WO2023214240A1

WO2023214240A1 - Flexible radiation-activated coating

Info

Publication number: WO2023214240A1
Application number: PCT/IB2023/054171
Authority: WO
Inventors: Joseph Wayne KREFT
Original assignee: Aladdin Manufacturing Corporation
Priority date: 2022-05-03
Filing date: 2023-04-24
Publication date: 2023-11-09

Abstract

A radiation-activated coating may be applied to a carpet backing having a matrix of openings and tufting woven through the matrix openings. The radiation-activated coating may be melted or partially melted to flow into interstitial spaces and/or cured to secure the tufting to the carpet backing and to provide a specific tack and/or a specific adhesion. The curing step primarily being initiated by exposure to radiation such as, but not limited to, ultraviolet (UV), visible, or infrared (IR) radiation amongst other wavelengths.

Description

Flexible radiation-activated coating.

The present invention relates to a flexible radiation-activated coating and a method for manufacturing a carpet with a flexible radiation-activated coating. Many types of radiation may be used to cure or set radiation-activated formulations. Throughout this specification, it must be understood that using the specific terms such as “UV”, “IR”, “ultraviolet”, “visible”, “infrared”, and other references to specific wavelengths of radiation are only exemplary embodiments of the many embodiments that are within the scope of the inventions disclosed and taught herein.

Currently many flooring products, such as but not limited to soft surfaces such as carpet, utilize a coating comprised of a water-based dispersion or emulsion formulation which, in the case of carpet, holds the tufts of carpet from being pulled out since they adhere as a coating from the back side of the tufted backing material into the tufts themselves.

After the carpet has this water-based formula applied as a liquid, it must pass through a series of drying ovens to evaporate off the water from the formulation.

As an alternative to the above, flexible radiation-reactive coating formulations, which may also be called radiation-activated formulations, may be applied and cured rapidly with fewer irradiating platforms at comparable speeds. This would eliminate the need to run multiple expensive drying ovens and operations to evaporate water from latex dispersions used today on carpet backings. This has the potential to reduce cost, reduce manufacturing steps, and improve product quality for carpets being treated on other lines with steam treatments such as in printing operations where delamination of a water-soluble latex polymer due to redissolution of the polymer may occur. In certain embodiments, the formulation may also act to adhere additional optically transparent backing layers having or not having coloration included. A coloration may be produced through adding a colorant, dye, or by any other means known to those of ordinary skill in the art. Configuring the surface roughness or smoothness of such a back coating may also provide better adhesion to any additional backing layers. This also has potential to improve adhesion to the base floor when adhesives are used due to the increased bonding surface area. In one of many embodiments that will be understood by those of ordinary skill in the art and in possession of the disclosures and teachings herein, several heating/drying ovens may be reduced to very few, or perhaps just one irradiating platform where a radiation-activated formulation may be applied as a powder rather than a liquid and then passed through one irradiating platform to melt it into place followed by exposure to radiation curing approach as described herein via radiation curing approach. Those of ordinary skill in the art will understand that the process step of melting the radiation-activated formulation may be combined with, or separated from, the process step of curing the radiation-activated formulation.

As one of many possible embodiments, the radiation-activated formulation may comprise a substance that melts when irradiated and then cures as the radiation is continually applied. Also encompassed within the inventions disclosed and taught herein are embodiments where the radiation-activated formulation may comprise a substance that melts when irradiated and another substance that cures and sets when irradiated. These may react to different frequencies or wavelengths of radiation. Therefore, a first step may be to apply the formulation; the second step may be to irradiate the applied formulation from a radiation source at a frequency that melts the radiation-meltable component; and a third step of irradiating the applied and melted formulation from a radiation source that cures the radiation-curable component. The radiation source in the second and third steps may be the same radiation source, or they may be different radiation sources.

As those ordinarily skilled in the art will appreciate, the amounts of radiation applied in the second and third steps may be precisely applied to produce reproducible results. For example, and without limitation, the step of irradiating the applied formulation to melt the formulation may be stopped when the formulation becomes molten and has penetrated the fibers and backing to a desirable amount. This desirable amount may be to an extent that the molten formulation has bubbled through the openings in the matrix of the backing to coat at least some portion of the matrix without further advancing into the yarn. In some situations, it may be desirable to not have any set glue in the base of any yarn strands, which may produce an uncomfortable feeling on skin such as bare feet. Similarly, the third step of irradiating the formulation may involve stopping the radiation when the radiation-curable formulation has cured to a state that has desirable properties such as, but not limited to tack and adhesion. The adiati on-activated formulation may comprise a photoinitiator. Those of ordinary skill in the art may understand that some types of radiation-activated formulations that may be used with the inventions disclosed and taught herein may have a higher efficacy when a photoinitiator is used withing the formulation, or is applied during any of the steps described herein.

The radiation-activated formulation may also include other components to produce a desirable end result. One envisioned embodiment may include an anti-skid component. In this envisioned embodiment, the radiation-activated formulation may comprise a component that melts when irradiated at a specific wavelength or frequency; a component that cures when irradiated at the same or at a different wavelength; and a component that may form an anti-skid layer. The component used to form an anti-skid layer may have a density different from the other two components. In this embodiment, the formulation may be applied to the backing of the carpet section while the backing is facing up. That is to say that the pile is facing down. In this orientation, gravity may be used to apply the formulation. The formulation may be applied from above the backing so that it falls onto the backing. This may include, but not be limited to spraying the formulation in a powder or liquid form onto the backing. The process step of irradiating the formulation may melt the formulation as described elsewhere herein such that the molten formulation seeps further down into the mesh of the backing and, if desired, to some extent further into the mesh. At the same time, particles of the component that may form the anti-skid layer may have a different density than the other components such that it rises to the top of the molten formulation and becomes exposed on the surface. When the step that melts the formulation is complete, there may be enough of an anti-skid component on the top surface of the carpet backing to provide desirable anti-skid properties to the carpet. The process may be continued by irradiating the formulation to cure the formulation. This may then set the anti-skid component. When the carpet is installed, the anti-skid component will then be on the bottom of the carpet segment and thus in contact with the foundation upon which the carpet will rest. This foundation may be a hard surface or a pad.

In another of many embodiments that may be envisioned by those of ordinary skill in the art and in possession of the inventions and teachings within this disclosure may be that the anti-skid coating may be applied to the radiation cured backing layer after the radiation-activated backing has been irradiated in any of the manners disclosed herein. The anti-skid layer may be applied with traditional adhesives or by any of the mechanisms disclosed and taught herein.

If the radiation-activated formulation is applied as fine powder particles, those of ordinary skill in the art will understand that they may fall into or be maneuvered further into the yam strands to facilitate better tuft binding via integration prior to going into the liquid or molten state and being cured or set with the radiation. Methods of introducing the fine particles further into the yam strands may include, without limitation, mechanical shaking, force blowing, vortex blowing, pressing with a roll coater, deforming the backing to expose more surface area, and other mechanisms known to those ordinarily skilled in the art.

Several of the many benefits of this technology for the carpet and flooring industry are: a shorter production line; smaller factory footprint; shorter manufacture time; reduced energy consumption cost; cure-on-demand capabilities; elimination, reduction, or control of mold and bacterial growths; and multi-functionality; along with quality improvements.

In cure-on-demand, the radiation-activated formulation may be applied at one time but not irradiated until a later time or step. This is different from applying a waterbased dispersant, which would require slowly drying. The drying process would need to begin almost immediately after applying the water-based adhesive since it takes so much time and energy and since the continued presence of that much water in the carpet may adversely affect the final product. Using a radiation-activated formulation and process may extend the shelf-life of raw materials and eliminate mold and bacterial growth which are concerns associated with water-based dispersions used today for the carpet industry, etc.

One of many possible choices of a pressure sensitive adhesive coating for carpet backing is a product that may be applied as a hot-melt and then cured with UV light to a specific desired level of tack and adhesion strength that can be varied based on its exposure to activating radiation.

To this aim, the invention relates to a flexible radiation-activated coating and a method as defined in the appended independent claims, wherein preferred embodiments are defined in the dependent claims. In a first independent aspect the invention relates to a backing of a section of carpet having a primary backing and a plurality of tufts comprising: at least one layer of UV-cured formulation; wherein the UV-cured formulation adheres to the primary backing; and wherein the UV-cured formulation secures the tufts to the primary backing.

In a second independent aspect the invention relates to a method of manufacturing a backing of a carpet comprising the steps of providing a carpet comprising a primary backing and a plurality of tufts; distributing a UV-curable formulation on the primary backing; and curing the UV-curable formulation.

In a third independent aspect the invention relates to a method of manufacturing a backing of a carpet comprising the steps of providing a carpet comprising a primary backing and a plurality of tufts; distributing a radiation-activated formulation on the primary backing; wherein the radiation-activated formulation comprises a radiation-meltable component and a radiation-curable component; and at least partially curing the radiation-curable formulation.

In a fourth independent aspect the invention relates to a method of manufacturing a carpet comprising the steps of providing a primary backing woven with a plurality of tufts; distributing a radiation-activated formulation onto the primary backing and onto at least a portion of the plurality of tufts; providing at least one source of radiation; and using the at least one source of radiation to at least partially set the radiation-activated formulation.

With the intention of better showing the characteristics of the invention, herein after, as an example without any limitative character, some preferred embodiments are described, with reference to the accompanying drawings, wherein:

Fig. 1 represents a prior art soft surface section;

Fig. 2 represents a soft surface section where tufting has been woven into a backing;

Fig. 3 represents a soft surface section where a radiation-activated formulation has been applied; and

Fig. 4 represents a soft surface section where a radiation-activated formulation has been cured. Fig. 1 represents an illustration of a prior art carpet section 100 as is described in U.S. Patent No. 7,635,099. In ways that are known to those of ordinary skill in the art, yarn or other fibers, which may be tufted, may be woven into a backing. This may be considered to be a substrate 104. The yam may be prepared in ordinary ways and the backing may be of any type of backing that may usually be used as carpet backing. In the prior art preparation methods, the fibers may be secured to the backing through the addition of water-based adhesives or water based latexes of adhesive polymers that must be dried for the adhesive to secure the fibers to the backing, and perhaps a secondary backing to the fibers and the primary backing. FIG. 1 illustrates a section 102 of the carpet 100 having been treated with an adhesive latex that has been dried on the substrate. The water from the water-based adhesive must be removed for the adhesive latex to set and secure the fibers to the primary backing. Evaporating the excess water from the water-based adhesive takes much energy. This has usually been done through using heated air blowing across the water-based adhesive, which is usually done in stages by passing the substrate and water-based-coated backing through multiple ovens.

One of many embodiments of the inventions disclosed and taught herein is a method of manufacturing a carpet comprising the steps of: providing a primary backing woven with a plurality of tufts; distributing a radiation-activated formulation onto the primary backing and onto at least a portion of the plurality of tufts; providing at least one source of radiation; and using the at least one source of radiation to at least partially set the radiation-activated formulation.

In the inventions disclosed and taught herein, an adhesive may be applied to a substrate that may be set in place and cured through the application of radiation. In one of many ways that will be known to those in possession of the disclosures and teachings contained herein, the radiation-activated adhesive may be set in place and cured by irradiating the radiation-activated adhesive.

FIGs. 2-4 represent a soft surface section according to the inventions disclosed and taught herein. In many carpet manufacturing processes, the backing layer 208 is placed face-up so that materials may be applied to that layer from above with the aid of gravity. This means that during the manufacturing process, the tufts 204 are face-down. Once the processing is complete, the carpet or other soft surface will be installed with the tuft 204 facing the direction of use. This usually means that on a carpet, the tufts 204 will be upwards so they may be walked upon. Unless otherwise stated herein, this disclosure will use the convention that the carpet will be processed with the backing 208 facing substantially upwards and the tufts 204 facing substantially downwards.

In a simple, but non-limiting example of the inventions disclosed and taught herein, a radiation-activated formulation may be applied to a backing 208 of a soft surface having tufts 204. The radiation-activated formulation may be in a powder form and dispersed evenly across a carpet’s back side 204. In one way, this may be applied across an entire segment of carpet at one time. In another way, the powder may be applied as the carpet is unwound from a roller as it is being processed. In those, and many other ways known to those of ordinary skill in the art, the powder may be applied consistently across the back surface of the carpet 204. The carpet with the radiation-activated formulation may then be irradiated with a type of radiation that will cure, or set, the radiation-activated formulation. The process of curing, or setting, the formulation may comprise curing the formulation to a desirable level of tackiness and/or adhesion. This includes a level of tack that is essentially zero or no tack and therefore the exterior facing cured surface 410 does not provide any adhesion on purpose.

In the process step of applying the formulation the formulation may be a powder, a granular solid, a slurry, a liquid, a hot melt, or a film, or any other substance that may be applied to a carpet backing as would be known to those of ordinary skill in the art.

In any form, the formulation may be applied by the process of using a roll-coater, kiss-coater, a sprayer, or it may be dusted (as a powder state) onto the substrate, or poured on and spread into place depending on the application needs of the substrate. The substrate application needs may include, but not be limited to, the type of the substrate in that it may be jute, a woven matrix, a needle pressed fabric, or any other type of backing known to those of ordinary skill in the art. The formulation in its different media (powder, hot melt, etc.) may coat the substrate in different ways. In any of these ways, it is the intent and scope of the inventions disclosed and taught herein, to distribute the formulation across the substrate in a manner best suited for a resultant adhesion and/or tack after the formulation is cured or set.

In an exemplary embodiment, the formulation may be applied in the form of a hot melt. Without further processing, the hot melt may just lay atop the substrate and not properly adhere to the backing and/or the fibers. Similarly, of the formulation is applied as a powder, it may only settle onto the surface and not properly adhere the fibers to the backing.

One way to address this may be through mechanical means. A powder on a surface may be shaken so that it settles further into the matrix and the fibers. The hot melt may be pressed into the fibers and the backing by rollers or other pressing means. Either may be forced into the substrate through the application of blowers or jets of air or any other gas.

Additionally, if the formulation is meltable under the application of radiation, then the formulation may be irradiated in such a way as to melt or partially melt the formulation so that in a molten state it permeates into the substrate. The property of flowing into the crevasses and interstitial voids of the fibers and between the fibers and the pores of the matrix of the backing may be a natural property of the formulation. Conversely, the natural property of the formulation may be that it flows too much when irradiated such that it may be preferable to slow the flowability of the formulation when it is in a molten state. To that end, the flow property of the formulation may be enhanced, augmented, or deprecated by flow enhancers, viscosity reducers or increasers, or other additives that may be added to the formulation to achieve a desired amount of flow during an initial irradiation to disperse itself into the spaces between the fibers and the backing.

This initial irradiation may be an exposure to a radiation source to transform the formulation to a molten state. That is to say that the formulation may be irradiated for a time to turn the formulation from its initial state into a molten state, or any less viscous state, to allow it to flow into interstitial voids to a desirable extent. The amount that the molten formulation flows into the interstitial spaces may be further controlled through temperature or other heat exchange methods. One of many exemplary methods of this type of control may be to control the temperature of the substrate and its ambient environment. That is to say that the substrate may enter a chamber with a controlled temperature and humidity wherein the applied formulation is irradiated to produce a molten formulation where it would be known that the irradiated molten formulation will cool at a certain rate within the chamber such that the molten formulation will flow for an extent that will only pass into the substrate for a known amount but will not pass through the matrix and into the tuft. In this it may be desirable that any adhesive not be allowed to enter into the tuft as it may produce an undesirable feeling on any skin surface coming in contact with the tuft, such as the sole of a foot walking upon the finished carpet.

Alternatively, the initial irradiation of the formulation may make the formulation flow into the interstitial voids, which would be stopped by changing at least one environmental condition, such as the temperature. In one exemplary embodiment, this may be accomplished by blowing cold air across the molten formulation at a certain point after it had been irradiated. In another exemplary embodiment, this may be accomplished by moving the carpet across a roller cooled to a temperature that would slow the flow of the molten formulation. In another embodiment, if the tufts and the backing are transparent or translucent to the activating radiation, the activating radiation may be applied from the tuft side of the substrate. The radiation may then be used to cure the radiation-activated formulation from the tuft side of the substrate while radiation-activated formulation remains molten and perhaps is still flowing on the backing side of the substrate.

In another embodiment, the irradiation of the formulation may be of a duration to melt the formulation and cure it. In this embodiment, the irradiation may at first melt the formulation such that it does penetrate the interstitial voids and also starts the curing process. The continued irradiation of the formulation-containing substrate would thereby cure the formulation at a point where it had penetrated the interstitial voids of the fibers and seeped into the backing matrix to a desirable amount. In this exemplary embodiment, the irradiation of the formulation would be of such an intensity so that it could be timed to stop at a point when the molten formulation had penetrated the interstitial voids and into the matrix to a desirable depth and be cured, or partially cured at that point such that it would no longer flow. In this exemplary embodiment, the formulation would be set, or cured, at a desirable point wherein the substrate with the radiation-activated formulation would have a desired tack and adhesion.

In any of these embodiments, a photoinitiator may be utilized. In one of many exemplary embodiments, a photoinitiator, or multiple photoinitiators may be mixed with the radiation-activated formulation prior to the application of the radiation- activated formulation to the carpet backing. Alternatively, a photoinitiator(s) may be applied before or after the application of the radiation-activated formulation. In the cases where a photoinitiator produces gases during irradiation, the gases may be incorporated into the finished product, or they may be removed through such means that include, but are not limited to the use of gas evacuation methods.

In any of these embodiments, the flexibility of the finished carpet may be set. That is to say that the formulation may be cured only to an extent desired to allow the finished product to still be rolled without cracking or plastically deforming the cured formulation. The formulation itself can also be tailored to deliver the cured coating as one in which the elastomeric properties it delivers are designed to be optimal for the application and allow for the rolling of the carpet but also such that the coating can relax back to its pre-rolled state in a short time period suitable to allow flattening of the carpet when it is installed.

In another of many exemplary embodiments that may be perceived by those of ordinary skill in the art and in possession of the disclosures and teachings contained herein, the substrate including the formulation may be subject to a first source of radiation to melt the formulation such that it flows to a desired depth in the substrate, and then be subject to a second source of radiation to stop the flow and to cure the formulation to a desired tack and adhesion. In this exemplary, and nonlimiting embodiment, the first source of radiation may be in the infrared bandwidth and the second source of radiation may be in the ultraviolet bandwidth. Alternatively, both sources of radiation may be either infrared or ultraviolet. Additionally, visible light may be used to either melt the formulation and/or cure the formulation, or visible light may be combined with the infrared and/or ultraviolet radiation.

In another exemplary embodiment, the radiation-activated formulation does not need to be cured to a desired tack and adhesion during one exposure to radiation. The radiation-activated formulation may be partially cured during a first exposure, and then may be cured to a desired tack and adhesion during a second exposure to radiation. Various processes may be performed between the first and second exposures. As those of ordinary skill in the art and in possession of the inventions and teachings in this disclosure may be aware, other exemplary embodiments may have more steps of radiation exposure.

In one non-limiting embodiment, after a first exposure to radiation, a first application of a radiation-activated formulation may be set to a degree such that additional material may be added to it. This additional material may comprise an antimicrobial substance, a non-microbial harboring substance, an elastomer, a plasticizer, a thickener, and a filler. In some cases, it may be desirable that the filler be transparent or translucent to the radiation being used to cure the radiation- activated formulation. Also, in some cases, the filler may be a material layer. In this exemplary embodiment, a second application of radiation may then be used to secure the additional material to the first layer of the radiation-activated formulation.

In many cases, it is desirable to keep the resulting carpet flexible and elastic. This may be done by not fully curing the radiation-activated formulation, but only curing the surfaces of it, while the interior of the radiation-activated formulation remains in a liquid, or semi-liquid state. In that case, a plasticizer may be added to the formulation so that the surface will retain some elasticity and flexibility. Similarly, a plasticizer may be added after the radiation-activated formulation has been cured to a desirable extent, which may be used to set a final flexibility and tack. That is to say that in an envisioned embodiment, the radiation-activated formulation in the carpet may be cured with radiation to a certain extent, and then a plasticizer may be added to the carpet backing to produce a finalized tack and flexibility.

In an additional embodiment, a second layer of a radiation-activated formulation may be added above any additive, such as a filler. The second layer of radiation- activated formulation may be irradiated to melt and/or cure the second layer and/or the first layer, thereby securing the additive between the layers.

In another embodiment, the radiation-activated formulation may be applied in several layers, or at different depths across the backing of the carpet. This may be used to provide a pattern of the adhesive across the carpet backing. Similarly, the irradiation of the substrate with the radiation-activated formulation may be irradiated in an irregular manner to provide wrinkles in the form of embossing and/or indentations, or combinations of them across the adhesive backing.

In a similar embodiment, an anti-slip layer may be applied over a layer of radiation- activated formulation such that irradiating the radiation-activated formulation will secure the anti-slip layer to the bottom of the carpet section.

The present invention is in no way limited to the herein above-described embodiments, on the contrary many such flexible radiation-activated coatings and methods may be realized according to various variants, without leaving the scope of the present invention.

Claims

Claims.

1 A backing of a section of carpet having a primary backing and a plurality of tufts comprising: at least one layer of radiation-activated formulation; wherein the radiation-activated formulation adheres to the primary backing; and wherein the radiation-activated formulation secures the tufts to the primary backing.

2.- The backing of a section of carpet according to claim 1, wherein the radiation-activated formulation comprises an antimicrobial, a non-microbial harboring substance, an elastomer, a plasticizer, a thickener, a filler, a colorant, or combinations thereof.

3.- The backing of a section of carpet according to claim 1 or 2, wherein the radiation-activated formulation is flexible and elastic.

4.- The backing of a section of carpet according to any of the preceding claims

1-3, wherein the backing further comprises an anti-slip layer or coating.

5.- The backing of a section of carpet according to any of the preceding claims

1-4, wherein the radiation-activated formulation forms or is formed into a texture comprised of embossing, indentations, or combinations thereof.

6.- The backing of a section of carpet according to any of the preceding claims

1-5, wherein the radiation used to at least partially cure the radiation-activated formulation comprises ultraviolet radiation.

7.- The backing of a section of carpet according to any of the preceding claims

1-6, wherein the radiation-activated formulation comprises a specific tack, a specific adhesion, or a combination thereof.

8.- A method of manufacturing a backing of a carpet comprising the steps of: providing a carpet comprising a primary backing and a plurality of tufts; distributing a radiation-activated formulation on the primary backing; and at least partially curing the radiation-activated formulation.

9.- The method according to claim 8, wherein the radiation-activated formulation is distributed as a powder, a granular solid, a slurry, a liquid, a hot melt, or a film.

10.- The method according to claim 8 or 9, wherein the radiation-activated formulation comprises an antimicrobial, a non-microbial harboring substance, an elastomer, a plasticizer, a thickener, a filler, a colorant, or combinations thereof.

11.- The method according to any of the preceding claims 8-10, wherein the radiation-activated formulation comprises a filler.

12.- The method according to any of the preceding claims 8-11, wherein the radiation-activated formulation is distributed in a pattern.

13.- The method according to any of the preceding claims 8-12, wherein the radiation-activated formulation is distributed at different depths on the primary backing.

14.- The method according to claim 12 or 13, wherein the distribution of the radiation-activated formulation forms a pattern.

15.- The method according to any of the preceding claims 8-14, further comprising the steps of: distributing a second radiation-activated formulation on the primary backing; and curing the second radiation-activated formulation.

16.- The method according to claim 15, further comprising the step of distributing a filler between the radiation-activated formulation and the second radiation-activated formulation.

17.- The method according to claim 16, wherein the filler is transparent or translucent to ultraviolet and/or visible radiation.

18.- The method according to claim 16 or 17, wherein the filler is a material layer.

19.- The method according to claim 8 or 15, wherein the radiation-activated formulation is at least partially cured with ultraviolet radiation.

20.- The method according to claim 8 or 19, wherein the plurality of tufts are transparent or translucent to the radiation.

21.- The method according to claim 8, 19, or 20, wherein the primary backing is transparent or translucent to the radiation.

22.- The method according to any preceding claim 8-21, wherein the step of distributing a radiation-activated formulation on the primary backing comprises distributing a photoinitiator on the primary backing.

23.- The method according to claim 22, wherein the radiation-activated formulation comprises the photoinitiator.

24.- The method according to claim 22, wherein the photoinitiator is applied separately from the radiation-activated formulation.

25.- A method of manufacturing a backing of a carpet comprising the steps of providing a carpet comprising a primary backing and a plurality of tufts; distributing a radiation-activated formulation on the primary backing; wherein the radiation-activated formulation comprises a radiation- meltable component and a radiation-curable component; and at least partially curing the radiation-curable formulation.

26.- The method according to claim 25, wherein the radiation-activated formulation is distributed as a powder, a granular solid, a slurry, a liquid, a hot melt, or a film.

27.- The method according to claim 25 or 26, wherein the radiation-activated formulation comprises an antimicrobial, a non-microbial harboring substance, an elastomer, a plasticizer, a thickener, a filler, a colorant, or combinations thereof.

28.- The method according to any of the preceding claims 25-27, wherein the radiation-activated formulation comprises a filler.

29.- The method according to any of the preceding claims 25-28, wherein the radiation-meltable component is activated at a first radiation frequency.

30.- The method according to claim 29, wherein the radiation-curable component reacts at a second radiation frequency.

31.- The method according to claim 29 or 30, further comprising the step of activating the radiation-meltable component and the radiation-curable component at the same time.

32.- The method according to claim 29 or 30, further comprising the steps of activating the radiation-meltable component at a first time, and activating the radiation-curable component at a second time.

33.- The method according to claim 31 or 32, wherein the radiation-activated formulation further comprises an anti-skid component wherein the anti-skid component has a density that is less than the density of the radiation-meltable component.

34.- The method according to any of the preceding claims 25-33, wherein the radiation-curable formulation is activated by ultraviolet radiation, or visible radiation, or infrared radiation.

35.- The method according to any of the preceding claims 25-33, wherein the radiation-meltable formulation is activated by ultraviolet radiation, or visible radiation, or infrared radiation.

36.- The method according to any preceding claim 25-35, wherein the step of distributing a radiation-activated formulation on the primary backing comprises distributing a photoinitiator on the primary backing.

37.- The method according to claim 36, wherein the radiation-activated formulation comprises the photoinitiator.

38.- The method according to claim 36, wherein the photoinitiator is applied separately from the radiation-activated formulation.

39.- A method of manufacturing a carpet comprising the steps of: providing a primary backing woven with a plurality of tufts; distributing a radiation-reactive formulation onto the primary backing and onto at least a portion of the plurality of tufts; providing at least one source of radiation; and using the at least one source of radiation to at least partially set the radiation-reactive formulation.

40.- The method according to claim 39, wherein the radiation-reactive formulation is distributed as a powder, a granular solid, a slurry, a liquid, a hot melt, or a film.

41.- The method according to claim 39 or 40, wherein the radiation-reactive formulation is cured to a specific tack, a specific adhesion, or a combination thereof.

42.- The method according to any of the preceding claims 39-41, wherein the radiation is ultraviolet radiation.

43.- The method according to any of the preceding claims 39-42, further comprising the steps of: providing at least a second source of radiation; and using the at least second source of radiation to melt the radiation-reactive formulation.

44.- The method according to claim 43, wherein the at least second source of radiation is ultraviolet radiation, or visible radiation, or infrared radiation.

45.- The method according to any preceding claim 39-44, wherein the step of distributing a radiation-activated formulation on the primary backing comprises distributing a photoinitiator on the primary backing.

46.- The method according to claim 46, wherein the radiation-activated formulation comprises the photoinitiator.

47.- The method according to claim 46, wherein the photoinitiator is applied separately from the radiation-activated formulation.

48.- A carpet made from any preceding claim 1-47.