and a silicone surfactant having the following physical properties:

Color White Total Solids 51-53% Silicone Solids 50% Emulsifier Anionic Density 8.2-8.3 No./gal.

When employing these additional additives it is preferred that from 1 to 5 parts total be employed per 100 parts of latex compound.

A third composition (Group C) which may be used as an adhesive formulation on the woven synthetic carpet backing prior to tufting thereof is a hot-melt adhesive of ethylene vinyl acetate. Since the results obtained with this formulation are not as desirable as the results obtained with the first two compositions, this formulation is not preferred but does provide suitable results.

When using the hot-melt adhesive it is preferred that from 15 to 25 parts of a paraffinic wax and 2 to 8 parts of a mineral or aromatic oil extender be employed per 100 parts of adhesive as an additive thereto. Isotatic polypropylene may also be used as an extender at a part concentration of 15 to 25 parts per 100 parts of adhesive.

A fourth composition (Group D) which may be used as the adhesive formulation is a thixotropic polyurethane material.

The polyurethane adhesive is an essentially non-solvent, non-aqueous polymerization product of a mixture of a polyol having a hydroxyl number less than one hundred, a small amount of water, a polyisocyanate, a filler and a catalyst system that promotes a polymerization reaction between the isocyanate andd the polyol to form a polyurethane within a short time after mixing.

The polyurethane composition is prepared by charging an aqueous polyol composition and a polyisocyanate composition separately to a mixing zone where the reactants are intimately mixed. Before a significant degree of polymerization and blowing occurs, the resultant mixture is evenly applied to the underside of a woven synthetic primary backing material by means of a doctor blade as the backing material moves under the doctor blade. The thixotropic nature of the polyurethane reaction product in combination with the shear forces created by application of the mixture with a doctor blade causes a sufficient reduction in the viscosity of the blend of reactants and product to promote spreading thereof. A polymerization reaction between the polyisocyanate, water and polyol is initiated when the reactants are mixed so that the reaction occurs both prior to and after the mixture-composition passes under the doctor blade. The small amount of water in the composition besides promoting the polymerization also causes controlled foaming to improve adhesive migration around the strands of backing material before the composition is cured and reduces the amount of composition needed to attain desired adhesion.

The thixotropic polyurethane material must have a Brookfield viscosity of between about 30,000 and 100,000 CPS as measured at 10 RPM No. 7 spindle on a Brookfield RVF viscometer to prevent migration thereof into the exposed yarn while permitting it to liquify sufficiently under application of force and be spread by means of a doctor blade. The Brookfield viscometer and its operation is described in "Development of Research Technique for Evaluating the Low Temperature Fluidity of Automatic Transmission Fluids," published by Coordinating Research Council, Inc., February, 1963, Appendix A, and designated as CRC L-45-1262. In order to attain these characteristics, it is essential that the polyol employed have a hydroxyl number less than one hundred, preferably less than fifty. As it well known in the art, the hydroxyl number is defined as the number of milligrams of potassium hydroxide required for the complete neutralization of the hydrolysis product of the fully acetylated derivative prepared from one gram of polyethyl polyol. The hydroxyl number can also be defined by the equation:

OH = 56.1 .times. 1000 .times. f/MW

wherein

OH = hydroxyl number of polyol

F = average functionality, i.e., the average number of hydroxyl groups per molecule of polyol

MW = average molecular weight of the polyol.

It is necessary that the polyol have a low hydroxyl number to reduce the concentration of the diisocynate needed to effect complete reaction of the reactants to form the polyurethane. When employing liquid diisocyanates, increased amounts of diisocyanate reduce the viscosity and thixotropocity of the resultant composition below that desired. On the other hand, when a solid diisocyanate reactant is employed, increased amounts thereof will cause the resultant composition to be paste-like rendering it very difficult to spread. Accordingly, while low molecular weight polyols can be employed with solid diisocyanates and high molecular weight polyols can be employed with liquid diisocyanates, in each case the hydroxyl number of the polyol must be low to attain proper physical characteristics of the resultant composition. Accordingly, when employing solid diisocyanates reactants, the polyol should have a molecular weight between about 1000 and 3000 to attain the proper viscosity characteristics of the resultant composition. On the other hand, when the liquid diisocyanate reactant is employed, the polyol should have a molecular weight of between about 3000 and about 9000 to attain the desired viscosity characteristics of the resultant composition.

In one aspect of the present invention, a polyurethane prepolymer can be employed to replace or to be mixed with the polyol in the composition. These prepolymers are prepared by means well known in the art, i.e., by incomplete reaction of a polyol with a diisocyanate. The molecular weight of the prepolymer and the type of diisocyanate should be selected while bearing in mind the considerations described above.

While careful selection of the polyol or prepolymer and the diisocyanate provide a means for controlling the viscosity of the resultant composition, the composition cannot be made thixotropic to the desired degree by controlling the relative concentrations of only these two reactants. A suitable filler must be added in amounts sufficient to render the overall composition thixotropic to the desired degree but less than that which will cause the composition to become excessively viscous and paste-like. The concentration of filler is dependent upon the type of filler employed since the degree of thixotropicity varies with the filler used. Generally, the filler is employed in amounts of between about 15 and 300 parts per one hundred parts of polyol or prepolymer reactant. Representative suitable fillers include silica, asbestos, calcium carbonate, zinc oxide, clay, feldspar, or the like, or mixtures thereof. When fillers are employed, such as silica or calcium carbonate, it is preferred that additional fillers be added to attain the desired level of thixotropocity. It is preferred to employ asbestos power as the filler either alone or in conjunction with another filler such as calcium carbonate as satisfactory thixotropic characteristics are achieved with asbestos and it additionally reduces the flamability of the composition.

The type of catalyst system employed in preparation of the thixotropic polyurethane composition should regulate the pot life (i.e., the time for a 100 percent viscosity increase) thereof to between 10 and about 60 seconds at moderate temperatures of up to about 23.degree.C. It is preferred that from 0.03 to one part of catalyst per one hundred parts of polyol be used in the reaction mixture.

It is desirable to employ a polyurethane composition that cures relatively quickly, and it is preferred that curing be effected at a temperature of from room temperature to 275.degree.F and a corresponding cure period of 45 minutes to 1 1/2 minutes.

Blowing or foaming the polyurethane composition is effected by controlling both the catalyst system and the water concentration. Generally, water is present in the reaction mass from between about 0.01 and 0.75 parts per hundred parts polyol, over and above the water normally present as absorbed on the filler. Since this is such a small quantity of water, the present polyurethane composition is considered non-aqueous and described as such. Conventionally, adhesive systems contain as much as 50% water. The catalyst system not only must effect rapid curing at ambient or slightly elevated temperature but also must control formation of carbon dioxide resulting from the reaction of water and diisocyanate. Suitable catalysts are those which promote polyurethane formation at a high rate but do not promote the blowing reaction in preference to the polyurethane reaction. Preferred catalysts are organic metal compounds, amines, and metal soaps; such catalysts include dibutyl tin dilaurate and stannous octoate.

Suitable polyols which can be employed in the present invention are the polyether polyols having a functionality of at least two, an average molecular weight between about 1000 and 9000 and a hydroxyl number less than one hundred. Such polyols include polybutylene glycol, polyethylene glycol, polypropylene glycol, 1,2-polydimethylene glycol, polydecamethylene glycol and mixtures thereof. When using a liquid diisocyanate reactant, preferred polyols have an average molecular weight of between 4000 and 8000, and particularly preferred polyols have a molecular weight of between 6000 and 7000. When using a solid diisocyanate reactant, preferred polyols have an average molecular weight of between 1200 and 2800, and particularly preferred polyols have a molecular weight of between 1500 and 2500.

A variety of polyisocyanates may be reacted with these polyols to obtain a satisfactory polyurethane composition. Particularly suitable polyisoicyanates are aromatic diisocyanates as they are more reactive and less toxic than the aliphatic diisocyanates. Such diisocyanates include 2,4-toluene diisocyanate, 2,6-toluene diisocyanate, methane diisocyanate, naphthylene 1,4-diisocyanate, diphpenylmethane-4, 4'-diisocyanate, 3,3'-dimethoxy biphenylene diisocyanate, 4,4-diphenylene diisocyanate and mixtures thereof. The diisocyanate usually is employed in stoichiometric excess to assure complete reaction with the functional groups of the polyol and with water which is present. Preferably from 18 to 50 parts of diisocyanate per one hundred parts of polyol are used in the reaction mass.

When using either of Groups A, B, C, or D adhesive formulation, it is preferred that from 0.2 ounces to 1.5 ounce of adhesive be applied to the backing per square yard of backing; a particularly preferable concentration is 0.3 to 0.45 ounces. As the adhesive material is applied to the backing an area of bonding is created at the points of crossing and in adjacent areas between warp and weft strands of synthetic yarn. Consequently, it is not necessary that the adhesive form a continuous coat over the woven backing material, only that areas of bonding be created at these points of junction and at adjacent points between strands.

The adhesive material may be applied to the backing material be several methods. One such method involves submerging the sheet of material in a bath of adhesive and then passing the sheet between pad rollers to squeeze off excess adhesive and enhance penetration of the adhesive through the backing material. Other methods involve painting the adhesive on the undersurface with rollers or doctor blades then passing the material through pad rollers to remove excess material and enhance penetration of the adhesive through the backing.

Referring now with more particularity to the drawings, there is shown in FIG. 1 an end or edge view of a tufted pile fabric having one row of carpet yarn stitched therethrough. FIG. 2 shows an undersurface view of the synethtic woven backing material with one row of carpet yarn stitched therethrough. The warp yarns of the weave are shown as 1 to 10 and the weft yarns are shown as 11 to 23. In a typical tufting operation, the woven carpet backing material is fed into a tufting machine where carpet yarn 28 is stitched through the backing to produce loops 27 of carpet yarn on the upper face of the backing. In the present invention, a primary backing composed of flat ribbons or strands of synthetic material are employed as the weaving material of the backing and an adhesive material 25 is applied to the backing prior to the tufting operation. Since such a small quantity of adhesive (0.2 ounces to 1 ounce per square yard of backing) is applied to the backing it is difficult to depict the presence of the adhesive in the drawing. It should be understood however that the adhesive is generally located at the points of crossing between warp and weft ribbons and between adjacent warp ribbons and weft ribbons to secure those ribbons to one another.

By contrast, as shown in FIG. 3, a conventional woven synthetic backing material composed of flat ribbons of weaving material has no coherence except that provided by the weave, and the backing tends to unravel at the edges and separate in central portions of the material. In use it has been found that the conventional material will undergo seam and tack slippage during installation of the finished carpet product.

As shown in FIG. 4, it is possible with this invention to use a secondary backing 30 of synthetic woven material which is treated according to the present invention to increase its dimensional stability and enhance its adhesion characteristics. A carpet product employing both primary and secondary backing of woven synthetic material would be stronger than a carpet employing conventional backing materials and would be virtually impervious to moisture and its attendant problems.

The present invention is further illustrated by the following examples:

EXAMPLE I

A primary backing of woven synthetic material is treated with an aqueous dispersion of latex material. The backing is woven from ribbons of polypropylene with a plain 1/1 weave. The ribbons are approximately one-eighth of an inch in width and one thirty-second of an inch in thickness. The aqueous dispersion of latex material has the following composition:

MATERIAL PARTS BY WEIGHT ______________________________________ Water 302.80 Styrene-butadiene hot- polymerized latex compound 100.00 Melamine-formaldehyde resin 4.00 Carboxymethylcellulose .40 Silicone wax emulsion 1.50 Sodium polyacrylate 4.00 Sulfur 2.50 Zinc Oxide 4.00 ______________________________________

The woven backing material is dipped into a bath of the latex material and passed through a pair of squeeze rollers. It is estimated that 0.4 ounces of latex material remains on the backing. The backing is then dried and passed through a tufting machine where row tufting needles stitch nylon carpet yarn into the backing. The tufting operation was performed with no difficulties and needle puncture was not impeded. A secondary backing was then adhesively laminated to the tufted primary backing and the resulting carpet product was tested for strength and raveling. It was found that the secondary backing was adhered to both the backs of the carpet yarn tufts and the undersurface of the primary backing. The carpet was tacked along one edge and stretched from an opposite edge and raveling did not occur.

EXAMPLE II

Example I is repeated except that the following latex formulation is employed:

MATERIAL PARTS BY WEIGHT ______________________________________ Water 133.43 Styrene-butadiene hot- polymerized latex compound 100.00 Melamine-formaldehyde resin 3.00 Carboxymethylcellulose .40 Silicon wax emulsion 1.50 Silicone antifoam emulsion .05 Highly sulfated fatty acid .50 Polyoxyethylene oleyl ether .15 Dry Casein .50 Pentasodium triphosphate .50 Hindered Bis Phenol 1.50 Zinc salt of z-mercaptobenzothiazole .50 Zinc diethyldithiocarbamate .50 Zinc oxide 4.00 Anionic emulsion of a silicone fluid as a surfactant 3.00 Sodium polyacrylate .40 Sulfur 2.00 ______________________________________

The formulation is applied to the backing material as in Example I and suitable results are obtained.

EXAMPLE III

Example I is repeated except that the following latex formulation is employed:

MATERIAL PARTS BY WEIGHT ______________________________________ Carboxylated styrene-butadiene latex 100 Water 328.60 Silicone emulsion antifoam .01 Melamine formaldehyde resin 3.00 Sodium tetradecyl sulfate .25 Anionic emulsion of a silicone fluid as a surfactant 3.00 ______________________________________

The formulation is applied to the backing material as in Example I and suitable results are obtained.

EXAMPLE IV

Example I is repeated except that the following hot-melt adhesive formulation is employed:

MATERIAL PARTS BY WEIGHT ______________________________________ Ethylene vinyl acetate 100 Paraffinic wax 20 Mineral oil extender 5 Isotatic polypropylene 20 ______________________________________

The formulation is heated and applied to the backing material as in Example I and suitable results are obtained.

EXAMPLE V

Example I is repeated except that the following polyurethane adhesive formulation is employed:

MATERIAL PARTS BY WEIGHT ______________________________________ Polypropylene glycol- 100 OH of 25 and M.W. of 6500 Water .50 Asbestos powder having an average particle size of about 5-50 microns 15.0 Calcium carbonate having an average particle size of about 50-150 microns 100.0 Dibutyl tin dilaurate 0.05 Modified diphenylmethane- 4,4-diisocyanate 30.0 ______________________________________

The formulation is applied to the backing with a doctor blade and the backing is then passed between squeeze rollers to remove excess adhesive. The adhesive is then cured for a period of 20 minutes at a temperature of 135.degree.C. The backing is then tufted and tested as in Example I and suitable results are obtained.

While this invention has been described in detail with particular reference to preferred embodiments thereof, it will be understood that variations and modifications can be effected within the spirit and scope of the invention as described hereinbefore and as defined in the appended claims.

Claims

I claim:

1. A tufted pile fabric comprising a woven sheet of backing material having a substantially uniform thickness and a plain 1/1 weave of substantially uniform flat strands of plastic material; an adhesive material adhering adjacent and crossing strands of plastic material to one another; and rows of carpet yarn piercing said strands and said adhesive material to provide a face of tufted yarn on one side of said woven backing and tuft loop backs of yarn on the other side of said woven backing; all of said adhesive material being disposed on the woven backing material and none of the adhesive material being disposed on the tuft loop backs for said carpet yarn.

2. A tufted pile fabric as in claim 1 wherein the adhesive material consists essentially of a styrene-butadiene latex material, melamine-formaldehyde resin and water.

3. A tufted pile fabric as in claim 1 wherein the adhesive material consists essentially of a carboxylated styrene-butadiene latex material, melamine-formaldehyde resin and water.

4. A tufted pile fabric as in claim 1 wherein the adhesive material consists essentially of ethylene vinyl acetate, paraffinic wax and an oil extender.

5. A tufted pile fabric as in claim 1 wherein the adhesive material consists essentially of a mixture of water; a polyol having a hydroxyl number of less than 100 and a functionality of at least two, said polyol being selected from the group consisting of polybutylene glycol, polyethylene glycol, 1,2-polydimethylene glycol, polydecamethylene glycol, and mixtures thereof; an aromatic diisocyanate selected from the group consisting of 2,4-toluene diisocyanate, 2,6-toluene diisocyanate, methane diisocyanate naphthylene 1,4-diisocyanate, diphenylmethane-4,4'-diisocyanate, 3,3'dimethoxy biphenylene diisocyanate, 4,4-diphenylene diisocyanate, and mixtures thereof; a filler selected from the group consisting of silica, asbestos, calcium carbonate, zinc oxide, clay, feldspar and mixtures thereof; and a polyurethane catalyst.

6. A tufted pile fabric as in claim 1 wherein a layer of second adhesive material is disposed on the tuft loop backs and the woven backing adhesive to secure the tuft loop backs in place in the woven backing material.

7. A tufted pile fabric as in claim 1 wherein a layer of second adhesive material is disposed on the tuft loop backs and the woven backing adhesive and a second woven backing material is adhered to the tufted woven backing material by the second adhesive material.