A carpet comprising a primary backing structure having a plurality of tufts comprising face yarn extending therefrom on a pile side and a plurality of stitches comprising face yarn disposed on a stitched side opposite the pile side, and a secondary backing laminated to the stitched side with a cured binder, wherein the secondary backing comprises nonwoven fabric.Carpets generally comprise a primary backing structure, face yarn, a binder and in many cases a secondary backing. Face yarn penetrates the primary backing structure to form tufts projecting from one side, providing a pile surface, and stitches on an opposite side. Binder is present on the stitched side, encapsulating and adhering stitches to the backing structure to anchor the tufts. Secondary backings normally are adhered to the stitched side with the binder. Carpets typically are made by tufting face yarn through a primary backing structure with reciprocating needles that carry face yarn back and forth through the structure to form the tufts and stitches, The secondary backing usually is laminated to the stitched side, normally by bringing it and the stitched side of the tufted structure together with binder applied to the stitched side, or to both it and the secondary backing, and curing the binder in contact with the stitched side and the secondary backing.
Dimensional stability of carpets has long been an area of emphasis. Carpets with inadequate stability can deform during installation and use. They also wear poorly. Lamination of secondary backings imparts added stability; however, if dimensional stability imparted by the secondary backing or delamination resistance of the bonded, tufted primary and secondary backing structure is inadequate, carpets can buckle. Delamination also can affect durability of a carpet in use. Therefore, it is important that secondary backings not only impart dimensional stability, but that they bond securely to the stitched side of the tufted backing structure in finished goods.