Patent Publication Number: US-7594975-B2

Title: Recyclable tufted carpet with improved stability and durability

Description:
This application is a divisional of U.S. patent application Ser. No. 10/827,497, filed Apr. 19, 2004, now U.S. Pat. No. 7,160,599, which is hereby incorporated by reference in its entirety. 

   TECHNICAL FIELD AND INDUSTRIAL APPLICABILITY OF THE INVENTION 
   The present invention relates generally to carpets and more specifically to recyclable tufted carpets having improved stability and durability. 
   BACKGROUND OF THE INVENTION 
   The look of a particular carpet is determined by its construction that may be loop, cut or combinations of loop and cut. In corridors, offices, classrooms, hotel rooms, patient care, and other public areas, loop piles of low, dense construction, tent to retain appearance and resiliency and, generally, provide a better surface for the rolling traffic of wheelchairs and roll carts. Cut pile or cut and loop pile carpets are very good choices for administration areas, libraries, individual offices and boardrooms. 
   Carpet performance is associated, in part, with pile yarn density, which is defined as the amount of pile yarn per given volume of carpet face. For a given carpet weight, lower pile height and higher pile yarn density typically gives the best performance. The number of tufts per inch and the size of the yarn in the tufts also influence density. 
   Commercial carpet is primarily manufactured by tufting, weaving, and by fusion bonding processes. Tufted carpets are the most popular, and account for upwards of 95 percent of all carpet construction. The tufting process is generally considered the most efficient and has advanced technology to provide capability for a myriad of patterns and styles. 
   Tufted carpet generally comprises yarn, a tufting primary into which the yarn is tufted, a secondary backing, and a binder, normally latex, which bonds the yarn, tufting primary and secondary backing together. The yarn is typically nylon and can be in the form of cut pile or loop pile. Cut pile carpet is made of short cut lengths of yarn and loop pile carpet is made of long continuous lengths of yarn. The tufting primary is typically a thin sheet of woven polyester or polypropylene material and the secondary backing is usually jute, woven polypropylene, or polyvinyl chloride (PVC) sheet. 
   Conventional tufted carpets are made by passing a flexible woven primary backing through a tufting machine having a large array of needles that force the carpet multifilament yarn through the backing where the yarn is restrained by a large array of hooks before the needles are retracted. The backing must accommodate needle penetration without damage. The backing is then advanced a short distance (about 1/10″ for a popular high quality tuft density), and the needles are reinserted through the backing to form the next series of yarn tufts. A large array of cutters may be employed in conjunction with the hooks to cut the tuft loop inserted through the backing to produce a cut-pile carpet. For loop-pile carpets, the tuft loops are not cut. 
   To assist in stabilizing, stiffening, strengthening, and protecting the tuft base from abrasion, a secondary backing is attached to the underside of the tufted primary backing. The secondary backing may be attached by the same adhesive layer or by the application of more adhesive. To save on costs, inexpensive latex adhesive is most often used. The secondary backing must resist damage during shipping, handling and installation. 
   Recent EPA requirements for recyclable carpeting require that carpet backings achieve at least 7% recyclable content. Traditional polypropylene type carpet backings do not currently meet this threshold requirement. 
   There is a need for a tufted carpet construction that is lightweight, dimensionally stable in use, and can be recycled easily to produce useful polymers and meet EPA recyclable content requirements. There is a need for an “all nylon and glass” tufted carpet that is stable to moisture and temperature changes in use. There is a need for a simple inexpensive method of making such tufted carpets. The present invention provides carpet backings for such carpets. 
   SUMMARY OF THE INVENTION 
   The present invention discloses a recyclable tufted carpet having improved dimensional stability that reduces skew, bow and wrinkles during manufacture and installation. The recyclable tufted carpet also does not creep after installation, therein providing improved durability. 
   The present invention combines the primary and secondary backings into a single fiber-reinforced primary backing layer that includes an adhesive for holding the tufts to the backing. 
   The present invention includes combination of the tufted primary and secondary backings with extruded nylon from, as needed, recycled nylon carpet. 
   The tufted carpet produced is fully recyclable, with only glass and nylon as its major components. 
   The present invention also discloses a fiber reinforced primary backing that can be used in forming a wide variety of carpets, including the recyclable tufted carpets described above and other types of open carpets. 
   The foregoing and other objects, features, and advantages of the invention will appear more fully hereinafter from a consideration of the detailed description that follows. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a perspective view of a preferred embodiment of the present invention. 
       FIG. 2  is a perspective view of the process for forming the glass fabric depicted in  FIG. 1 . 
       FIG. 3  is a perspective view of the continuation of the process, depicted in  FIG. 2 , for forming the glass fabric depicted in  FIG. 1 . 
       FIG. 4  is a perspective view of a preferred embodiment of the present invention. 
       FIG. 5  is a perspective view of a process for forming the carpet depicted in  FIG. 4 . 
       FIG. 6  is a perspective view of a another embodiment of the present invention. 
       FIG. 7  is a perspective view of a process for forming the carpet depicted in  FIG. 6 . 
       FIG. 8  is a perspective view of another embodiment of the present invention. 
       FIG. 9  is a perspective view of a process for forming the carpet depicted in  FIG. 8 . 
       FIG. 10  is a perspective view of another embodiment of the present invention. 
       FIG. 11  is a perspective view of a process for forming the carpet depicted in  FIG. 10 . 
       FIG. 12  is a perspective view of another embodiment of the present invention. 
       FIG. 13  is a perspective view of a process for forming the carpet depicted in  FIG. 12 . 
   

   DETAILED DESCRIPTION AND PREFERRED EMBODIMENTS OF THE INVENTION 
   In the following figures the same reference numerals will be used to refer to the same components. 
     FIGS. 1 and 4  illustrate two preferred embodiments of a recyclable carpet having improved dimensional stability that reduces skew, bow and wrinkles during manufacture and installation. The recyclable carpet also does not creep after installation, therein providing improved durability. 
   Referring now to  FIG. 1 , one preferred embodiment of the recyclable carpet  20  is shown having a plurality of pile elements  22  tufted within a primary backing layer  24 . To form the fiber-reinforced primary backing layer  24 , a layer of extruded film  28  is first applied to a glass fiber fabric layer  26 . After the pile elements  22  have been tufted into the glass fabric fiber layer  26 , the extruded film  28  is heated and consolidated therein forming the reinforced primary backing layer  24  having a length l and a width w. The thickness t of the fiber-reinforced primary backing layer  24  depends on the tufting density required and can range from 1 to 5 mm. The glass fiber fabric layer composition and weight also depends on the required nylon facing tuft density. The glass fiber layer in a non-woven discrete, random assembly combined by adhesive binder or stitched together with or without continuous fiber bundles. 
   The fabric layer  26  as shown in  FIG. 1  is formed of a fabric glass fibers  30  layered in a 0/90 orientation that gives strength required during the tufting process. The 0/90 orientation also gives the backing layer  24  biaxial dimensional stability and minimizes creep and shrinkage as the extruded film  28  is consolidated with the fabric layer  26 . A 0/90 orientation, a shown in  FIG. 1 , is defined for the purposes of the present invention as describing a first layer  32  of glass fibers  30  running parallel in a first direction (shown as top (or 0 degrees) to bottom (or 180 degrees) in  FIG. 1 ) and a second layer  34  of glass fibers  30  layered onto the first layer  32  and running parallel and in a second direction (shown as right (or 90 degrees) to left (or −90 degrees) on  FIG. 1 ), with the second layer  34  having fibers  30  rotated 90 degrees with respect to fibers  30  lying in the first layer  32 . The first layer  32  of glass fibers  30  run generally parallel to the length l of the fabric  26  while the second layer  34  of glass fibers  30  run generally parallel to the width w of the fabric  26  and perpendicular to the length l of the fabric  26 . Of course, in alternative arrangements, the first layer  32  may run parallel to the width w and the second layer  34  run parallel to the length l without affecting the properties of the primary backing  24  after consolidation. While  FIG. 1  is described with respect to two layers  32 ,  34 , it is understood that additional layers (not shown) that continue to alternate in a 0/90 pattern could be added to the glass fabric layer  26 . For example, as shown below in  FIGS. 2 and 3 , four layers  64 ,  66 ,  68 ,  70  of glass fibers form the glass fabric  26 . 
   In alternative embodiments, the glass fabric  26  may be formed of layers of fibers  30  oriented in a +45/−45 orientation. A +45 orientation, for the purposes of the present invention, is defined wherein the first layer  32  of glass fibers  30  are oriented to run from 45 degrees at top right to −135 degrees at bottom left. A +45 orientation is thus defined wherein the fibers in the first layer are rotated 45 degrees clockwise relative to fibers oriented in a 0 degree orientation. A −45 orientation, for the purposes of the present invention, is defined wherein the second layer  34  of glass fibers  30  are oriented to run from −45 degrees at top right to +135 degrees at bottom left. A −45 orientation is thus defined wherein the fibers in the first layer are rotated 45 degrees counterclockwise relative to fibers oriented in a 0 degree orientation. The +45/−45 orientation thus appears to form an X-shape as compared with the length l and width w of the fabric  26 , while fibers oriented in a 0/90 appear to form a cross-shape relative to the length l and width w. As above, additional layers (not shown) that continue to alternate in a +45/−45 pattern could be added to the glass fabric layer  26 . 
   Further, in yet another alternative embodiment, the layers of glass fibers  30  forming the glass fabric  26  may take on any of a number of other alternative arrangements to give the primary backing a varying degree of dimensional stability depending upon the desired end use. For example, a four-layer glass fabric  26  may have a 0/+45/90/−45 orientation. In addition, other fiber orientations, such as a +30 or −65 orientation, may also be utilized in one or more of the layers. 
   The extruded film  28  preferably is formed of nylon 6, nylon 66 and copolymers thereof. The extruded film also preferably incorporates recycled glass fibers  29 . The glass content of the extruded film  28  adds additional strength properties and creep resistance in the formed backing  24 . The extruded film  28  provides dispersed fibers and friction that helps to hold the tufted pile elements  22  during the tufting process and permanently hold (adhere to) the tuft pile elements  22  after consolidation. The extruded film  28  thus aids in improving durability of the finished carpet  20 . 
   The pile elements  22  are tufted yarn, preferably tufted nylon that are in the form of a cut pile or loop pile. The pile elements  22  are tufted into the backing  24  in conventional tufting patterns using conventional tufting equipment well known to those of ordinary skill in the art. In the illustrations provided (as shown in  FIGS. 1-13 ), the pile elements  22  of the recycled carpet are shown in a cut-pile arrangement, and thus illustrate wherein the cut ends  23  of the pile elements extend above the surface of the backing  24  to a desired pile height. While not shown, the pile elements  22  of the recycled carpet could also remain in a loop-pile arrangement, wherein the loops are not cut above the surface of the backing, but instead loop continuously through the backing for each row of tufts. 
   The fibers  30  are preferably continuous glass fibers, sized or unsized, having a diameter of about 10-24 micrometers formed in conventional fiber forming operations. 
   The process for forming the glass fabric  26  of  FIG. 1  is described below with respect to  FIG. 2 , while the process for forming the recyclable carpet  20  from the glass fabric  26  is described in  FIG. 3 . 
   Referring now to  FIG. 2 , a process for forming the glass fabric  26  of  FIG. 1  is depicted. Glass rods  62 , preferably about 2000 mm by 5 mm, are first melted and spun within a conventional device  65  to produce attenuated glass fibers  30  (sized or unsized) having a diameter of between about 10 and 24 micrometers. The glass fibers  30  are then introduced onto a perforated moving belt  60  in layer form at a desired fiber layer orientation. For example, as shown in  FIG. 3 , three layers  64 ,  66 ,  68  of glass fibers are depicted previously introduced from bottom to top in an (−45/90/+45) orientation. A fourth layer  70  of glass fiber  30  is shown as being introduced in the 0 orientation. The layers  64 ,  66 ,  68 ,  70  are compacted under a roller  72 . Of course, the number of layers of fibers  30 , and the respective orientations, is a matter of design choice based on numerous factors, including mechanical properties and cost. 
   Next, the fiber fabric  26  is passed through a conventional tufting machine  100  having a large array of needles that force the carpet multifilament yarn  22  through the fabric  26  where the yarn  22  is restrained by a large array of hooks before the needles are retracted. This forms a tufted fiber fabric  75 . The fabric  26  must accommodate needle penetration without damage. The fabric  26  is then advanced a short distance (about 1/10″ for a popular high quality tuft density), and the needles are reinserted through the fabric  26  to form the next series of yarn tufts. A large array of cutters may be employed in conjunction with the hooks to cut the tuft loop  22  inserted through the fabric  26  to produce a cut-pile carpet having ends  23  extending above the tufted fiber fabric  75 . For loop-pile carpets, the tuft loops are not cut. 
   Next, as shown in  FIG. 3 , a layer of extruded film  28  is introduced onto the tufted glass fabric layer  75  produced in  FIG. 2 . The extruded film  28  and tufted glass fabric layer  75  then pass through an oven  74 , or otherwise heated, wherein the nylon component of the extruded film  28  melts to consolidate the layers  64 ,  66 ,  68 ,  70  to form the fiber-reinforced primary backing layer  24 . The oven  74  temperature is insufficient to melt the tufted pile elements  22 . In an alternative method, the extruded film  28  could be introduced directly from an extruder onto the tufted glass fabric layer  75  in melted form, thus eliminating the need for an oven  74 . 
   In an alternative preferred embodiment, as shown in  FIG. 4 , another preferred embodiment of the recyclable carpet  90  is shown having a plurality of pile elements  22  tufted within a primary backing layer  45 . 
   To form the fiber-reinforced primary backing layer  45 , a layer of extruded film  28  is first sandwiched between a pair of glass fiber fabric layers  40 ,  42 . The extruded film  28  and fiber layers  40 ,  42  are then heated to consolidate the fiber layers  40 ,  42  together to form a fiber-reinforced primary backing layer  45  having a length l and a width w. The thickness t of the fiber-reinforced primary backing layer  45  is between about 1 to 5 mm. Finally, a plurality of pile elements  22  are tufted within the backing layer  45  in a desired warp and weft knitting pattern to form the recyclable carpet  90 . 
   The layers of glass fabric  40 ,  42  are formed in the same manner as glass fabric  26  in  FIG. 1 . The glass fabric  40 ,  42  have a varying number of potential layers of glass fibers  30  oriented in various directions. In a preferred arrangement, to maximize dimensional stability for the recycled carpet  90 , the fibers  30  of the glass fabric  40  are oriented in a 0/90 orientation while the fibers  30  of the glass fabric  42  are oriented in either a 0/90 or +45/−45 orientation. The process for forming a recyclable carpet  90  having the fiber-reinforced backing layer  45  is described below in  FIGS. 5 and 6 . 
   Referring now to  FIG. 5 , one method for forming the recyclable carpet  90  of  FIG. 4  is illustrated. First, the glass fabric layer  40  is formed according to the process described above with respect to the formation of the glass fabric  26  of  FIG. 2 . Thus, glass rods  62 , preferably about 2000 mm by 5 mm, are first melted and spun within a conventional device  65  to produce attenuated glass fibers  30  (sized or unsized) having a diameter of between about 10-24 micrometers. The glass fibers  30  are then introduced onto a perforated moving belt  60  in layer form at a desired fiber layer orientation. For example, as shown in  FIG. 3 , three layers  74 ,  76 ,  78  of glass fibers  30  are depicted previously introduced from bottom to top in a −45/90/+45 orientation. A fourth layer  80  of glass fiber  30  is shown as being introduced in the 0 orientation. The layers  74 ,  76 ,  78 ,  80  are compacted under a roller  82  to form the glass fiber fabric  40 . 
   A layer of extruded film  28  is unrolled and applied onto the glass fabric layer  40  and the additional attenuated glass fiber layers  84 ,  86  forming glass fabric layer  42  are layered onto the extruded film  28  in a similar process as described above with respect to fabric layer  40 . The material is then pulled under roller  88  to form a sandwich having the extruded film sandwiched between fiber layers  40 ,  42 . For illustrative purposes, fiber layer  84  is shown having a 0 orientation, while fiber layer  86  is shown in a +90 orientation, thus fabric layer  42  is illustrated in  FIG. 5  as having a 0/+90 orientation. 
   In alternative arrangements, as one of ordinary skill appreciates, the fabric layers  40 ,  42  could be preformed in an off-line process and introduced onto the moving belt  60  in one piece. 
   The sandwich of fabric layers  40 ,  42  and extruded film  28  are then introduced to oven  92 , wherein the nylon component of the extruded film  28  melts and consolidates fiber layers  40 ,  42  together to form the fiber-reinforced primary backing layer  45 . Again, as described above in  FIG. 3 , the extruded film  28  could be introduced directly from an extruder onto the fabric layer  40  in melted form and fabric layer  42  unrolled onto the melted extruded film  28 . The nylon component would then consolidate layer  40  to layer  42  to form the fiber-reinforced primary backing  45  without the need for oven  92 . 
   Finally, backing layer  45  is passed through a conventional tufting machine  100  having a large array of needles that force the carpet multifilament yarn pile elements  22  through the backing layer  45  where the yarn  22  is restrained by a large array of hooks before the needles are retracted. The backing layer  45  must accommodate needle penetration without damage. The backing layer  45  is then advanced a short distance (about 1/10″ for a popular high quality tuft density), and the needles are reinserted through the backing layer  45  to form the next series of yarn tuft pile elements  22 . A large array of cutters may be employed in conjunction with the hooks to cut the tuft loops  22  inserted through the backing  45  to produce a cut-pile recyclable carpet  90  having ends  23  extending above the backing layer  45 . For loop-pile carpets, the tuft loops are not cut. 
   The extruded film  28  provides dispersed fibers  29  and friction that helps to hold the tufted pile elements  22  during the tufting process and permanently hold (adhere to) the tuft pile elements  22  to the fiber-reinforced backing layer  45 . 
     FIGS. 6 and 8  illustrate two other preferred embodiments of the present invention, in which a low cost veil  128  replaces the glass fabric layers  26  in the recyclable carpets of the embodiments of  FIGS. 1 and 4 , respectively.  FIGS. 7 and 9  describe the method for forming the respective recyclable carpets of  FIGS. 6 and 8 . In addition,  FIGS. 10 and 12  illustrate two more preferred embodiments, in which a low cost glass mat replaces the glass fabric layers of  FIGS. 1 and 4 , respectively.  FIGS. 11 and 13  describe the method for forming the respective recyclable carpets of  FIGS. 10 and 12 . Each is described below: 
   Referring now to  FIG. 6 , the recyclable carpet  120  is shown having a plurality of pile elements  22  tufted within a primary backing layer  124 . To form the fiber-reinforced primary backing layer  124 , a layer of extruded film  28  is first applied to a glass veil  128 . The extruded film  28  could be applied as a film or applied in melted form and consolidated. After the pile elements  22  have been tufted into the veil  128 , the extruded film  28  is heated and consolidated therein forming the reinforced primary backing layer  124  having a length l and a width w. The thickness t of the fiber-reinforced primary backing layer  124  depends on the tufting density required and can range from 1 to 5 mm. The veil composition and weight also depends on the required nylon facing tuft density. 
   The glass veil  128  is preferably a commercially available glass veil formed via conventional wet-laid or dry-laid methods. The veils may be formed as part of the manufacturing process described below or be preformed and stored on a roll. 
   Commercially available glass veils are formed, via a wet-laid process, by introducing a plurality of glass fibers and a bicomponent fiber to a whitewater chemical dispersion to form a thick whitewater slurry at consistency levels of approximately 0.2 to 1 percent. The thick slurry formed is maintained under agitation in a single tank and delivered to a former. The former, or headbox, functions to equally distribute and randomly align the fibers onto a moving woven fabric, or forming wire, therein forming the filament network. Formers that can accommodate the initial fiber formation include Fourdrinier machines, Stevens Former, Roto Former, Inver Former, cylinder, and VertiFormer machines. These formers offer several control mechanisms to control fiber orientation within the network such as drop leg and various pond regulator/wall adjustments. 
   Deposited fibers forming the network are partially dried over a suction box. The dewatered network is then run through a drying oven at a temperature sufficient to remove any excess water and sufficient to melt the sheath of the bicomponent fiber without melting the core of the bicomponent fiber. Upon removal from the oven, the sheath material cools and adheres to both the core and to the structural fibers, therein forming a conformable surfacing veil. 
   In a dry-laid process, glass rods, preferably about 2000 mm by 5 mm, are first melted and spun within a conventional device to produce glass fibers  30  having a diameter of between about 11 and 14 micrometers. The fibers are then introduced to oscillating (latitudinal) multiple fiber distribution heads that buildup a random mat of chopped glass fibers on a moving perforated conveyor belt with a down draft airflow. Air drawn through the perforated belt is used to allow the chopped fibers to lie down on the conveyor belt to form the random mat. 
   The mat is then impregnated with a binder from a curtain coater or similar application device to form an impregnated mat. The impregnated mat is then introduced to an oven, or furnace, wherein water is removed. The binder is melted within the oven to glue the fibers together, therein forming a smooth veil of fibers (i.e. a veil similar to  128 ). 
   Referring now to  FIG. 7 , a method for forming the recyclable carpet  120  of  FIG. 6  begins by introducing the glass veil  128  a perforated moving belt  60 . As described above, the glass veil  128  may be formed as part of the processing line or produced prior to and stored on rolls  127 . Next, the glass veil  128  is passed through a conventional tufting machine  100  having a large array of needles that force the carpet multifilament yarn  22  through the veil  128  where the yarn  22  is restrained by a large array of hooks before the needles are retracted. This forms a tufted fiber fabric  151 . The veil  128  must accommodate needle penetration without damage. The veil  128  is then advanced a short distance (about 1/10″ for a popular high quality tuft density), and the needles are reinserted through the veil  128  to form the next series of yarn tufts. A large array of cutters may be employed in conjunction with the hooks to cut the tuft loop  22  inserted through the veil  128  to produce a cut-pile carpet having ends  23  extending beyond the veil  128 . For loop-pile carpets, the tuft loops are not cut. 
   Next, a layer of extruded film  28  is introduced onto the tufted glass fabric layer  151 . The extruded film  28  and tufted glass fabric layer  151  then pass through an oven  74 , or otherwise heated, wherein the nylon component of the extruded film  28  melts to consolidate the film  28  to the veil  128  to form the recyclable carpet  120  having a fiber-reinforced primary backing layer  124 . The oven  74  temperature is insufficient to melt the tufted pile elements  22  and the veil  128 . Again, as similarly described above with respect to  FIGS. 3 and 5 , the extruded film  28  may be applied to the tufted glass fabric layer  151  and consolidated to the tufted glass fabric layer  151  without the need for oven  74 . 
   In an alternative preferred embodiment, as shown in  FIG. 8 , another preferred embodiment of the recyclable carpet  135  is shown having a plurality of pile elements  22  tufted within a primary backing layer  138 . 
   To form the fiber-reinforced primary backing layer  138 , a layer of extruded film  28  is first sandwiched between the veil  128  and fabric layer  42 . The extruded film  28  may alternatively be introduced in melted form from an extruder onto the fabric layer  42  and consolidated prior to introducing the veil  128 . The veil  128 , extruded film  28  and fiber layer  42  are then heated to consolidate the veil  128  and fiber layer  42  together to form a fiber-reinforced primary backing layer  138  having a length l and a width w. The thickness t of the fiber-reinforced primary backing layer  138  is between about 1 to 5 mm. Finally, a plurality of pile elements  22  are tufted within the backing layer  138  in a desired warp and weft knitting pattern to form the recyclable carpet  135 . 
   The layer of glass fabric is formed in the same manner as glass fabric  42  in  FIG. 5 . The glass fabric  42  has a varying number of potential layers of glass fibers  30  oriented in various directions. In a preferred arrangement, to maximize dimensional stability for the recycled carpet  135 , the fibers  30  of the glass fabric  42  are layered in either a 0/90 (shown here) or +45/−45 orientation. The process for forming a recyclable carpet  135  having the fiber-reinforced backing layer  138  is described below in  FIG. 9 . 
   Referring now to  FIG. 9 , one method for forming the recyclable carpet  135  of  FIG. 8  is illustrated. First, the veil  128  is formed according to the process described above with respect to  FIG. 7 . The veil  128  is then introduced onto a perforated moving belt  60 . 
   A layer of extruded film  28  is unrolled and applied onto the additional attenuated glass fiber layers  84 ,  86  forming the glass fabric layer  42 . The veil  128  is then layered onto the extruded film  28  in a similar process as described in  FIG. 5 . The extruded film  28  may alternatively be introduced in melted form from an extruder onto fabric layer  42  and consolidated prior to introducing the veil  128 . The material is then pulled under roller  88  to form a sandwich having the extruded film  28  sandwiched between the veil  128  and fiber layer  42 . For illustrative purposes, fiber layer  84  is shown having a 0 orientation, while fiber layer  86  is shown in a +90 orientation, thus fabric layer  42  is illustrated in  FIG. 8  as having a 0/+90 orientation. 
   The sandwich of veil  128 , extruded film  28 , and fabric layer  42  is then introduced to oven  92 , wherein the nylon component of the extruded film  28  melts and consolidates the veil  128  and fabric layer  42  together to form the fiber-reinforced primary backing layer  138 . 
   Finally, backing layer  138  is passed through a conventional tufting machine  100  having a large array of needles that force the carpet multifilament yarn pile elements  22  through the backing layer  138  where the yarn  22  is restrained by a large array of hooks before the needles are retracted. The backing layer  138  must accommodate needle penetration without damage. The backing layer  138  is then advanced a short distance (about 1/10″ for a popular high quality tuft density), and the needles are reinserted through the backing layer  138  to form the next series of yarn tuft pile elements  22 . A large array of cutters may be employed in conjunction with the hooks to cut the tuft loops  22  inserted through the backing  138  to produce a cut-pile recyclable carpet  90  having ends  23  extending above the backing  138 . For loop-pile carpets, the tuft loops are not cut. 
   The extruded film  28  provides dispersed fibers  29  and friction that helps to hold the tufted pile elements  22  during the tufting process and permanently hold (adhere to) the tuft pile elements  22  to the fiber-reinforced backing layer  138 . 
   In another preferred low cost alternative, as shown in  FIG. 10 , a mat  158  replaces the veil  128  in forming the fiber-reinforced backing layer  154  that is used to form a recyclable carpet  150 . The mat  158  is formed of a plurality of randomly oriented glass fibers  159 . The randomly oriented glass fibers  159  are preferably attenuated glass fibers  159  (sized or unsized) having a diameter of between about 10 and 24 micrometers. 
   To form the recyclable carpet  150  of  FIG. 10 , as shown in  FIG. 11 , a layer of extruded film  28  is unrolled onto a moving conveyor belt  60 . At the same time, glass rods  62 , preferably about 2000 mm by 5 mm, are melted and spun within a conventional device  65  to produce attenuated glass fibers  159  (sized or unsized) having a diameter of between about 10 and 24 micrometers. The glass fibers  159  are chopped and then introduced onto extruded film  28  in random fashion, therein forming a mat  158  on the extruded film  28 . The extruded film  28  and mat  128  are then pressed through a roller  88  and consolidated in an oven  74  to form the fiber-reinforced backing layer  154 . 
   Next, the layer  154  is passed through a conventional tufting machine  100  having a large array of needles that force the carpet multifilament yarn  22  through the layer  154  where the yarn  22  is restrained by a large array of hooks before the needles are retracted. The layer  154  must accommodate needle penetration without damage. The layer  154  is then advanced a short distance (about 1/10″ for a popular high quality tuft density), and the needles are reinserted through the layer  154  to form the next series of yarn tufts. A large array of cutters may be employed in conjunction with the hooks to cut the tuft loop  22  inserted through the mat  154  to produce a cut-pile carpet  150  having ends  23  extending above the mat  154 . For loop-pile carpets, the tuft loops are not cut. 
   Referring now to  FIG. 12  another preferred embodiment of the recyclable carpet  180  is shown having a plurality of pile elements  22  tufted within a primary backing layer  188 . 
   To form the fiber-reinforced primary backing layer  188 , a layer of extruded film  28  is first sandwiched between the mat  158  and fabric layer  42 . The mat  158 , extruded film  28  and fiber layer  42  are then heated to consolidate the mat  158  and fiber layer  42  together to form a fiber-reinforced primary backing layer  188  having a length l and a width w. The thickness t of the fiber-reinforced primary backing layer  188  is between about 1 to 5 mm. Finally, a plurality of pile elements  22  are tufted within the backing layer  188  in a desired warp and weft knitting pattern to form the recyclable carpet  180 . 
   Referring now to  FIG. 13 , to form a recyclable carpet  180  having a fiber-reinforced primary backing layer  188  as in  FIG. 12 . First, glass rods  62 , preferably about 2000 mm by 5 mm, are melted and spun within a conventional device  65  to produce attenuated glass fibers  30  (sized or unsized) having a diameter of between about 10-24 micrometers. The glass fibers  30  are then introduced onto a perforated moving belt  60  in random fashion to form the mat  158 . 
   A layer of extruded film  28  is unrolled and applied onto the mat  158  and the additional attenuated glass fiber layers  84 ,  86  forming glass fabric layer  42  are layered (here shown as previously formed) onto the extruded film  28  having the desired layered fiber orientation. Again, as described previously, the film  28  could be introduced onto the fabric layer  42  in molten form and consolidated to the mat  158  directly without the need for oven  74 . The material is then pulled under roller  88  to form a sandwich having the extruded film  28  sandwiched between mat  158  and fiber layer  42 . For illustrative purposes, fiber layer  84  is shown having a 0 orientation, while fiber layer  86  is shown in a +90 orientation, thus fabric layer  42  is illustrated in  FIG. 5  as having a 0/+90 orientation. 
   The sandwich of mat  158 , extruded film  28 , and fiber layer  42  is then introduced to oven  74 , wherein the nylon component of the extruded film  28  melts and consolidates the mat  158  and fiber layer  42  together to form the fiber-reinforced primary backing layer  188 . 
   Finally, backing layer  188  is passed through a conventional tufting machine  100  having a large array of needles that force the carpet multifilament yarn pile elements  22  through the backing layer  82  where the yarn  22  is restrained by a large array of hooks before the needles are retracted. The backing layer  188  must accommodate needle penetration without damage. The backing layer  188  is then advanced a short distance (about 1/10″ for a popular high quality tuft density), and the needles are reinserted through the backing layer  188  to form the next series of yarn tuft pile elements  22 . A large array of cutters may be employed in conjunction with the hooks to cut the tuft loops  22  inserted through the backing  188  to produce a cut-pile recyclable carpet  180  having ends  23  extending above the backing  188 . For loop-pile carpets, the tuft loops are not cut. 
   The extruded film  28  helps to hold the tufted pile elements  22  during the tufting process and permanently hold (adhere to) the tuft pile elements  22  to the fiber-reinforced backing layer  180 . Dispersed fibers  29  within the extruded film  28  provides friction that further aids in holding the tufted pile elements during the tufting process. 
   The recyclable carpets  20 ,  90 ,  120 ,  135 ,  150 ,  180  formed according to these preferred embodiments have improved dimensional stability that reduces skew, bow and wrinkles during manufacture and installation. The recyclable carpet  20 ,  90 ,  120 ,  135 ,  150 ,  180  also does not creep after installation, therein providing improved durability. Further, the recyclable carpet  20 ,  90 ,  120 ,  135 ,  150 ,  180  constructions is lightweight and can be recycled easily to produce useful polymers and meet EPA recyclable content requirements. Further, the recyclable carpets  20 ,  90 ,  120 ,  135 ,  150 ,  180  are stable to moisture and temperature changes in use. In addition, by combining the primary and secondary backing into a single backing layer, manufacturing costs associated with reducing one step of the manufacturing process are realized. 
   The invention of this application has been described above both generically and with regard to specific embodiments. Although the invention has been set forth in what is believed to be the preferred embodiments, a wide variety of alternatives known to those of skill in the art can be selected within the generic disclosure. The invention is not otherwise limited, except for the recitation of the claims set forth below.