CA2340555C - A process for manufacturing a floor covering having a foamed backing formed from recycled polymeric material - Google Patents
A process for manufacturing a floor covering having a foamed backing formed from recycled polymeric material Download PDFInfo
- Publication number
- CA2340555C CA2340555C CA 2340555 CA2340555A CA2340555C CA 2340555 C CA2340555 C CA 2340555C CA 2340555 CA2340555 CA 2340555 CA 2340555 A CA2340555 A CA 2340555A CA 2340555 C CA2340555 C CA 2340555C
- Authority
- CA
- Canada
- Prior art keywords
- polymeric material
- sheet
- waste polymeric
- blowing agent
- backing
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
Links
- 239000000463 material Substances 0.000 title claims abstract 101
- 238000004519 manufacturing process Methods 0.000 title claims 23
- 238000000034 method Methods 0.000 title claims 23
- 239000002699 waste material Substances 0.000 claims abstract 54
- 239000004604 Blowing Agent Substances 0.000 claims abstract 37
- 239000004953 Aliphatic polyamide Substances 0.000 claims abstract 18
- 229920003231 aliphatic polyamide Polymers 0.000 claims abstract 18
- 238000000354 decomposition reaction Methods 0.000 claims 25
- 239000000203 mixture Substances 0.000 claims 23
- 238000002844 melting Methods 0.000 claims 11
- 230000008018 melting Effects 0.000 claims 11
- 238000003490 calendering Methods 0.000 claims 7
- 238000010438 heat treatment Methods 0.000 claims 7
- 238000002156 mixing Methods 0.000 claims 7
- 238000000227 grinding Methods 0.000 claims 6
- 239000000843 powder Substances 0.000 claims 4
- 239000012634 fragment Substances 0.000 claims 3
- 239000008188 pellet Substances 0.000 claims 2
- 239000010812 mixed waste Substances 0.000 claims 1
Classifications
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
- Y02W30/00—Technologies for solid waste management
- Y02W30/50—Reuse, recycling or recovery technologies
- Y02W30/62—Plastics recycling; Rubber recycling
Abstract
The present invention provides a cushioned floor covering having a backing material formed from waste polymeric material and a blowing agent wherein the blowing agent may be activated either before or after the backing material is adhered to the floor covering. The waste polymeric material includes from about 0 to 40 percent aliphatic polyamide material and is granulated, densified and extruded at a temperature that does not exceed the temperature at which the blowing agent would be activated.
Claims (22)
1. A process for manufacturing a backing material for a floor covering comprising the steps of:
chopping a mixture of waste polymeric material wherein the waste polymeric material has about 0.1 to 40 percent aliphatic polyamide material having a predetermined melting temperature;
granulating the chopped mixture into fragments that are smaller than the original size of the waste polymeric material;
densifying the granulated mixture into pelletized waste polymeric material;
mixing the waste polymeric material with a blowing agent having a predetermined decomposition temperature;
extruding the mixed waste polymeric material and blowing agent at a temperature less than the melting temperature of a majority of the aliphatic polyamide material and less than the decomposition temperature of the blowing agent to form an extrudate;
calendering the extrudate to form a backing sheet;
adhering the backing sheet to the floor covering; and heating the backing sheet to a temperature above the decomposition temperature of the blowing agent, thereby causing the backing sheet to expand to form a cushioned backing layer.
chopping a mixture of waste polymeric material wherein the waste polymeric material has about 0.1 to 40 percent aliphatic polyamide material having a predetermined melting temperature;
granulating the chopped mixture into fragments that are smaller than the original size of the waste polymeric material;
densifying the granulated mixture into pelletized waste polymeric material;
mixing the waste polymeric material with a blowing agent having a predetermined decomposition temperature;
extruding the mixed waste polymeric material and blowing agent at a temperature less than the melting temperature of a majority of the aliphatic polyamide material and less than the decomposition temperature of the blowing agent to form an extrudate;
calendering the extrudate to form a backing sheet;
adhering the backing sheet to the floor covering; and heating the backing sheet to a temperature above the decomposition temperature of the blowing agent, thereby causing the backing sheet to expand to form a cushioned backing layer.
2. A process for manufacturing a backing material for a floor covering comprising:
granulating a mixture of waste polymeric material including from about 0.1 to about 40 percent aliphatic polyamide material into a granulated mixture of fragments at least an order of magnitude smaller than the original size of the waste polymeric material;
densifying the granulated mixture of waste polymeric material;
mixing the waste polymeric material with a blowing agent having a predetermined decomposition temperature;
forming a sheet from the mixture of waste polymeric material and blowing agent;
adhering the sheet to a back surface of the floor covering; and heating the sheet to a temperature above the decomposition temperature of the blowing agent, thereby causing the sheet to expand to form a cushioned backing layer, wherein the step of forming a sheet is carried out at temperatures below the melting temperature of a majority of the aliphatic polyamide material and below the decomposition temperature of the blowing agent.
granulating a mixture of waste polymeric material including from about 0.1 to about 40 percent aliphatic polyamide material into a granulated mixture of fragments at least an order of magnitude smaller than the original size of the waste polymeric material;
densifying the granulated mixture of waste polymeric material;
mixing the waste polymeric material with a blowing agent having a predetermined decomposition temperature;
forming a sheet from the mixture of waste polymeric material and blowing agent;
adhering the sheet to a back surface of the floor covering; and heating the sheet to a temperature above the decomposition temperature of the blowing agent, thereby causing the sheet to expand to form a cushioned backing layer, wherein the step of forming a sheet is carried out at temperatures below the melting temperature of a majority of the aliphatic polyamide material and below the decomposition temperature of the blowing agent.
3. A process for manufacturing a backing material according to claim 2 wherein the step of forming a sheet includes extruding the waste polymeric material at a temperature less than the melting temperature of a majority of the aliphatic polyamide material and less than the decomposition temperature of the blowing agent.
4. A process for manufacturing a backing material according to claim 2 wherein the step of forming a sheet includes calendering the waste polymeric material.
5. A process for manufacturing a backing material according to claim 2 further comprising cryogenically grinding the waste polymeric material.
6. A process for manufacturing a backing material according to claim 2 wherein the step of densifying the waste polymeric material includes forming the waste polymeric material into pellets.
7. A process for manufacturing a backing material for a floor covering comprising:
cryogenically grinding a mixture of waste polymeric material including from about 0.1 to about 40 percent aliphatic polyamide material;
densifying the granulated mixture of waste polymeric material;
mixing the waste polymeric material with a blowing agent having a predetermined decomposition temperature;
extruding the waste polymeric material at a temperature less than the melting temperature of a majority of the aliphatic polyamide material and less than the decomposition temperature of the blowing agent;
calendering the extruded waste polymeric material to form a sheet;
adhering the sheet to a back surface of the floor covering; and heating the sheet to a temperature above the decomposition temperature of the blowing agent, thereby causing the sheet to expand to form a cushioned backing layer.
cryogenically grinding a mixture of waste polymeric material including from about 0.1 to about 40 percent aliphatic polyamide material;
densifying the granulated mixture of waste polymeric material;
mixing the waste polymeric material with a blowing agent having a predetermined decomposition temperature;
extruding the waste polymeric material at a temperature less than the melting temperature of a majority of the aliphatic polyamide material and less than the decomposition temperature of the blowing agent;
calendering the extruded waste polymeric material to form a sheet;
adhering the sheet to a back surface of the floor covering; and heating the sheet to a temperature above the decomposition temperature of the blowing agent, thereby causing the sheet to expand to form a cushioned backing layer.
8. A process for manufacturing a backing material for a floor covering comprising:
cryogenically grinding a mixture of waste polymeric material including from about 0.1 to about 40 percent aliphatic polyamide material to form a powder of waste polymeric material;
mixing the powder of waste polymeric material with a blowing agent having a predetermined decomposition temperature;
forming a sheet from the mixture of waste polymeric material and blowing agent;
adhering the sheet to a back surface of the floor covering; and heating the sheet to a temperature above the decomposition temperature of the blowing agent, thereby causing the sheet to expand to form a cushioned backing layer, wherein the step of forming a sheet is carried out at temperatures below the melting temperature of a majority of the aliphatic polyamide material and below the decomposition temperature of the blowing agent.
cryogenically grinding a mixture of waste polymeric material including from about 0.1 to about 40 percent aliphatic polyamide material to form a powder of waste polymeric material;
mixing the powder of waste polymeric material with a blowing agent having a predetermined decomposition temperature;
forming a sheet from the mixture of waste polymeric material and blowing agent;
adhering the sheet to a back surface of the floor covering; and heating the sheet to a temperature above the decomposition temperature of the blowing agent, thereby causing the sheet to expand to form a cushioned backing layer, wherein the step of forming a sheet is carried out at temperatures below the melting temperature of a majority of the aliphatic polyamide material and below the decomposition temperature of the blowing agent.
9. A process for manufacturing a backing material according to claim 8 wherein the step of forming a sheet includes extruding the mixture of waste polymeric material and blowing agent at a temperature less than the melting temperature of a majority of the aliphatic polyamide material and less than the decomposition temperature of the blowing agent.
10. A process for manufacturing a backing material according to claim 9 wherein the mixture of waste polymeric material and blowing agent is extruded through a sheet die.
11. A process for manufacturing a backing material according to claim 8 wherein the step of forming a sheet includes calendering the waste polymeric material.
12. A process for manufacturing a foamed backing material from waste polymeric material derived in part from recycled carpet, the foamed backing material having a substantially uniform thickness, for a floor covering comprising:
granulating a mixture of waste polymeric material derived in part from recycled carpet including from about 0.1 to about 40 percent aliphatic polyamide material into a granulated mixture of fragments at least an order of magnitude smaller than the original size of the waste polymeric material;
densifying the granulated mixture of waste polymeric material;
mixing the waste polymeric material with a blowing agent having a predetermined decomposition temperature;
forming a sheet from the mixture of waste polymeric material and blowing agent;
heating the sheet to a temperature above the decomposition temperature of the blowing agent, thereby causing the sheet to expand to form a cushioned backing layer;
and adhering the cushioned backing layer to a back surface of the floor covering, wherein the step of forming a sheet is carried out at temperatures below the melting temperature of a majority of the aliphatic polyamide material and below the decomposition temperature of the blowing agent.
granulating a mixture of waste polymeric material derived in part from recycled carpet including from about 0.1 to about 40 percent aliphatic polyamide material into a granulated mixture of fragments at least an order of magnitude smaller than the original size of the waste polymeric material;
densifying the granulated mixture of waste polymeric material;
mixing the waste polymeric material with a blowing agent having a predetermined decomposition temperature;
forming a sheet from the mixture of waste polymeric material and blowing agent;
heating the sheet to a temperature above the decomposition temperature of the blowing agent, thereby causing the sheet to expand to form a cushioned backing layer;
and adhering the cushioned backing layer to a back surface of the floor covering, wherein the step of forming a sheet is carried out at temperatures below the melting temperature of a majority of the aliphatic polyamide material and below the decomposition temperature of the blowing agent.
13. A process for manufacturing a backing material according to claim 12 wherein the step of forming a sheet includes extruding the waste polymeric material at a temperature less than the melting temperature of a majority of the aliphatic polyamide material and less than the decomposition temperature of the blowing agent;
14. A process for manufacturing a backing material according to claim 12 wherein the step of forming a sheet includes calendering the waste polymeric material.
15. A process for manufacturing a backing material according to claim 12 further comprising cryogenically grinding the waste polymeric material.
16. A process for manufacturing a backing material according to claim 12 wherein the step of densifying the waste polymeric material includes forming the waste polymeric material into pellets.
17. A process for manufacturing a foamed backing material from waste polymeric material derived in part from recycled carpet, the foamed backing material having a substantially uniform thickness, for a floor covering comprising:
cryogenically grinding a mixture of waste polymeric material derived in part from recycled carpet including from about 0.1 to about 40 percent aliphatic polyamide material;
densifying the granulated mixture of waste polymeric material;
mixing the waste polymeric material with a blowing agent having a predetermined decomposition temperature;
extruding the waste polymeric material at a temperature less than the melting temperature of a majority of the aliphatic polyamide material and less than the decomposition temperature of the blowing agent;
calendering the extruded waste polymeric material to form a sheet;
heating the sheet to a temperature above the decomposition temperature of the blowing agent, thereby causing the sheet to expand to form a cushioned backing layer;
and adhering the cushioned backing layer to a back surface of the floor covering.
cryogenically grinding a mixture of waste polymeric material derived in part from recycled carpet including from about 0.1 to about 40 percent aliphatic polyamide material;
densifying the granulated mixture of waste polymeric material;
mixing the waste polymeric material with a blowing agent having a predetermined decomposition temperature;
extruding the waste polymeric material at a temperature less than the melting temperature of a majority of the aliphatic polyamide material and less than the decomposition temperature of the blowing agent;
calendering the extruded waste polymeric material to form a sheet;
heating the sheet to a temperature above the decomposition temperature of the blowing agent, thereby causing the sheet to expand to form a cushioned backing layer;
and adhering the cushioned backing layer to a back surface of the floor covering.
18. A process for manufacturing a foamed backing material from waste polymeric material derived in part from recycled carpet, the foamed backing material having a substantially uniform thickness, for a floor covering comprising:
cryogenically grinding a mixture of waste polymeric material derived in part from recycled carpet including from about 0.1 to about 40 percent aliphatic polyamide material to form a powder of waste polymeric material;
mixing the powder of waste polymeric material with a blowing agent having a predetermined decomposition temperature;
forming a sheet from the mixture of waste polymeric material and blowing agent; and heating the sheet to a temperature above the decomposition temperature of the blowing agent, thereby causing the sheet to expand to form a cushioned backing,, wherein the step of forming a sheet is carried out at temperatures below the melting temperature of a majority of the aliphatic polyamide material and below the decomposition temperature of the blowing agent.
cryogenically grinding a mixture of waste polymeric material derived in part from recycled carpet including from about 0.1 to about 40 percent aliphatic polyamide material to form a powder of waste polymeric material;
mixing the powder of waste polymeric material with a blowing agent having a predetermined decomposition temperature;
forming a sheet from the mixture of waste polymeric material and blowing agent; and heating the sheet to a temperature above the decomposition temperature of the blowing agent, thereby causing the sheet to expand to form a cushioned backing,, wherein the step of forming a sheet is carried out at temperatures below the melting temperature of a majority of the aliphatic polyamide material and below the decomposition temperature of the blowing agent.
19. A process for manufacturing a backing material according to claim 18, further comprising the step of adhering the sheet to a back surface of the floor covering.
20. A process for manufacturing a backing material according to claim 18 wherein the step of forming a sheet includes extruding the mixture of waste polymeric material and blowing agent at a temperature less than the decomposition temperature of the blowing agent to form a sheet.
21. A process for manufacturing a backing material according to claim 20 wherein the mixture of waste polymeric material and blowing agent is extruded through a sheet die.
22. A process for manufacturing a backing material according to claim 18 wherein the step of forming a sheet includes calendering the waste polymeric material.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US09/621,591 US6860953B1 (en) | 1994-02-09 | 2000-07-21 | Process for manufacturing a floor covering having a foamed backing formed from recycled polymeric material |
| US09/621,591 | 2000-07-21 |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2340555A1 CA2340555A1 (en) | 2002-01-21 |
| CA2340555C true CA2340555C (en) | 2006-07-04 |
Family
ID=24490798
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2340555 Expired - Lifetime CA2340555C (en) | 2000-07-21 | 2001-03-12 | A process for manufacturing a floor covering having a foamed backing formed from recycled polymeric material |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2340555C (en) |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2021137086A1 (en) * | 2019-12-31 | 2021-07-08 | Shpp Global Technologies B.V. | Thermoplastic powders and methods for producing the same from foam pellets |
-
2001
- 2001-03-12 CA CA 2340555 patent/CA2340555C/en not_active Expired - Lifetime
Also Published As
| Publication number | Publication date |
|---|---|
| CA2340555A1 (en) | 2002-01-21 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| EEER | Examination request | ||
| MKEX | Expiry |
Effective date: 20210312 |