Patent ID: 7364634

Claim:
A method for making tufted carpet comprising a primary backing having a back side and a face side and tufts of yarn sewn therein, said method comprising: (a) selecting a primary backing which does not include an adhesive component; (b) selecting a yarn to tuft through the primary backing, said yarn being comprised of a thermoplastic material having a yarn melting point; (c) tufting the selected yarn through said primary backing so as to form face yarns on the face side of the primary backing and a plurality of back stitches on the back side; (d) providing a secondary backing comprising: (i) a thermoplastic material in the form of a fluid-impervious film or a fabric having a softening temperature that is no lower than the yarn melting point; or (ii) a thermoplastic material in the form of a fabric having a softening temperature that is no lower than the yarn melting point; or (iii) a laminate having an inner layer and an outer layer, said outer layer comprising a thermoplastic material having a softening temperature that is no lower than the yarn melting point; (e) bringing the secondary backing into contact with at least some of the back stitches on the back side of the primary backing; (f) heating the combination of the primary backing and the secondary backing to a temperature sufficient to adhere the secondary backing to the yarn of the back stitches by passing the secondary backing around a heated drum to soften the yarn of the back stitches without melting the secondary backing.