CA2663809A1 - Polyurethane backed products and methods - Google Patents
Polyurethane backed products and methods Download PDFInfo
- Publication number
- CA2663809A1 CA2663809A1 CA002663809A CA2663809A CA2663809A1 CA 2663809 A1 CA2663809 A1 CA 2663809A1 CA 002663809 A CA002663809 A CA 002663809A CA 2663809 A CA2663809 A CA 2663809A CA 2663809 A1 CA2663809 A1 CA 2663809A1
- Authority
- CA
- Canada
- Prior art keywords
- polyurethane
- backing
- layer
- composition
- carpet tile
- 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.)
- Abandoned
Links
- 239000004814 polyurethane Substances 0.000 title claims abstract description 311
- 229920002635 polyurethane Polymers 0.000 title claims abstract description 309
- 238000000034 method Methods 0.000 title description 37
- 239000000203 mixture Substances 0.000 claims abstract description 178
- 239000004753 textile Substances 0.000 claims abstract description 102
- 239000004359 castor oil Substances 0.000 claims abstract description 77
- 235000019438 castor oil Nutrition 0.000 claims abstract description 77
- ZEMPKEQAKRGZGQ-XOQCFJPHSA-N glycerol triricinoleate Natural products CCCCCC[C@@H](O)CC=CCCCCCCCC(=O)OC[C@@H](COC(=O)CCCCCCCC=CC[C@@H](O)CCCCCC)OC(=O)CCCCCCCC=CC[C@H](O)CCCCCC ZEMPKEQAKRGZGQ-XOQCFJPHSA-N 0.000 claims abstract description 77
- 229920005862 polyol Polymers 0.000 claims description 116
- 150000003077 polyols Chemical class 0.000 claims description 115
- 239000000463 material Substances 0.000 claims description 111
- 239000000945 filler Substances 0.000 claims description 80
- 239000012948 isocyanate Substances 0.000 claims description 77
- 239000011521 glass Substances 0.000 claims description 70
- 150000002513 isocyanates Chemical class 0.000 claims description 65
- 239000003054 catalyst Substances 0.000 claims description 55
- 239000003245 coal Substances 0.000 claims description 54
- 239000010881 fly ash Substances 0.000 claims description 54
- 239000010440 gypsum Substances 0.000 claims description 18
- 229910052602 gypsum Inorganic materials 0.000 claims description 18
- 229920001451 polypropylene glycol Polymers 0.000 claims description 16
- 239000007795 chemical reaction product Substances 0.000 claims description 15
- 239000003795 chemical substances by application Substances 0.000 claims description 9
- 239000004094 surface-active agent Substances 0.000 claims description 9
- 239000000654 additive Substances 0.000 claims description 8
- 239000000080 wetting agent Substances 0.000 claims description 7
- 239000003208 petroleum Substances 0.000 claims description 4
- 239000010410 layer Substances 0.000 description 191
- 239000000047 product Substances 0.000 description 130
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 description 39
- 239000000853 adhesive Substances 0.000 description 29
- 230000001070 adhesive effect Effects 0.000 description 29
- 239000012975 dibutyltin dilaurate Substances 0.000 description 23
- 238000009408 flooring Methods 0.000 description 23
- 239000002131 composite material Substances 0.000 description 22
- 239000004576 sand Substances 0.000 description 20
- 229910000019 calcium carbonate Inorganic materials 0.000 description 19
- 235000010216 calcium carbonate Nutrition 0.000 description 19
- -1 for example Substances 0.000 description 18
- 229920001971 elastomer Polymers 0.000 description 17
- 238000010276 construction Methods 0.000 description 16
- 239000006260 foam Substances 0.000 description 15
- 239000005361 soda-lime glass Substances 0.000 description 13
- UKLDJPRMSDWDSL-UHFFFAOYSA-L [dibutyl(dodecanoyloxy)stannyl] dodecanoate Chemical compound CCCCCCCCCCCC(=O)O[Sn](CCCC)(CCCC)OC(=O)CCCCCCCCCCC UKLDJPRMSDWDSL-UHFFFAOYSA-L 0.000 description 12
- 238000005452 bending Methods 0.000 description 12
- 230000008569 process Effects 0.000 description 12
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Chemical compound O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 12
- 230000015572 biosynthetic process Effects 0.000 description 10
- 239000011248 coating agent Substances 0.000 description 10
- 239000002245 particle Substances 0.000 description 10
- 238000000576 coating method Methods 0.000 description 9
- 238000004519 manufacturing process Methods 0.000 description 9
- 230000000087 stabilizing effect Effects 0.000 description 9
- 230000005484 gravity Effects 0.000 description 8
- 239000002184 metal Substances 0.000 description 8
- 229910052751 metal Inorganic materials 0.000 description 8
- 229920000728 polyester Polymers 0.000 description 8
- 239000000758 substrate Substances 0.000 description 8
- 239000002374 bone meal Substances 0.000 description 7
- 229940036811 bone meal Drugs 0.000 description 7
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 6
- TZCXTZWJZNENPQ-UHFFFAOYSA-L barium sulfate Chemical compound [Ba+2].[O-]S([O-])(=O)=O TZCXTZWJZNENPQ-UHFFFAOYSA-L 0.000 description 6
- 230000008901 benefit Effects 0.000 description 6
- 239000000806 elastomer Substances 0.000 description 6
- 239000013536 elastomeric material Substances 0.000 description 6
- 238000009472 formulation Methods 0.000 description 6
- 238000003475 lamination Methods 0.000 description 6
- 238000005520 cutting process Methods 0.000 description 5
- 239000008367 deionised water Substances 0.000 description 5
- 229910021641 deionized water Inorganic materials 0.000 description 5
- 239000003365 glass fiber Substances 0.000 description 5
- 239000003921 oil Substances 0.000 description 5
- 229920001223 polyethylene glycol Polymers 0.000 description 5
- 229920000098 polyolefin Polymers 0.000 description 5
- 239000000126 substance Substances 0.000 description 5
- 239000004606 Fillers/Extenders Substances 0.000 description 4
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 4
- 239000004677 Nylon Substances 0.000 description 4
- 229920002302 Nylon 6,6 Polymers 0.000 description 4
- 239000004743 Polypropylene Substances 0.000 description 4
- 230000002860 competitive effect Effects 0.000 description 4
- 239000007799 cork Substances 0.000 description 4
- 238000000151 deposition Methods 0.000 description 4
- 239000004744 fabric Substances 0.000 description 4
- 239000000835 fiber Substances 0.000 description 4
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N iron oxide Inorganic materials [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 description 4
- 230000005291 magnetic effect Effects 0.000 description 4
- 229920001778 nylon Polymers 0.000 description 4
- 230000009257 reactivity Effects 0.000 description 4
- 229920002994 synthetic fiber Polymers 0.000 description 4
- 239000004604 Blowing Agent Substances 0.000 description 3
- 239000004952 Polyamide Substances 0.000 description 3
- 239000002202 Polyethylene glycol Substances 0.000 description 3
- 239000011230 binding agent Substances 0.000 description 3
- 238000007664 blowing Methods 0.000 description 3
- 210000000988 bone and bone Anatomy 0.000 description 3
- 239000000428 dust Substances 0.000 description 3
- 239000010408 film Substances 0.000 description 3
- 239000012943 hotmelt Substances 0.000 description 3
- 235000013980 iron oxide Nutrition 0.000 description 3
- SZVJSHCCFOBDDC-UHFFFAOYSA-N iron(II,III) oxide Inorganic materials O=[Fe]O[Fe]O[Fe]=O SZVJSHCCFOBDDC-UHFFFAOYSA-N 0.000 description 3
- 150000002739 metals Chemical class 0.000 description 3
- 229920002647 polyamide Polymers 0.000 description 3
- 229920000642 polymer Polymers 0.000 description 3
- 229920001155 polypropylene Polymers 0.000 description 3
- 238000004064 recycling Methods 0.000 description 3
- 239000012209 synthetic fiber Substances 0.000 description 3
- 238000011144 upstream manufacturing Methods 0.000 description 3
- 229910000859 α-Fe Inorganic materials 0.000 description 3
- 229920002292 Nylon 6 Polymers 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 2
- 229920006397 acrylic thermoplastic Polymers 0.000 description 2
- 239000012790 adhesive layer Substances 0.000 description 2
- 230000004888 barrier function Effects 0.000 description 2
- 229910052601 baryte Inorganic materials 0.000 description 2
- 239000010428 baryte Substances 0.000 description 2
- 150000001875 compounds Chemical class 0.000 description 2
- 230000002708 enhancing effect Effects 0.000 description 2
- 239000003302 ferromagnetic material Substances 0.000 description 2
- 231100001261 hazardous Toxicity 0.000 description 2
- 229910052742 iron Inorganic materials 0.000 description 2
- VBMVTYDPPZVILR-UHFFFAOYSA-N iron(2+);oxygen(2-) Chemical class [O-2].[Fe+2] VBMVTYDPPZVILR-UHFFFAOYSA-N 0.000 description 2
- 239000004816 latex Substances 0.000 description 2
- 229920000126 latex Polymers 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 229910052759 nickel Inorganic materials 0.000 description 2
- 230000000704 physical effect Effects 0.000 description 2
- 229920003229 poly(methyl methacrylate) Polymers 0.000 description 2
- 239000002994 raw material Substances 0.000 description 2
- 230000009467 reduction Effects 0.000 description 2
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N silicon dioxide Inorganic materials O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 2
- 239000010959 steel Substances 0.000 description 2
- ISXSCDLOGDJUNJ-UHFFFAOYSA-N tert-butyl prop-2-enoate Chemical compound CC(C)(C)OC(=O)C=C ISXSCDLOGDJUNJ-UHFFFAOYSA-N 0.000 description 2
- 239000002699 waste material Substances 0.000 description 2
- 210000002268 wool Anatomy 0.000 description 2
- OYPRJOBELJOOCE-IGMARMGPSA-N Calcium-40 Chemical compound [40Ca] OYPRJOBELJOOCE-IGMARMGPSA-N 0.000 description 1
- TWRXJAOTZQYOKJ-UHFFFAOYSA-L Magnesium chloride Chemical compound [Mg+2].[Cl-].[Cl-] TWRXJAOTZQYOKJ-UHFFFAOYSA-L 0.000 description 1
- 229920005830 Polyurethane Foam Polymers 0.000 description 1
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 1
- 240000008042 Zea mays Species 0.000 description 1
- 235000005824 Zea mays ssp. parviglumis Nutrition 0.000 description 1
- 235000002017 Zea mays subsp mays Nutrition 0.000 description 1
- 239000004599 antimicrobial Substances 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 235000010290 biphenyl Nutrition 0.000 description 1
- 239000004305 biphenyl Substances 0.000 description 1
- 238000009835 boiling Methods 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 239000003086 colorant Substances 0.000 description 1
- 230000008602 contraction Effects 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 235000005822 corn Nutrition 0.000 description 1
- 239000006063 cullet Substances 0.000 description 1
- 238000000354 decomposition reaction Methods 0.000 description 1
- 238000004043 dyeing Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000008030 elimination Effects 0.000 description 1
- 238000003379 elimination reaction Methods 0.000 description 1
- 239000000839 emulsion Substances 0.000 description 1
- 238000001704 evaporation Methods 0.000 description 1
- 230000008020 evaporation Effects 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 230000005294 ferromagnetic effect Effects 0.000 description 1
- 239000011152 fibreglass Substances 0.000 description 1
- 239000003063 flame retardant Substances 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 238000000227 grinding Methods 0.000 description 1
- 238000011065 in-situ storage Methods 0.000 description 1
- 239000002440 industrial waste Substances 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 238000010030 laminating Methods 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 239000000314 lubricant Substances 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 229910044991 metal oxide Inorganic materials 0.000 description 1
- 150000004706 metal oxides Chemical class 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- ZUOUZKKEUPVFJK-UHFFFAOYSA-N phenylbenzene Natural products C1=CC=CC=C1C1=CC=CC=C1 ZUOUZKKEUPVFJK-UHFFFAOYSA-N 0.000 description 1
- 238000006116 polymerization reaction Methods 0.000 description 1
- 239000004810 polytetrafluoroethylene Substances 0.000 description 1
- 229920001343 polytetrafluoroethylene Polymers 0.000 description 1
- 239000011527 polyurethane coating Substances 0.000 description 1
- 239000011496 polyurethane foam Substances 0.000 description 1
- 239000010817 post-consumer waste Substances 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 230000002787 reinforcement Effects 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- 238000005096 rolling process Methods 0.000 description 1
- 230000011218 segmentation Effects 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
- 239000002356 single layer Substances 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 238000010025 steaming Methods 0.000 description 1
- 239000004636 vulcanized rubber Substances 0.000 description 1
- 239000002023 wood Substances 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G18/00—Polymeric products of isocyanates or isothiocyanates
- C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
- C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
- C08G18/30—Low-molecular-weight compounds
- C08G18/36—Hydroxylated esters of higher fatty acids
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
- D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
- D06N7/0068—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by the primary backing or the fibrous top layer
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
- D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
- D06N7/0071—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
- D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
- D06N7/0071—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing
- D06N7/0086—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing characterised by the cushion backing, e.g. foamed polyurethane
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G2110/00—Foam properties
- C08G2110/0008—Foam properties flexible
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/01—Use of inorganic substances as compounding ingredients characterized by their specific function
- C08K3/013—Fillers, pigments or reinforcing additives
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N2203/00—Macromolecular materials of the coating layers
- D06N2203/06—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
- D06N2203/068—Polyurethanes
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N2205/00—Condition, form or state of the materials
- D06N2205/10—Particulate form, e.g. powder, granule
- D06N2205/106—Scrap or recycled particles
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N2205/00—Condition, form or state of the materials
- D06N2205/18—Scraps or recycled materials
-
- 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
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
- Y02P70/50—Manufacturing or production processes characterised by the final manufactured product
- Y02P70/62—Manufacturing or production processes characterised by the final manufactured product related technologies for production or treatment of textile or flexible materials or products thereof, including footwear
-
- 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
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/23907—Pile or nap type surface or component
- Y10T428/23914—Interlaminar
-
- 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
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/23907—Pile or nap type surface or component
- Y10T428/23979—Particular backing structure or composition
Landscapes
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Health & Medical Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Medicinal Chemistry (AREA)
- Polymers & Plastics (AREA)
- Organic Chemistry (AREA)
- Carpets (AREA)
- Laminated Bodies (AREA)
Abstract
A surface covering such as a carpet, carpet tile, area rug, floor mat or the like incorporating a textile face disposed in contacting overlying relation to at least one polyurethane layer. One or more optional intermediate structure layers may be disposed within, on, over, or under the polyurethane layer and one or more optional backing layers may be disposed across the underside of the polyurethane layer. Polyurethane compositions preferably including castor oil may form the precoat, tiecoat, and/or backing.
Description
2 PCT/US2007/021430 POLYURETHANE BACKED PRODUCTS AND METHODS
Technical Field In accordance with at least one embodiment, the present invention relates to surface coverings such as floor coverings having a show surface material in contacting overlying relation to a backing of polyurethane with or without additional structures, layers, backings, and/or the like. In particular, but not exclusively, at least one embodiment of the invention relates to a surface covering such as a carpet, carpet tile, area rug, floor mat or the like incorporating a textile face, such as a tufted, bonded, flocked, needled, needle punched, woven, non-woven, or knit fabric structure disposed in contacting overlying relation to at least a polyurethane layer. The polyurethane layer may form a precoat, tiecoat and/or backing and may be foam or non-foam, and may preferably be flexible. One or more optional intermediate structure layers may be disposed over, in, on, or under the polyurethane and one or more optional backing layers may be disposed across the underside of the polyurethane.
Methods of making such surface coverings, processes, uses, apparatus, components, materials, and/or products are also provided.
Background to the Invention It is known to provide carpeting and carpet tile with, for example, tufted or bonded carpet faces, and with backing layers formed from so-called "virgin" or "filled" foam, for example, polyurethane foam, or from "rebond" or "bonded"
foam wherein chips or pieces of recycled foam are held together by a binder. It is also known to form mats such as floor mats or entry way mats from tufted or bonded carpet faces secured in bonded relation to rubber backings.
One disadvantage of prior flooring or floor covering, constructions has been the relatively complex arrangement of various structural layers to provide dimensional stability and wear performance of the products. In this regard, various prior constructions have relied on the inclusion of various adhesive layers, stabilizing layers, and/or on the use of relatively high strength backing layers such as PVC or vulcanized rubber to provide a structure that remains flat across a floor or sub-floor without deforming over time.
Examples of prior carpet tile constructions are described, for example, in U.S. Patents 4,522,857; 5,545,276; 5,948,500; 6,203,881; and 6,468,623 each of which are hereby incorporated by reference herein.
Examples of prior floor mats are described in, for example, U.S. Patents 6,296,919; 6,478,995; and RE38,422 each of which are hereby incorporated by reference herein.
Summary of the Invention At least one embodiment of the present invention provides advantages and/or alternatives over the prior art by providing a surface covering such as a carpet, carpet tile, area rug, floor mat, flooring, floor tile, rug, mat, broadloom carpet, stabilized broadloom, roll goods, modular flooring, 6-foot broadloom or the like incorporating a textile face, such as a tufted, bonded, flocked, needled, needle punched, woven, non-woven, or kn'it fabric structure disposed in contacting overlying relation to at least one polyurethane layer. One or more optional intermediate structure layers may be disposed over, in, on, or under the polyurethane and one or more optional backing layers may be disposed across the underside of the polyurethane.
According to a potentially preferred feature, the polyurethane is in direct contacting relation with the underside of the textile face structure without the need for any intermediate binder or pre-coat.
According to another potentially preferred feature, the textile face structure is preferably substantially relaxed such as by steaming, dyeing or the like prior to application of the polyurethane so as to substantially avoid subsequent deformation due to shrinkage.
According to another possibly preferred feature, a polyurethane material
Technical Field In accordance with at least one embodiment, the present invention relates to surface coverings such as floor coverings having a show surface material in contacting overlying relation to a backing of polyurethane with or without additional structures, layers, backings, and/or the like. In particular, but not exclusively, at least one embodiment of the invention relates to a surface covering such as a carpet, carpet tile, area rug, floor mat or the like incorporating a textile face, such as a tufted, bonded, flocked, needled, needle punched, woven, non-woven, or knit fabric structure disposed in contacting overlying relation to at least a polyurethane layer. The polyurethane layer may form a precoat, tiecoat and/or backing and may be foam or non-foam, and may preferably be flexible. One or more optional intermediate structure layers may be disposed over, in, on, or under the polyurethane and one or more optional backing layers may be disposed across the underside of the polyurethane.
Methods of making such surface coverings, processes, uses, apparatus, components, materials, and/or products are also provided.
Background to the Invention It is known to provide carpeting and carpet tile with, for example, tufted or bonded carpet faces, and with backing layers formed from so-called "virgin" or "filled" foam, for example, polyurethane foam, or from "rebond" or "bonded"
foam wherein chips or pieces of recycled foam are held together by a binder. It is also known to form mats such as floor mats or entry way mats from tufted or bonded carpet faces secured in bonded relation to rubber backings.
One disadvantage of prior flooring or floor covering, constructions has been the relatively complex arrangement of various structural layers to provide dimensional stability and wear performance of the products. In this regard, various prior constructions have relied on the inclusion of various adhesive layers, stabilizing layers, and/or on the use of relatively high strength backing layers such as PVC or vulcanized rubber to provide a structure that remains flat across a floor or sub-floor without deforming over time.
Examples of prior carpet tile constructions are described, for example, in U.S. Patents 4,522,857; 5,545,276; 5,948,500; 6,203,881; and 6,468,623 each of which are hereby incorporated by reference herein.
Examples of prior floor mats are described in, for example, U.S. Patents 6,296,919; 6,478,995; and RE38,422 each of which are hereby incorporated by reference herein.
Summary of the Invention At least one embodiment of the present invention provides advantages and/or alternatives over the prior art by providing a surface covering such as a carpet, carpet tile, area rug, floor mat, flooring, floor tile, rug, mat, broadloom carpet, stabilized broadloom, roll goods, modular flooring, 6-foot broadloom or the like incorporating a textile face, such as a tufted, bonded, flocked, needled, needle punched, woven, non-woven, or kn'it fabric structure disposed in contacting overlying relation to at least one polyurethane layer. One or more optional intermediate structure layers may be disposed over, in, on, or under the polyurethane and one or more optional backing layers may be disposed across the underside of the polyurethane.
According to a potentially preferred feature, the polyurethane is in direct contacting relation with the underside of the textile face structure without the need for any intermediate binder or pre-coat.
According to another potentially preferred feature, the textile face structure is preferably substantially relaxed such as by steaming, dyeing or the like prior to application of the polyurethane so as to substantially avoid subsequent deformation due to shrinkage.
According to another possibly preferred feature, a polyurethane material
3 PCT/US2007/021430 or layer is the reaction product of castor oil, an isocyanate and an optional catalyst, an optional filler, and an optional additional polyol.
According to still yet another possibly preferred feature, a polyurethane material or layer is the reaction product of a chemically unmodified castor oil (preferably filtered and dried), an isocyanate, a filler (preferably at least 42% by weight filler), and an optional catalyst, an optional additional polyol, or both.
According to still another potentially preferred feature, a cured flexible polyurethane material is the reaction product of (i) a polyol component in which castor oil is the predominant reactive polyol; and (ii) an isocyanate component, and the polyurethane material further comprising a filler, the filler being at least 42% by weight of the polyurethane material.
According to still another potentially preferred feature, a cured flexible polyurethane material, is the reaction product of (i) a polyol component; and (ii) an isocyanate component, and the polyurethane material further comprising a filler, the filler being at least 42% by weight of the polyurethane material, and the cured flexible material being formed substantially in the absence of catalyst.
According to still another potentially preferred feature, a cured flexible polyurethane material, is the reaction product of (i) a polyol component; and (ii) an isocyanate component, and the polyurethane material further comprising a filler, the filler being at least 42% by weight of the polyurethane material, and the cured flexible material being formed substantially in the absence of
According to still yet another possibly preferred feature, a polyurethane material or layer is the reaction product of a chemically unmodified castor oil (preferably filtered and dried), an isocyanate, a filler (preferably at least 42% by weight filler), and an optional catalyst, an optional additional polyol, or both.
According to still another potentially preferred feature, a cured flexible polyurethane material is the reaction product of (i) a polyol component in which castor oil is the predominant reactive polyol; and (ii) an isocyanate component, and the polyurethane material further comprising a filler, the filler being at least 42% by weight of the polyurethane material.
According to still another potentially preferred feature, a cured flexible polyurethane material, is the reaction product of (i) a polyol component; and (ii) an isocyanate component, and the polyurethane material further comprising a filler, the filler being at least 42% by weight of the polyurethane material, and the cured flexible material being formed substantially in the absence of catalyst.
According to still another potentially preferred feature, a cured flexible polyurethane material, is the reaction product of (i) a polyol component; and (ii) an isocyanate component, and the polyurethane material further comprising a filler, the filler being at least 42% by weight of the polyurethane material, and the cured flexible material being formed substantially in the absence of
4 a surfactant or a wetting agent.
According to yet another possibly preferred feature, a carpet tile has a textile face structure disposed in overlying contacting relation to at least one layer of flexible, polyurethane backing composition, the polyurethane composition being the reaction product of (i) a polyol component in which castor oil is the predominant reactive polyol; and (ii) an isocyanate component, and the polyurethane composition further comprising a filler, the filler being at least 42% by weight of the polyurethane composition and being preferably selected from coal fly ash, recycled gypsum, recycled glass, and combinations thereof.
The feature above, wherein substantially the entire polyol component is castor oil, wherein the polyurethane composition is substantially free of surfactant, wherein the polyurethane composition is substantially free of catalyst, wherein said layer of flexible, polyurethane backing composition is at least one of a precoat, tiecoat, and backing, further comprising at least one structural support layer disposed in, on, under, or over said layer of flexible, polyurethane backing composition, wherein the filler component is at least 50% by weight of the polyurethane composition, further comprising a minor polyol component which is not castor oil, wherein the minor polyol component is selected from the group consisting of petroleum based polyols, natural polyols, polyols with functionality of 2 or 3 and a molecular weight of about 750 to about 7500, polypropylene glycol (PPG) polyols, polyethylene glycol (PEG) polyols, PPG-PEG copolymer polyols, and combinations thereof, wherein the minor polyol component is present in an amount of less than about 50% by weight of the polyol component of the polyurethane composition, wherein the minor polyol component is present in an amount of less than about 10% by weight of the polyurethane composition, wherein the minor polyol component is present in an amount of less than about 7% by weight of the polyurethane composition, and/or wherein the minor polyol
According to yet another possibly preferred feature, a carpet tile has a textile face structure disposed in overlying contacting relation to at least one layer of flexible, polyurethane backing composition, the polyurethane composition being the reaction product of (i) a polyol component in which castor oil is the predominant reactive polyol; and (ii) an isocyanate component, and the polyurethane composition further comprising a filler, the filler being at least 42% by weight of the polyurethane composition and being preferably selected from coal fly ash, recycled gypsum, recycled glass, and combinations thereof.
The feature above, wherein substantially the entire polyol component is castor oil, wherein the polyurethane composition is substantially free of surfactant, wherein the polyurethane composition is substantially free of catalyst, wherein said layer of flexible, polyurethane backing composition is at least one of a precoat, tiecoat, and backing, further comprising at least one structural support layer disposed in, on, under, or over said layer of flexible, polyurethane backing composition, wherein the filler component is at least 50% by weight of the polyurethane composition, further comprising a minor polyol component which is not castor oil, wherein the minor polyol component is selected from the group consisting of petroleum based polyols, natural polyols, polyols with functionality of 2 or 3 and a molecular weight of about 750 to about 7500, polypropylene glycol (PPG) polyols, polyethylene glycol (PEG) polyols, PPG-PEG copolymer polyols, and combinations thereof, wherein the minor polyol component is present in an amount of less than about 50% by weight of the polyol component of the polyurethane composition, wherein the minor polyol component is present in an amount of less than about 10% by weight of the polyurethane composition, wherein the minor polyol component is present in an amount of less than about 7% by weight of the polyurethane composition, and/or wherein the minor polyol
5 PCT/US2007/021430 component is present in an amount of less than about 5% by weight of the polyurethane composition.
According to still yet another potentially preferred feature, a polyurethane for application to a woven, non-woven, or tufted textile face structure, including a polyol component, an isocyanate component, a catalyst and other agents, fillers, additives, and the like wherein the catalyst is eliminated, the polyol is replaced with castor oil, or both.
According to still another potentially preferred feature, a common formation unit and process may be used to produce carpet, area rugs, carpet tile, floor mats, and the like.
Other features and further scope of the applicability of the present invention will become apparent from the detailed description to follow, taken in conjunction with the accompanying drawings wherein like parts are designated by like reference numerals in the various views.
Brief Description of the Drawings The invention will now be further described by way of example only and with reference to the drawings, which are briefly described as follows:
FIG. 1 is schematic view illustrating apparatus and process for forming various polyurethane-backed surface coverings.
FIG. 2 is a cross-sectional illustration of an exemplary polyurethane-backed surface covering incorporating a tufted face structure;
FIG. 3 is a cross-sectional illustration of an exemplary polyurethane-backed surface covering incorporating a woven face structure;
FIG. 4 is a cross-sectional illustration of an exemplary polyurethane-backed surface covering incorporating a non-woven face structure;
According to still yet another potentially preferred feature, a polyurethane for application to a woven, non-woven, or tufted textile face structure, including a polyol component, an isocyanate component, a catalyst and other agents, fillers, additives, and the like wherein the catalyst is eliminated, the polyol is replaced with castor oil, or both.
According to still another potentially preferred feature, a common formation unit and process may be used to produce carpet, area rugs, carpet tile, floor mats, and the like.
Other features and further scope of the applicability of the present invention will become apparent from the detailed description to follow, taken in conjunction with the accompanying drawings wherein like parts are designated by like reference numerals in the various views.
Brief Description of the Drawings The invention will now be further described by way of example only and with reference to the drawings, which are briefly described as follows:
FIG. 1 is schematic view illustrating apparatus and process for forming various polyurethane-backed surface coverings.
FIG. 2 is a cross-sectional illustration of an exemplary polyurethane-backed surface covering incorporating a tufted face structure;
FIG. 3 is a cross-sectional illustration of an exemplary polyurethane-backed surface covering incorporating a woven face structure;
FIG. 4 is a cross-sectional illustration of an exemplary polyurethane-backed surface covering incorporating a non-woven face structure;
6 PCT/US2007/021430 FIG. 5 is a cross-sectional illustration of an exemplary polyurethane-backed surface covering incorporating a bonded pile face structure;
FIG. 6 is schematic view illustrating apparatus and process for forming various surface coverings incorporating backed polyurethane;
FIG. 7 is a cross-sectional illustration of an exemplary surface covering incorporating a tufted face structure in contacting relation to a backed polyurethane layer;
FIG. 8 is a cross-sectional illustration of an exemplary surface covering incorporating a woven face structure in contacting relation to a backed polyurethane layer;
FIG. 9 is a cross-sectional illustrational of an exemplary surface covering incorporating a non-woven face structure in contacting relation to a backed polyurethane layer;
FIG. 10 is a cross-sectional illustration of an exemplary surface covering incorporating a bonded pile face structure in contacting relation to a backed polyurethane layer;
FIG. 11 is schematic view illustrating apparatus and process for forming various surface coverings incorporating stabilized polyurethane;
FIG. 12 is a cross-sectional illustration of an exemplary surface covering incorporating a tufted face structure in contacting relation to a stabilized polyurethane layer;
FIG. 13 is a cross-sectional illustration of an exemplary surface covering incorporating a woven face structure in contacting relation to a stabilized polyurethane layer;
FIG. 14 is a cross-sectional illustration of an exemplary surface covering incorporating a non-woven face structure in contacting relation to a stabilized polyurethane layer;
FIG. 6 is schematic view illustrating apparatus and process for forming various surface coverings incorporating backed polyurethane;
FIG. 7 is a cross-sectional illustration of an exemplary surface covering incorporating a tufted face structure in contacting relation to a backed polyurethane layer;
FIG. 8 is a cross-sectional illustration of an exemplary surface covering incorporating a woven face structure in contacting relation to a backed polyurethane layer;
FIG. 9 is a cross-sectional illustrational of an exemplary surface covering incorporating a non-woven face structure in contacting relation to a backed polyurethane layer;
FIG. 10 is a cross-sectional illustration of an exemplary surface covering incorporating a bonded pile face structure in contacting relation to a backed polyurethane layer;
FIG. 11 is schematic view illustrating apparatus and process for forming various surface coverings incorporating stabilized polyurethane;
FIG. 12 is a cross-sectional illustration of an exemplary surface covering incorporating a tufted face structure in contacting relation to a stabilized polyurethane layer;
FIG. 13 is a cross-sectional illustration of an exemplary surface covering incorporating a woven face structure in contacting relation to a stabilized polyurethane layer;
FIG. 14 is a cross-sectional illustration of an exemplary surface covering incorporating a non-woven face structure in contacting relation to a stabilized polyurethane layer;
7 PCT/US2007/021430 FIG. 15 is a cross-sectional illustration of an exemplary surface covering incorporating a bonded pile face structure in contacting relation to a stabilized polyurethane layer;
FIG. 16 is schematic view illustrating apparatus and process for forming various surface coverings incorporating stabilized and backed polyurethane;
FIG. 17 is a cross-sectional illustration of an exemplary surface covering incorporating a tufted face structure in contacting relation to a stabilized and backed polyurethane backing;
FIG. 18 is a cross-sectional illustration of an exemplary surface covering incorporating a woven face structure in contacting relation to a stabilized and backed polyurethane backing;
FIG. 19 is a cross-sectional illustration of an exemplary surface covering incorporating a non-woven face structure in contacting relation to a stabilized and backed polyurethane backing; and FIG. 20 is a cross-sectional illustration of an exemplary surface covering incorporating a bonded pile face structure in contacting relation to a stabilized and backed polyurethane backing;
FIG. 21 is a cross-sectional illustration of an exemplary surface covering like that of FIG. 2 with the addition of a backing such as a coating, film, or the like;
FIG. 22 is a cross-sectional illustration of an exemplary surface covering like that of FIG. 7 with the addition of a backing such as a coating, film, or the like;
FIG. 23 is a cross-sectional illustration of an exemplary surface-covering like that of FIG. 12 except that the stabilizing layer or material is adjacent or abutting the tufts;
FIG. 24 is a cross-sectional illustration of an exemplary surface covering like that of FIG. 13 except that the stabilizing layer or material is near or on the bottom of the polyurethane backing;
FIG. 16 is schematic view illustrating apparatus and process for forming various surface coverings incorporating stabilized and backed polyurethane;
FIG. 17 is a cross-sectional illustration of an exemplary surface covering incorporating a tufted face structure in contacting relation to a stabilized and backed polyurethane backing;
FIG. 18 is a cross-sectional illustration of an exemplary surface covering incorporating a woven face structure in contacting relation to a stabilized and backed polyurethane backing;
FIG. 19 is a cross-sectional illustration of an exemplary surface covering incorporating a non-woven face structure in contacting relation to a stabilized and backed polyurethane backing; and FIG. 20 is a cross-sectional illustration of an exemplary surface covering incorporating a bonded pile face structure in contacting relation to a stabilized and backed polyurethane backing;
FIG. 21 is a cross-sectional illustration of an exemplary surface covering like that of FIG. 2 with the addition of a backing such as a coating, film, or the like;
FIG. 22 is a cross-sectional illustration of an exemplary surface covering like that of FIG. 7 with the addition of a backing such as a coating, film, or the like;
FIG. 23 is a cross-sectional illustration of an exemplary surface-covering like that of FIG. 12 except that the stabilizing layer or material is adjacent or abutting the tufts;
FIG. 24 is a cross-sectional illustration of an exemplary surface covering like that of FIG. 13 except that the stabilizing layer or material is near or on the bottom of the polyurethane backing;
8 PCT/US2007/021430 FIG. 25 is a cross-sectional illustration of an exemplary surface covering like that of FIG. 3 except that it is inverted as constructed using an exemplary apparatus and process as shown in FIG. 27;
FIG. 26 is a cross-sectional illustration of an exemplary surface covering like that of FIG. 8 except that it is inverted like in FIGS. 25 and 27; and, FIG. 27 is a schematic illustration of an exemplary apparatus and process for forming polyurethane backed surface coverings in accordance with another embodiment of the present invention.
Detailed Description Referring to FIG. 1 of the drawings, an exemplary formation system 10 is illustrated for use in the production of surface coverings or polyurethane backed products such as carpeting, carpet tile, area rugs, roll goods, and/or floor mats.
According to the illustrated and potentially preferred embodiment, the formation system 10 includes an endless belt 12 formed from a material such as PTFE
woven fiberglass or the like. As shown according to the illustrated process, a mass of uncured polyurethane composition 14 is preferably deposited directly onto the belt 12 and then adjusted to a desired height by a leveller 16 such as a doctor blade, air knife, or the like. The thickness of the levelled polyurethane composition is preferably in the range of about 0.10 inches to about 1.0 inches, more preferably about 0.16 inches to about 0.60 inches although higher or lower thickness levels may likewise be used. While direct application of the polyurethane composition onto the belt 12 may be preferred, it is likewise contemplated that a release layer, film, paper or the like (not shown) on or over the belt or other deposit surface may likewise be used if desired.
By way of example only, one contemplated polyurethane composition is believed to be disclosed in U.S. Patent No. 5,104,693 to Jenkines, the teachings of which are incorporated herein by reference in their entirety. Fillers, agents, additives, extenders, and the like such as calcium carbonate, coal fly ash, sand, foundry sand, used foundry sand, crushed glass, crushed recycled glass, post-
FIG. 26 is a cross-sectional illustration of an exemplary surface covering like that of FIG. 8 except that it is inverted like in FIGS. 25 and 27; and, FIG. 27 is a schematic illustration of an exemplary apparatus and process for forming polyurethane backed surface coverings in accordance with another embodiment of the present invention.
Detailed Description Referring to FIG. 1 of the drawings, an exemplary formation system 10 is illustrated for use in the production of surface coverings or polyurethane backed products such as carpeting, carpet tile, area rugs, roll goods, and/or floor mats.
According to the illustrated and potentially preferred embodiment, the formation system 10 includes an endless belt 12 formed from a material such as PTFE
woven fiberglass or the like. As shown according to the illustrated process, a mass of uncured polyurethane composition 14 is preferably deposited directly onto the belt 12 and then adjusted to a desired height by a leveller 16 such as a doctor blade, air knife, or the like. The thickness of the levelled polyurethane composition is preferably in the range of about 0.10 inches to about 1.0 inches, more preferably about 0.16 inches to about 0.60 inches although higher or lower thickness levels may likewise be used. While direct application of the polyurethane composition onto the belt 12 may be preferred, it is likewise contemplated that a release layer, film, paper or the like (not shown) on or over the belt or other deposit surface may likewise be used if desired.
By way of example only, one contemplated polyurethane composition is believed to be disclosed in U.S. Patent No. 5,104,693 to Jenkines, the teachings of which are incorporated herein by reference in their entirety. Fillers, agents, additives, extenders, and the like such as calcium carbonate, coal fly ash, sand, foundry sand, used foundry sand, crushed glass, crushed recycled glass, post-
9 PCT/US2007/021430 consumer recycled glass, soda lime glass, post-consumer recycled soda lime glass, glass particles, glass fibers, bone, bone meal, metal, recycled metal, iron, steel, ferrite, magnetite, iron oxides, barite, nickel, recycled soda lime glass having a pH in deionized water of greater than 8.4, fillers with a specific gravity (SG) greater than 2, fillers with a specific gravity greater than 5, inert oil, rubber, recycled rubber, SBR particles, mixed fines glass, mixed course glass, crushed bone meal, crushed gypsum, barium sulphate, castor oil, foam chips, recycled carpet tile, natural and/or synthetic fibers, colorants, anti-microbial agents, flame retardants, blowing agents, catalyst, water, recycled materials, renewable materials, bio-based materials, post-consumer recycled materials, post-industrial recycled materials, blends, combinations thereof, and/or the like. Fillers may be added at amounts of about 0.0% to about 99% by weight, most preferably about
10% to about 90% by weight, and more preferably from about 20% to about 80%
by weight. Fillers, agents, additives, extenders, liquids, and/or the like may be added in combination with air (or other gases) mixing or frothing and/or blowing to provide density levels as desired. In accordance with at least one particular example, a polyurethane froth density of about 887 grams per litre has been found to provide good results.
In accordance with one example of an indoor/outdoor polyurethane backed area rug having a construction like that of FIG. 2 of the drawings, a preferred polyurethane backing which serves as precoat and backing (combined precoat/backing) is a mechanically frothed methyl diphenyl diisocyanate (MDI) based polyurethane having an about 750 gram cup weight and an about 27 oz/yd2 add on.
Potentially preferred filler examples include (% by weight of the polyurethane):
Used foundry sand (UFS) - 50% to 80% by weight Crushed glass - 65% by weight Calcium carbonate - 50% to 65% by weight Coal fly ash - 50% by weight Blend of used foundry sand (UFS) and calcium carbonate - % by weight 13% UFS and 44% calcium carbonate 21% UFS and 40% calcium carbonate 26% UFS and 37% calcium carbonate Blend of calcium carbonate and 40 mesh ground tires (SBR) - % by weight 55% calcium carbonate and 10% SBR
Blend of used foundry sand (UFS) and 40 mesh SBR rubber particles (%
by weight) 60% UFS and 10% SBR
51% UFS and 13% SBR
47% UFS and 12% SBR
Used foundry sand 42%
72%
Crushed glass 72%
Blend of crushed glass with coal fly ash (CFA) 24% crushed glass and 48% CFA
Blend of crushed glass with calcium carbonate 24% crushed glass and 48% calcium carbonate Blend of crushed glass with used foundry sand (UFS) 24% crushed glass and 48% UFS
Calcium carbonate 42%
72%
40 mesh SBR
by weight. Fillers, agents, additives, extenders, liquids, and/or the like may be added in combination with air (or other gases) mixing or frothing and/or blowing to provide density levels as desired. In accordance with at least one particular example, a polyurethane froth density of about 887 grams per litre has been found to provide good results.
In accordance with one example of an indoor/outdoor polyurethane backed area rug having a construction like that of FIG. 2 of the drawings, a preferred polyurethane backing which serves as precoat and backing (combined precoat/backing) is a mechanically frothed methyl diphenyl diisocyanate (MDI) based polyurethane having an about 750 gram cup weight and an about 27 oz/yd2 add on.
Potentially preferred filler examples include (% by weight of the polyurethane):
Used foundry sand (UFS) - 50% to 80% by weight Crushed glass - 65% by weight Calcium carbonate - 50% to 65% by weight Coal fly ash - 50% by weight Blend of used foundry sand (UFS) and calcium carbonate - % by weight 13% UFS and 44% calcium carbonate 21% UFS and 40% calcium carbonate 26% UFS and 37% calcium carbonate Blend of calcium carbonate and 40 mesh ground tires (SBR) - % by weight 55% calcium carbonate and 10% SBR
Blend of used foundry sand (UFS) and 40 mesh SBR rubber particles (%
by weight) 60% UFS and 10% SBR
51% UFS and 13% SBR
47% UFS and 12% SBR
Used foundry sand 42%
72%
Crushed glass 72%
Blend of crushed glass with coal fly ash (CFA) 24% crushed glass and 48% CFA
Blend of crushed glass with calcium carbonate 24% crushed glass and 48% calcium carbonate Blend of crushed glass with used foundry sand (UFS) 24% crushed glass and 48% UFS
Calcium carbonate 42%
72%
40 mesh SBR
11 PCT/US2007/021430 38%
31%
36%
Coal fly ash 42%
69%
72%
75%
Magnetite 76%
Ground bone meal, 30-80%
Ground gypsum, 30-80%
Barium sulphate, 30-80%
Blend of 80x325 mesh mixed course (MC) glass and calcium carbonate Blend of 80x325 mesh mixed course (MC) glass and used foundry sand Blend of 100x325 mesh mixed fines (MF) glass and coal fly ash Blends by grams or parts:
16g glass 100x325 mesh mixed fines (MF) glass 49g coal fly ash (CFA) PV 20A
8g glass 100x325 mesh mixed fines (MF) glass 8g glass 80x325 mesh mixed course (MC) glass 49g coal fly ash (CFA) 16g glass 80x325 mesh mixed course (MC) glass 49g coal fly ash (CFA) 16g glass 80x325 mesh mixed course (MC) glass 49g calcium carbonate
31%
36%
Coal fly ash 42%
69%
72%
75%
Magnetite 76%
Ground bone meal, 30-80%
Ground gypsum, 30-80%
Barium sulphate, 30-80%
Blend of 80x325 mesh mixed course (MC) glass and calcium carbonate Blend of 80x325 mesh mixed course (MC) glass and used foundry sand Blend of 100x325 mesh mixed fines (MF) glass and coal fly ash Blends by grams or parts:
16g glass 100x325 mesh mixed fines (MF) glass 49g coal fly ash (CFA) PV 20A
8g glass 100x325 mesh mixed fines (MF) glass 8g glass 80x325 mesh mixed course (MC) glass 49g coal fly ash (CFA) 16g glass 80x325 mesh mixed course (MC) glass 49g coal fly ash (CFA) 16g glass 80x325 mesh mixed course (MC) glass 49g calcium carbonate
12 PCT/US2007/021430 65g coal fly ash (CFA) 16g glass 80x325 mesh mixed course (MC) glass 49g used foundry sand 32.5g bone 65g bone 65g 40 mesh gypsum from recycled drywall 30g gypsum wet with 15g water 16g glass 100x325 mesh mixed fines (MF) glass 49g calcium carbonate 16g glass 100x325 mesh mixed fines (MF) glass 49g used foundry sand As illustrated, once the polyurethane composition 14 is set to a desired level, a textile face structure 20 with a fibrous underside is preferably delivered into direct contacting relation with the polyurethane composition. For polyurethane backed products such as carpet, area rugs and mats, preferably no intermediate layer is disposed between the polyurethane and the underside of the textile face structure (see FIGS. 2 - 5). According to one contemplated practice, the textile face structure 20 may be pre-treated at a steam box 22 to relieve internal stresses by application of moisture and heat, may be dyed, may be range dyed, or the like. Such treatment permits the face structure 20 to remain substantially tensionless during subsequent curing of the polyurethane composition 14 as will be described further hereinafter. The elimination of tension in the face structure 20 facilitates the avoidance of undue levels of
13 PCT/US2007/021430 cupping or curling in the final structure. It is preferred that the polyurethane backing be relatively thin, dense, and flexible and that the face material or fabric be substantially tensionless. Such a product lies flat on the floor, can be bent or rolled, and the like.
Following introduction of the textile face structure 20 across the polyurethane composition 14, the resulting composite structure may thereafter be moved through, for example, an elevated temperature curing range 26. The temperature in the curing range is set to provide substantially complete curing of the polyurethane composition 14. By way of example only and not limitation, such a curing range 26 having, for example, heated platens below belt 12, a platen temperature setting of about 250 degrees F in a first zone, and with a setting of about 290 degrees F in subsequent zones has been found to provide good curing results when the belt 12 is operating at a rate of about 30 feet per minute. Of course, these setting may be readily adjusted as desired. For example, certain polyurethane backings may cure at room temperature.
As shown, upon exiting the curing range 26, the composite structure with cured polyurethane may thereafter be removed from the belt 12 and sent to a cutter 30 for segmentation to a length and width as desired based on the final intended use or rolled to be cut later. Cutter 30 may be a clicker for carpet tiles, a cut table for mats or rugs, a slitter, ultrasonic cutter, or the like.
Accordingly, the formation system 10 may be used to form carpet, carpet tile, area rugs, roll goods, and/or floor mats as may be desired. In this regard, it is to be understood that the density and thickness levels of polyurethane may be adjusted depending upon the product being produced. Specifically, it is contemplated that the mass per unit area of polyurethane may be slightly higher for carpeting than for floor mats. By way of example only, it has been found that a polyurethane mass per unit area of about 26 to 28 ounces per square yard with a thickness of about mils may be suitable for carpeting while a mass per unit area of about 25 ounces per square yard with a thickness of about 100 mils may be more suitable for dust control mats.
Following introduction of the textile face structure 20 across the polyurethane composition 14, the resulting composite structure may thereafter be moved through, for example, an elevated temperature curing range 26. The temperature in the curing range is set to provide substantially complete curing of the polyurethane composition 14. By way of example only and not limitation, such a curing range 26 having, for example, heated platens below belt 12, a platen temperature setting of about 250 degrees F in a first zone, and with a setting of about 290 degrees F in subsequent zones has been found to provide good curing results when the belt 12 is operating at a rate of about 30 feet per minute. Of course, these setting may be readily adjusted as desired. For example, certain polyurethane backings may cure at room temperature.
As shown, upon exiting the curing range 26, the composite structure with cured polyurethane may thereafter be removed from the belt 12 and sent to a cutter 30 for segmentation to a length and width as desired based on the final intended use or rolled to be cut later. Cutter 30 may be a clicker for carpet tiles, a cut table for mats or rugs, a slitter, ultrasonic cutter, or the like.
Accordingly, the formation system 10 may be used to form carpet, carpet tile, area rugs, roll goods, and/or floor mats as may be desired. In this regard, it is to be understood that the density and thickness levels of polyurethane may be adjusted depending upon the product being produced. Specifically, it is contemplated that the mass per unit area of polyurethane may be slightly higher for carpeting than for floor mats. By way of example only, it has been found that a polyurethane mass per unit area of about 26 to 28 ounces per square yard with a thickness of about mils may be suitable for carpeting while a mass per unit area of about 25 ounces per square yard with a thickness of about 100 mils may be more suitable for dust control mats.
14 PCT/US2007/021430 As previously noted, the textile face structure 20 may have any number of suitable constructions. By way of example only, FIGS. 2-5 illustrate a number of polyurethane-backed constructions such as may be formed on the system 10 using various face structures.
FIG. 2 illustrates a tufted textile face structure 20 incorporating an arrangement of yarn elements 36 tufted through a so called "primary backing"
such as a woven material, a scrim, a non-woven material, combined woven and non-woven material, or the like. As shown, the cured polyurethane composition 14 extends substantially to the primary backing 38 thereby aiding in locking the yarn elements 36 in place. Although a loop pile is shown, the pile may be loop, cut, or cut and loop.
FIG. 3 illustrates a woven textile face structure 20A disposed in contacting relation to the cured polyurethane composition 14. As shown, the cured polyurethane composition 14 extends substantially to the surface of the woven textile face structure 20A and preferably migrates at least partially into the interstices between yarn elements forming the woven textile face structure 20A
to promote good adhesion.
FIG. 4 illustrates a non-woven textile face structure 20B such as a needlepunched, flocked, spunbond, wet laid, or other non-woven construction disposed in contacting relation to the cured polyurethane composition 14. As shown, the cured polyurethane composition 14 extends substantially to the surface of the non-woven textile face structure 20B and preferably migrates at least partially into the interstices between fiber elements forming the non-woven textile face structure 20B to promote good adhesion.
FIG. 5 illustrates a bonded yarn textile face structure 20C incorporating an arrangement of yarn or pile elements 37 bonded in place across a primary backing or substrate layer 44 by an adhesive 42 disposed across at least the upper surface of the primary backing layer 44. Although a loop pile is shown, the pile may be loop, cut, or cut and loop. As shown, the cured polyurethane composition 14 preferably extends substantially to the primary backing 44.
FIG. 2 illustrates a tufted textile face structure 20 incorporating an arrangement of yarn elements 36 tufted through a so called "primary backing"
such as a woven material, a scrim, a non-woven material, combined woven and non-woven material, or the like. As shown, the cured polyurethane composition 14 extends substantially to the primary backing 38 thereby aiding in locking the yarn elements 36 in place. Although a loop pile is shown, the pile may be loop, cut, or cut and loop.
FIG. 3 illustrates a woven textile face structure 20A disposed in contacting relation to the cured polyurethane composition 14. As shown, the cured polyurethane composition 14 extends substantially to the surface of the woven textile face structure 20A and preferably migrates at least partially into the interstices between yarn elements forming the woven textile face structure 20A
to promote good adhesion.
FIG. 4 illustrates a non-woven textile face structure 20B such as a needlepunched, flocked, spunbond, wet laid, or other non-woven construction disposed in contacting relation to the cured polyurethane composition 14. As shown, the cured polyurethane composition 14 extends substantially to the surface of the non-woven textile face structure 20B and preferably migrates at least partially into the interstices between fiber elements forming the non-woven textile face structure 20B to promote good adhesion.
FIG. 5 illustrates a bonded yarn textile face structure 20C incorporating an arrangement of yarn or pile elements 37 bonded in place across a primary backing or substrate layer 44 by an adhesive 42 disposed across at least the upper surface of the primary backing layer 44. Although a loop pile is shown, the pile may be loop, cut, or cut and loop. As shown, the cured polyurethane composition 14 preferably extends substantially to the primary backing 44.
15 PCT/US2007/021430 As indicated previously, it is also contemplated that one or more backing or release layers may be applied across the underside of the cured polyurethane facing away from the textile face structure. By way of example only, FIG. 6 illustrates a formation system 110 for production of surface coverings incorporating backed polyurethane, such as felt or scrim backed polyurethane, wherein elements corresponding to those previously described are designated by like reference numerals increased by 100. As will be appreciated, the formation system 110 is substantially identical to the system illustrated and described in relation to FIG. 1 but with the addition of backing material, such as felt 140 across the belt 112 at a position upstream of the location at which the polyurethane composition 114 is deposited.
By way of example only, one felt that may be particularly preferred is a needle punched felt formed from polyester and/or polypropylene as described in U.S. Patent 5,540,968 hereby incorporated by reference herein. Of course other woven and/or non-woven backings may likewise be utilized as desired.
The textile face structure 120 may have any number of suitable constructions. By way of example only, FIGS. 7-10 illustrate a number of backed polyurethane constructions such as may be formed on the system 110 using various face structures.
FIG. 7 illustrates a tufted textile face structure 120 incorporating an arrangement of yarn elements 136 tufted through a primary backing 138 such as a woven, a non-woven or the like. As shown, the cured polyurethane composition 114 extends substantially between the backing, such as non-woven felt or a woven or nonwoven scrim or mesh 140 and the primary backing 138 thereby aiding in locking the yarn elements 136 in place.
FIG. 8 illustrates a woven textile face structure 120A disposed in contacting relation to the cured polyurethane composition 114. As shown, the cured polyurethane composition 114 extends substantially between the backing, such as non-woven felt 140 and the surface of the woven textile face structure 120A and preferably migrates at least partially into the interstices between yarn
By way of example only, one felt that may be particularly preferred is a needle punched felt formed from polyester and/or polypropylene as described in U.S. Patent 5,540,968 hereby incorporated by reference herein. Of course other woven and/or non-woven backings may likewise be utilized as desired.
The textile face structure 120 may have any number of suitable constructions. By way of example only, FIGS. 7-10 illustrate a number of backed polyurethane constructions such as may be formed on the system 110 using various face structures.
FIG. 7 illustrates a tufted textile face structure 120 incorporating an arrangement of yarn elements 136 tufted through a primary backing 138 such as a woven, a non-woven or the like. As shown, the cured polyurethane composition 114 extends substantially between the backing, such as non-woven felt or a woven or nonwoven scrim or mesh 140 and the primary backing 138 thereby aiding in locking the yarn elements 136 in place.
FIG. 8 illustrates a woven textile face structure 120A disposed in contacting relation to the cured polyurethane composition 114. As shown, the cured polyurethane composition 114 extends substantially between the backing, such as non-woven felt 140 and the surface of the woven textile face structure 120A and preferably migrates at least partially into the interstices between yarn
16 PCT/US2007/021430 elements forming the woven textile face structure 120A so as to promote good adhesion.
FIG. 9 illustrates a non-woven textile face structure 120B such as a needlepunched, flocked, spun bond or other non-woven construction disposed in contacting relation to the cured polyurethane composition 114. As shown, the cured polyurethane composition 114 extends substantially between the felt backing, such as a non-woven 140 and the surface of the non-woven textile face structure 120B and preferably migrates at least partially into the interstices between fiber elements forming the non-woven textile face structure 120B so as to promote good adhesion.
FIG. 10 illustrates a bonded yarn textile face structure 120C incorporating an arrangement of yarn elements 137 bonded in place across a primary backing or substrate layer 144 by an adhesive 142 disposed across the upper surface of the primary backing layer 144. As shown, the cured polyurethane composition 114 preferably extends substantially between the backing, such as a non-woven felt 140 and the primary backing 144.
The backings 140 of FIGS. 6 - 10 may be a woven, non-woven, or combined woven and non-woven material or fabric, a film, a scrim, a mesh, or combinations thereof. In accordance with one example, the backing 140 is a non-woven bonded glass scrim material marketed as STABILON TRIAXT"" by Milliken & Company of Spartanburg, SC. It is preferred that the backing 140 be a flexible material which prevents growth and which tends to prevent curling of the surface covering 120 (such as a carpet tile). A glass scrim, mat, or the like may be preferred.
As indicated previously, it is also contemplated that one or more structural support layers may be placed within, over, or under the cured polyurethane. By way of example only, FIG. 11 illustrates a formation system 210 for production of surface coverings incorporating polyurethane with an intermediate structural support layer, wherein elements corresponding to those previously described are designated by like reference numerals in a 200 series.
FIG. 9 illustrates a non-woven textile face structure 120B such as a needlepunched, flocked, spun bond or other non-woven construction disposed in contacting relation to the cured polyurethane composition 114. As shown, the cured polyurethane composition 114 extends substantially between the felt backing, such as a non-woven 140 and the surface of the non-woven textile face structure 120B and preferably migrates at least partially into the interstices between fiber elements forming the non-woven textile face structure 120B so as to promote good adhesion.
FIG. 10 illustrates a bonded yarn textile face structure 120C incorporating an arrangement of yarn elements 137 bonded in place across a primary backing or substrate layer 144 by an adhesive 142 disposed across the upper surface of the primary backing layer 144. As shown, the cured polyurethane composition 114 preferably extends substantially between the backing, such as a non-woven felt 140 and the primary backing 144.
The backings 140 of FIGS. 6 - 10 may be a woven, non-woven, or combined woven and non-woven material or fabric, a film, a scrim, a mesh, or combinations thereof. In accordance with one example, the backing 140 is a non-woven bonded glass scrim material marketed as STABILON TRIAXT"" by Milliken & Company of Spartanburg, SC. It is preferred that the backing 140 be a flexible material which prevents growth and which tends to prevent curling of the surface covering 120 (such as a carpet tile). A glass scrim, mat, or the like may be preferred.
As indicated previously, it is also contemplated that one or more structural support layers may be placed within, over, or under the cured polyurethane. By way of example only, FIG. 11 illustrates a formation system 210 for production of surface coverings incorporating polyurethane with an intermediate structural support layer, wherein elements corresponding to those previously described are designated by like reference numerals in a 200 series.
17 PCT/US2007/021430 As will be appreciated, the formation system 210 is substantially identical to the system illustrated and described in relation to FIG. 1 but with the addition of a structural support layer 250, such as a glass mat or scrim, between deposited layers of polyurethane composition 214, 214'. As shown, in the illustrated practice the structural support layer 250 is placed in contacting overlying relation to a first layer of polyurethane composition 214 following a first leveller 216. A second layer of polyurethane composition 214' is then applied across the structural support layer 250 followed by a leveller 216' thereby yielding a sandwich structure for application of the textile face structure 220.
With reference to FIGS. 11 - 15, 23 and 24 of the drawings, the location of support, stabilizing or reinforcement layer or material 250 can be determined by the amount of polyurethane composition added upstream and downstream of the support layer 250. Although it may be preferred that the support layer 250 be located at the top of, in the middle of, or at the bottom of the polyurethane backing (FIGS. 23, 12, and 24, respectively), it may be located anywhere in between by controlling the add of polyurethane 214 and 214' in the system of FIG. 11.
By way of example only, one structural support layer 250 is in the form of woven or non-woven glass, although other materials including polyester, polypropylene, and the like may also be utilized if desired. The textile face structure 220 may have any number of suitable constructions. By way of example only, FIGS. 12-15 illustrate a number of constructions incorporating a structural support layer 250 such as may be formed on the system 210 using various face structures.
FIG. 12 illustrates a tufted textile face structure 220 incorporating an arrangement of yarn elements 236 tufted through a primary backing 238 such as a scrim, a non-woven or the like. As shown, the upper layer of cured polyurethane composition 214' extends substantially between the structural support layer 250 and the primary backing 238 thereby aiding in locking the yarn elements 236 in place. The lower layer of cured polyurethane composition 214 extends away from the structural support layer 250 to define a lower surface.
With reference to FIGS. 11 - 15, 23 and 24 of the drawings, the location of support, stabilizing or reinforcement layer or material 250 can be determined by the amount of polyurethane composition added upstream and downstream of the support layer 250. Although it may be preferred that the support layer 250 be located at the top of, in the middle of, or at the bottom of the polyurethane backing (FIGS. 23, 12, and 24, respectively), it may be located anywhere in between by controlling the add of polyurethane 214 and 214' in the system of FIG. 11.
By way of example only, one structural support layer 250 is in the form of woven or non-woven glass, although other materials including polyester, polypropylene, and the like may also be utilized if desired. The textile face structure 220 may have any number of suitable constructions. By way of example only, FIGS. 12-15 illustrate a number of constructions incorporating a structural support layer 250 such as may be formed on the system 210 using various face structures.
FIG. 12 illustrates a tufted textile face structure 220 incorporating an arrangement of yarn elements 236 tufted through a primary backing 238 such as a scrim, a non-woven or the like. As shown, the upper layer of cured polyurethane composition 214' extends substantially between the structural support layer 250 and the primary backing 238 thereby aiding in locking the yarn elements 236 in place. The lower layer of cured polyurethane composition 214 extends away from the structural support layer 250 to define a lower surface.
18 PCT/US2007/021430 FIG. 13 illustrates a woven textile face structure 220A disposed in contacting relation to the upper layer of cured polyurethane composition 214'.
As shown, the upper layer of cured polyurethane composition 214' extends substantially between the structural support layer 250 and the underside of the woven textile face structure 220A and preferably migrates at least partially into the interstices between yarn elements forming the woven textile face structure 220A so as to promote good adhesion. The lower layer of cured polyurethane composition 214 extends away from the structural support layer 250 to define a lower surface.
FIG. 14 illustrates a non-woven textile face structure 220B such as a needlepunched, flocked, spun bond or other non-woven construction disposed in contacting relation to the upper layer of cured polyurethane composition 214'.
As shown, the upper layer of cured polyurethane composition 214' extends substantially between the structural support layer 250 and the underside of the non-woven textile face structure 220B and preferably migrates at least partially into the interstices between fiber elements forming the non-woven textile face structure 220B so as to promote good adhesion. The lower layer of cured polyurethane composition 214 extends away from the structural support layer 250 to define a lower surface.
FIG. 15 illustrates a bonded yarn textile face structure 220C incorporating an arrangement of yarn elements 237 bonded in place across a primary backing or substrate layer 244 by an adhesive 242 disposed across the upper surface of the primary backing layer 244. As shown, the upper layer of cured polyurethane composition 214' extends substantially between the structural support layer and the underside of the primary backing layer 244. The lower layer of cured polyurethane composition 214 extends away from the structural support layer 250 to define a lower surface.
It is also contemplated that combinations of structural support layers and backings, such as felt backings, may be utilized. By way of example only, FIG.
16 illustrates a formation system 310 for production of surface coverings incorporating polyurethane with an intermediate structural support layer and with
As shown, the upper layer of cured polyurethane composition 214' extends substantially between the structural support layer 250 and the underside of the woven textile face structure 220A and preferably migrates at least partially into the interstices between yarn elements forming the woven textile face structure 220A so as to promote good adhesion. The lower layer of cured polyurethane composition 214 extends away from the structural support layer 250 to define a lower surface.
FIG. 14 illustrates a non-woven textile face structure 220B such as a needlepunched, flocked, spun bond or other non-woven construction disposed in contacting relation to the upper layer of cured polyurethane composition 214'.
As shown, the upper layer of cured polyurethane composition 214' extends substantially between the structural support layer 250 and the underside of the non-woven textile face structure 220B and preferably migrates at least partially into the interstices between fiber elements forming the non-woven textile face structure 220B so as to promote good adhesion. The lower layer of cured polyurethane composition 214 extends away from the structural support layer 250 to define a lower surface.
FIG. 15 illustrates a bonded yarn textile face structure 220C incorporating an arrangement of yarn elements 237 bonded in place across a primary backing or substrate layer 244 by an adhesive 242 disposed across the upper surface of the primary backing layer 244. As shown, the upper layer of cured polyurethane composition 214' extends substantially between the structural support layer and the underside of the primary backing layer 244. The lower layer of cured polyurethane composition 214 extends away from the structural support layer 250 to define a lower surface.
It is also contemplated that combinations of structural support layers and backings, such as felt backings, may be utilized. By way of example only, FIG.
16 illustrates a formation system 310 for production of surface coverings incorporating polyurethane with an intermediate structural support layer and with
19 PCT/US2007/021430 a backing. In this figure and related figures, elements corresponding to those previously described are designated by like reference numerals within a 300 series. As will be appreciated, the formation system 310 is substantially identical to the system illustrated and described in relation to FIG. 11 but with the addition of a layer of backing such as felt 340 across the belt 312 at a position upstream of the location at which the polyurethane composition 314 is deposited.
As shown, in the illustrated practice a first layer of polyurethane composition 314 is deposited over the backing material or layer 340 and levelled by a first leveller 316. The structural support layer 350 is placed in contacting overlying relation to the first layer of polyurethane composition 314 following a first leveller 316. A second layer of polyurethane composition 314' is then applied across the structural support layer 350 followed by a leveller 316' thereby yielding a stabilized and backed sandwich structure for application of the textile face structure 320.
The textile face structure 320 may have any number of suitable constructions. By way of example only, FIGS. 17-20 illustrate a number of constructions incorporating a structural support layer 350 and a backing 340 such as may be formed on the system 310 using various face structures.
FIG. 17 illustrates a tufted textile face structure 320 incorporating an arrangement of yarn elements 336 tufted through a primary backing 338 such as a woven, a non-woven or the like. As shown, the upper layer of cured polyurethane composition 314' extends substantially between the structural support layer 350 and the primary backing 338 thereby aiding in locking the yarn elements 336 in place. The lower layer of cured polyurethane composition 314 extends away from the structural support layer 350 to the backing layer 340.
FIG. 18 illustrates a woven textile face structure 320A disposed in contacting relation to the upper layer of cured polyurethane composition 314'.
As shown, the upper layer of cured polyurethane composition 314' extends substantially between the structural support layer 350 and the underside of the woven textile face structure 320A and preferably migrates at least partially into the interstices between yarn elements forming the woven textile face structure
As shown, in the illustrated practice a first layer of polyurethane composition 314 is deposited over the backing material or layer 340 and levelled by a first leveller 316. The structural support layer 350 is placed in contacting overlying relation to the first layer of polyurethane composition 314 following a first leveller 316. A second layer of polyurethane composition 314' is then applied across the structural support layer 350 followed by a leveller 316' thereby yielding a stabilized and backed sandwich structure for application of the textile face structure 320.
The textile face structure 320 may have any number of suitable constructions. By way of example only, FIGS. 17-20 illustrate a number of constructions incorporating a structural support layer 350 and a backing 340 such as may be formed on the system 310 using various face structures.
FIG. 17 illustrates a tufted textile face structure 320 incorporating an arrangement of yarn elements 336 tufted through a primary backing 338 such as a woven, a non-woven or the like. As shown, the upper layer of cured polyurethane composition 314' extends substantially between the structural support layer 350 and the primary backing 338 thereby aiding in locking the yarn elements 336 in place. The lower layer of cured polyurethane composition 314 extends away from the structural support layer 350 to the backing layer 340.
FIG. 18 illustrates a woven textile face structure 320A disposed in contacting relation to the upper layer of cured polyurethane composition 314'.
As shown, the upper layer of cured polyurethane composition 314' extends substantially between the structural support layer 350 and the underside of the woven textile face structure 320A and preferably migrates at least partially into the interstices between yarn elements forming the woven textile face structure
20 PCT/US2007/021430 320A so as to promote good adhesion. The lower layer of cured polyurethane composition 314 extends away from the structural support layer 350 to the backing layer 340.
FIG. 19 illustrates a non-woven textile face structure 320B such as a needlepunched, flocked, spun bond or other non-woven construction disposed in contacting relation to the upper layer of cured polyurethane composition 314'.
As shown, the upper layer of cured polyurethane composition 314' extends substantially between the structural support layer 350 and the underside of the non-woven textile face structure 320B and preferably migrates at least partially into the interstices between fiber elements forming the non-woven textile face structure 320B so as to promote good adhesion. The lower layer of cured polyurethane composition 314 extends away from the structural support layer 350 to the backirig layer 340.
FIG. 20 illustrates a bonded yarn textile face structure 320C incorporating an arrangement of yarn elements 337 bonded in place across a primary backing or substrate layer 344 by an adhesive 342 disposed across the upper surface of the primary backing layer 344. As shown, the upper layer of cured polyurethane composition 314' extends substantially between the structural support layer and the underside of the primary backing layer 340. The lower layer of cured polyurethane composition 314 extends away from the structural support layer 350 to the layer of felt 340.
With reference to FIG. 21, a tufted face surface covering like that of FIG. 2 is shown with a backing 60 such as a coating, film, or the like. For example, backing 60 may be an adhesive or other friction enhancing coating such as TractionBack coating offered by Milliken & Company of LaGrange, GA.
The underside or lower surface of polyurethane layer 14 or 214 may be textured, embossed, cleated, nubbed, ribbed, or the like to, for example, increase sliding friction with a floor or subfloor. Likewise, the lower surface of backing 140, 340, or 250, or of coating or film 60 or 160 may be embossed, textured, or the like.
FIG. 19 illustrates a non-woven textile face structure 320B such as a needlepunched, flocked, spun bond or other non-woven construction disposed in contacting relation to the upper layer of cured polyurethane composition 314'.
As shown, the upper layer of cured polyurethane composition 314' extends substantially between the structural support layer 350 and the underside of the non-woven textile face structure 320B and preferably migrates at least partially into the interstices between fiber elements forming the non-woven textile face structure 320B so as to promote good adhesion. The lower layer of cured polyurethane composition 314 extends away from the structural support layer 350 to the backirig layer 340.
FIG. 20 illustrates a bonded yarn textile face structure 320C incorporating an arrangement of yarn elements 337 bonded in place across a primary backing or substrate layer 344 by an adhesive 342 disposed across the upper surface of the primary backing layer 344. As shown, the upper layer of cured polyurethane composition 314' extends substantially between the structural support layer and the underside of the primary backing layer 340. The lower layer of cured polyurethane composition 314 extends away from the structural support layer 350 to the layer of felt 340.
With reference to FIG. 21, a tufted face surface covering like that of FIG. 2 is shown with a backing 60 such as a coating, film, or the like. For example, backing 60 may be an adhesive or other friction enhancing coating such as TractionBack coating offered by Milliken & Company of LaGrange, GA.
The underside or lower surface of polyurethane layer 14 or 214 may be textured, embossed, cleated, nubbed, ribbed, or the like to, for example, increase sliding friction with a floor or subfloor. Likewise, the lower surface of backing 140, 340, or 250, or of coating or film 60 or 160 may be embossed, textured, or the like.
21 PCT/US2007/021430 The tufted face surface covering of FIG. 22 is like that of FIG. 7 with the addition of backing 160 such as a coating, film, or the like.
The tufted face surface covering of FIG. 23 is like that of FIG. 12 except that the support layer 250 is shown just below tufts 236.
The woven face surface covering of FIG. 24 is like that of FIG. 13 except that the support layer 250 is shown at the bottom of polyurethane 214.
FIGS. 25 - 27 relate to an alternative production process wherein the face material 20, 120, 220 is inverted and then laid on the belt 112. Next, polyurethane composition 114 is poured or applied to the back of the face material 20A or 120A and doctored by blade 116.
With respect to FIGS. 26 and 27, a backing 140 is added over the polyurethane 114 and nip or gauge roll 162 presses backing 140 into the polyurethane 114.
One advantage of the system 110A of FIG. 27 is that the face material 120 tends to keep the belt 112 clean of polyurethane 114.
The face material 20, 20A, 20B, 20C, 120, 120A, ' 120B, 120C, 220, 220A, 220B, 220C, 320, 320A, 320B, and 320C may be formed of natural or synthetic fibers or materials, or blends thereof. For example, tufts 36 may be Nylon 6, Nylon 6,6, polyolefin, wool, or blends thereof.
If face material 20 must be dyed or printed, it is preferred that it be dyed prior to addition of polyurethane 14.
Polyurethane 14 may include a polyol component, an isocyanate component, a catalyst, and other agents, fillers, additives, and the like. It has been discovered that the catalyst may be eliminated, that the polyol may be replaced with castor oil, or both.
In accordance with at least selected examples, castor oil was used in place of the polyol component of a two component MDI based polyurethane system typically having a polyol component and an isocyanate component (in grams or parts).
The tufted face surface covering of FIG. 23 is like that of FIG. 12 except that the support layer 250 is shown just below tufts 236.
The woven face surface covering of FIG. 24 is like that of FIG. 13 except that the support layer 250 is shown at the bottom of polyurethane 214.
FIGS. 25 - 27 relate to an alternative production process wherein the face material 20, 120, 220 is inverted and then laid on the belt 112. Next, polyurethane composition 114 is poured or applied to the back of the face material 20A or 120A and doctored by blade 116.
With respect to FIGS. 26 and 27, a backing 140 is added over the polyurethane 114 and nip or gauge roll 162 presses backing 140 into the polyurethane 114.
One advantage of the system 110A of FIG. 27 is that the face material 120 tends to keep the belt 112 clean of polyurethane 114.
The face material 20, 20A, 20B, 20C, 120, 120A, ' 120B, 120C, 220, 220A, 220B, 220C, 320, 320A, 320B, and 320C may be formed of natural or synthetic fibers or materials, or blends thereof. For example, tufts 36 may be Nylon 6, Nylon 6,6, polyolefin, wool, or blends thereof.
If face material 20 must be dyed or printed, it is preferred that it be dyed prior to addition of polyurethane 14.
Polyurethane 14 may include a polyol component, an isocyanate component, a catalyst, and other agents, fillers, additives, and the like. It has been discovered that the catalyst may be eliminated, that the polyol may be replaced with castor oil, or both.
In accordance with at least selected examples, castor oil was used in place of the polyol component of a two component MDI based polyurethane system typically having a polyol component and an isocyanate component (in grams or parts).
22 PCT/US2007/021430 A. 16g 100x325 mesh mixed fines (MF) glass 49g coal fly ash (CFA) 12g castor oil 23g isocyanate drop dibutyl tin dilaurate (about 0.026g) catalyst B. 16g 100x325 mesh mixed fines (MF) glass 49g coal fly ash (CFA) 12g castor oil 8g inert oil 23g isocyanate drop dibutyl tin dilaurate (about 0.026g) catalyst C. 16g 100x325 mesh mixed fines (MF) glass 49g coal fly ash (CFA) 20g castor oil 23g isocyanate drop dibutyl tin dilaurate (about 0.026g) catalyst D. 65g coal fly ash (CFA) 20g castor oil 23g isocyanate 2 drops catalyst E. 16g 100x325 mesh mixed fines (MF) glass 49g coal fly ash (CFA) 18g castor oil 23g isocyanate 2 drops catalyst F. 32.5g bone meal 13g castor oil
23 PCT/US2007/021430 13g isocyanate 3 drops catalyst G. 65g bone meal 26g castor oil 26g isocyanate 0.23 mL catalyst H. 65g 40 mesh gypsum from recycled drywall 49g castor oil 46g isocyanate 0.46 mL dibutyl tin dilaurate 0.46 mL water 1. 30g gypsum wet with 15g water lOg castor oil lOg isocyanate 0.1 mL dibutyl tin dilaurate J. 16g 100x325 mesh mixed fines (MF) glass 49g coal fly ash (CFA) 17g castor oil 23g isocyanate 0.5 mL dibutyl tin dilaurate K. 16g 100x325 mesh mixed fines (MF) glass 49g coal fly ash (CFA) 16g castor oil 23g isocyanate 0.5 mL dibutyl tin dilaurate L. 65 parts 100x325 mesh mixed fines (MF)
24 PCT/US2007/021430 crushed post-consumer glass 23g isocyanate 12 parts castor oil 0.026 parts dibutyl tin dilaurate catalyst M. 62.5 parts coal fly ash (PV 20A) parts castor oil 9.93 parts PPG polyol MW 6000 f=3 17.57 parts prepolymer isocyanate dibutyl tin dilaurate catalyst N. 62.5 parts coal fly ash (PV 20A) 13.52 parts castor oil 13.43 parts PPG polyol MW 6000 f=3 5.26 parts isocyanate 5.29 parts prepolymer isocyanate dibutyl tin dilaurate catalyst 0. 62.5 parts coal fly ash (PV 20A) 15.04 parts castor oil 14.94 parts PPG polyol MW 6000 f=3 7.52 parts isocyanate dibutyl tin dilaurate catalyst P. 62.5 parts coal fly ash (PV 20A) 13.62 parts castor oil 13.55 parts PPG polyol MW 6000 f=3 4.98 parts isocyanate 5.34 parts prepolymer isocyanate dibutyl tin dilaurate catalyst
25 PCT/US2007/021430 Polyurethane 14 may include a polyol component, an isocyanate component, a catalyst, and other agents, fillers, additives, and the like. It has been discovered that the petrochemical polyol may be replaced with chemically unmodified (preferably filtered and dried) castor oil (a natural oil polyol).
In accordance with at least selected examples, castor oil is used in place of at least the major polyol component of a two component MDI based polyurethane system typically having a petrochemical or petroleum based polyol or polyol blend component and an isocyanate component (in grams or parts).
Q. 16g 100x325 mesh mixed fines (MF) glass 49g coal fly ash (CFA) 12g dry, filtered castor oil 23g isocyanate drop dibutyl tin dilaurate (about 0.026g) catalyst R. 16g 100x325 mesh mixed fines (MF) glass 49g coal fly ash (CFA) 12g dry, filtered castor oil 8g inert oil 23g isocyanate S. 69g coal fly ash (CFA) 20g castor oil 23g isocyanate T. 65g coal fly ash (CFA) 20g dry, filtered castor oil 23g isocyanate 2 drops catalyst U. 16g 100x325 mesh mixed fines (MF) glass
In accordance with at least selected examples, castor oil is used in place of at least the major polyol component of a two component MDI based polyurethane system typically having a petrochemical or petroleum based polyol or polyol blend component and an isocyanate component (in grams or parts).
Q. 16g 100x325 mesh mixed fines (MF) glass 49g coal fly ash (CFA) 12g dry, filtered castor oil 23g isocyanate drop dibutyl tin dilaurate (about 0.026g) catalyst R. 16g 100x325 mesh mixed fines (MF) glass 49g coal fly ash (CFA) 12g dry, filtered castor oil 8g inert oil 23g isocyanate S. 69g coal fly ash (CFA) 20g castor oil 23g isocyanate T. 65g coal fly ash (CFA) 20g dry, filtered castor oil 23g isocyanate 2 drops catalyst U. 16g 100x325 mesh mixed fines (MF) glass
26 PCT/US2007/021430 49g coal fly ash (CFA) 18g castor oil 6g PPG polyol 29g isocyanate 2 drops catalyst V. 32.5g bone meal 13g castor oil 5g PEG polyol 18g isocyanate 3 drops catalyst W. 65g bone meal 26g castor oil 13g PPG-PEG copolymer polyol 39g isocyanate 0.23 mL catalyst X. 65g 40 mesh gypsum from recycled drywall 49g castor oil 12g minor polyol with functionality of 2 or 3 and a molecular weight ranging from 750 to 7500 58g isocyanate 0.46 mL dibutyl tin dilaurate Y. 30g gypsum wet with 15g water 10g dry castor oil 10g isocyanate Z. 16g 100x325 mesh mixed fines (MF) glass 49g coal fly ash (CFA) 17g polyurethane grade, dry castor oil
27 PCT/US2007/021430 23g isocyanate 0.5 mL dibutyl tin dilaurate AA. 16g 100x325 mesh mixed fines (MF) glass 49g coal fly ash (CFA) 16g polyurethane grade castor oil 23g isocyanate 0.5 mL dibutyl tin dilaurate BB. 65 parts 100x325 mesh mixed fines (MF) crushed post-consumer glass 23 parts isocyanate 12 parts castor oil CC. at least 42% by weight coal fly ash (CFA) unmodified, dry, filtered castor oil isocyanate DD. at least 50% by weight coal fly ash (CFA) castor oil optional additional polyol isocyanate optional catalyst EE. at least 60% by weight coal fly ash (CFA) castor oil isocyanate optional catalyst FF. at least 70% by weight coal fly ash (CFA) castor oil optional additional polyol
28 PCT/US2007/021430 isocyanate optional catalyst GG. coal fly ash (CFA) castor oil polyol blend isocyanate optional catalyst HH. coal fly ash (CFA) castor oil isocyanate blend optional catalyst II. coal fly ash (CFA) castor oil prepolymer isocyanate optional catalyst JJ. coal fly ash (CFA) castor oil prepolymer isocyanate blend optional catalyst KK. coal fly ash (CFA) castor oil optional polyol blend prepolymer isocyanate optional catalyst LL. 62.5 parts coal fly ash (PV 20A) parts castor oil
29 PCT/US2007/021430 4.97 parts PPG polyol MW 3,000 f=3 17.57 parts prepolymer isocyanate optional catalyst MM. 62.5 parts coal fly ash (PV 20A) 13.52 parts castor oil 6.72 parts PPG polyol MW 3000 f=3 5.26 parts isocyanate 5.29 parts prepolymer isocyanate dibutyl tin dilaurate catalyst NN. 62:5 parts coal fly ash (PV 20A) 15.04 parts castor oil 7.47 parts PPG polyol MW 3000 f=3 7.52 parts isocyanate dibutyl tin dilaurate catalyst 00. 62.5 parts coal fly ash (PV 20A) 13.62 parts castor oil 6.78 parts PPG polyol MW 3000 f=3 4.98 parts isocyanate 5.34 parts prepolymer isocyanate dibutyl tin dilaurate catalyst PP. 62.5 parts coal fly ash (PV 20A) 13.52 parts castor oil 13.43 parts PPG polyol MW 4000 f=2 5.26 parts isocyanate 5.29 parts prepolymer isocyanate dibutyl tin dilaurate catalyst
30 PCT/US2007/021430 QQ. 62.5 parts coal fly ash (PV 20A) 15.04 parts castor oil 1 14.94 parts PPG polyol MW 4000 f=2 7.52 parts isocyanate dibutyl tin dilaurate catalyst RR. 62.5 parts coal fly ash (PV 20A) 13.62 parts castor oil 6.78 parts PPG polyol MW 2000 f=2 4.98 parts isocyanate 5.34 parts prepolymer isocyanate dibutyl tin dilaurate catalyst SS. 62.5 parts coal fly ash (PV 20A) 13.52 parts castor oil 6.72 parts PPG polyol MW 2000 f=2 5.26 parts isocyanate 5.29 parts prepolymer isocyanate dibutyl tin dilaurate catalyst In accordance with another possibly preferred embodiment of the present invention, the preferred filler is a post-consumer recycled soda lime glass having a pH in deionized water of greater than 8.4, more preferably greater than 9.0, most preferably greater than 10Ø
In accordance with one test in deionized water, the recycled soda lime glass had a pH of 10.73, in another test the pH was 9.24.
Such a recycled soda lime glass also has the following specifications:
1. PRODUCT INFORMATION
In accordance with one test in deionized water, the recycled soda lime glass had a pH of 10.73, in another test the pH was 9.24.
Such a recycled soda lime glass also has the following specifications:
1. PRODUCT INFORMATION
31 PCT/US2007/021430 Product Name: Cullet - Recycled Glass Chemical Family: Silicon Synonyms: Soda Lime Glass, Crushed Glass Formula: Si02 + Metal Oxides (Na20, CaO, A12O3) CAS Number: None DOT Shipping Name: None DOT Shipping ID No.: N/A
DOT Hazard Class: N/A
EPA Hazard Waste Class: None EPA Hazard Waste ID No.:None Moisture: 0.1 % max LOI: 0.1 % max Tramp Metals: 0.01% max II. CHEMICAL COMPOSTION
NAME % ACGIH TLV OSHA PEL CAS #
Soda Lime Glass 100 10mg/M3 *15mg/M3 None * 5mg/M3 (OSHA PEL based on Nuisance Dust) * Total Dust ** Respirable Dust III. PHYSICAL PROPERTIES
Boiling Point: N/A Vapor Density (Air-1): N/A
Melting Point: 3100 F or 1704 C Specific Gravity (Water=1):2 Vapor Pressure (mmHg): N/A % Volatile: None
DOT Hazard Class: N/A
EPA Hazard Waste Class: None EPA Hazard Waste ID No.:None Moisture: 0.1 % max LOI: 0.1 % max Tramp Metals: 0.01% max II. CHEMICAL COMPOSTION
NAME % ACGIH TLV OSHA PEL CAS #
Soda Lime Glass 100 10mg/M3 *15mg/M3 None * 5mg/M3 (OSHA PEL based on Nuisance Dust) * Total Dust ** Respirable Dust III. PHYSICAL PROPERTIES
Boiling Point: N/A Vapor Density (Air-1): N/A
Melting Point: 3100 F or 1704 C Specific Gravity (Water=1):2 Vapor Pressure (mmHg): N/A % Volatile: None
32 PCT/US2007/021430 Solubility in Water: Insoluble Evaporation Rate: N/A
Appearance & Odor: Solid having variable appearance without odor.
IV. REACTIVITY DATA
Stability: Stable Incompatibilities: None 'Hazardous Decomposition Products: None Conditions to Avoid: None Hazardous Polymerization: Will not occur Conditions to Avoid: None V. SIZES
70 to 100 mesh, 100 to 120 mesh, 70 to 325 mesh, 80 to 325 mesh, 100 to 325 mesh VI. SOURCE
100% post-consumer glass from private and municipal recycling programs.
In accordance with another example, one can blend recycled post-industrial waste filler (such as coal fly ash) with recycled post-consumer waste filler (such as crushed glass) to produce a hybrid recycled filler.
In accordance with still another example, one can mix recycled post-industrial filler and recycled post-consumer filler, with renewable or bio-based fillers or extenders such as cork, wood, corn, and/or the like.
Appearance & Odor: Solid having variable appearance without odor.
IV. REACTIVITY DATA
Stability: Stable Incompatibilities: None 'Hazardous Decomposition Products: None Conditions to Avoid: None Hazardous Polymerization: Will not occur Conditions to Avoid: None V. SIZES
70 to 100 mesh, 100 to 120 mesh, 70 to 325 mesh, 80 to 325 mesh, 100 to 325 mesh VI. SOURCE
100% post-consumer glass from private and municipal recycling programs.
In accordance with another example, one can blend recycled post-industrial waste filler (such as coal fly ash) with recycled post-consumer waste filler (such as crushed glass) to produce a hybrid recycled filler.
In accordance with still another example, one can mix recycled post-industrial filler and recycled post-consumer filler, with renewable or bio-based fillers or extenders such as cork, wood, corn, and/or the like.
33 PCT/US2007/021430 The surface coverings of the present invention may be hardback or cushion back products. For example, the precoat, the tiecoat, and the backing may each be foam or non-foam layers. In accordance with one example, the precoat is non-foamed and the backing is foamed. It may be preferred that the polyurethane composition layer form a precoat, tiecoat, or backing, a combined precoat and tiecoat, a combined precoat and backing, a combined tiecoat and backing, or the like. One can increase the cushion or resilience of the backing by adding more air, more blowing agent, felt, thickness, or the like. It is possibly preferred that a polyurethane hardback or cushion back product such as a polyurethane hardback or cushion back carpet tile have the structure of one of FIGS. 2 - 5, 7 - 10, 12 - 15, 17 - 20, and 21 - 26. It may also be preferred that a polyurethane backed area rug, roll goods, or floor mat of the present invention have the structure of one of FIGS. 2 - 5, 21, and 25.
In accordance with a particular example of an indoor/outdoor polyurethane backed area rug having a structure like that of FIG. 2, a tufted face greige carpet material (no precoat) had a cut pile, Nylon 6,6, jet dyed, 20 oz/yd2 face yarn, 8th gauge, tufted through a 4 oz/yd2 non-woven, polyester primary backing, was laid over a mechanically frothed, MDI based polyurethane at a 750 gram cup weight and an average add-on of 27 oz/yd2. The uncured polyurethane composition was poured onto a belt, doctored and then joined to the carpet greige goods under a marriage roll. The polyurethane was cured under heat.
In accordance with another example, an indoor/outdoor polyurethane backed area rug had an overall average height of about 7458.03pm (micrometers), an average polyurethane backing height of about 1507.64 pm (micrometers), and a total weight of about 51.79 oz/yd2.
In accordance with at least selected embodiments of the present invention, a nip, marriage, or gauge roll 62 (FIG. 1), 162, (FIG. 6), 262 (FIG. 11), 362 (FIG. 16) presses the face material 20, 120, 220, 320 into the uncured polyurethane composition and sets the height of the total product (prior to any chemical blowing).
In accordance with a particular example of an indoor/outdoor polyurethane backed area rug having a structure like that of FIG. 2, a tufted face greige carpet material (no precoat) had a cut pile, Nylon 6,6, jet dyed, 20 oz/yd2 face yarn, 8th gauge, tufted through a 4 oz/yd2 non-woven, polyester primary backing, was laid over a mechanically frothed, MDI based polyurethane at a 750 gram cup weight and an average add-on of 27 oz/yd2. The uncured polyurethane composition was poured onto a belt, doctored and then joined to the carpet greige goods under a marriage roll. The polyurethane was cured under heat.
In accordance with another example, an indoor/outdoor polyurethane backed area rug had an overall average height of about 7458.03pm (micrometers), an average polyurethane backing height of about 1507.64 pm (micrometers), and a total weight of about 51.79 oz/yd2.
In accordance with at least selected embodiments of the present invention, a nip, marriage, or gauge roll 62 (FIG. 1), 162, (FIG. 6), 262 (FIG. 11), 362 (FIG. 16) presses the face material 20, 120, 220, 320 into the uncured polyurethane composition and sets the height of the total product (prior to any chemical blowing).
34 PCT/US2007/021430 The surface covering of the present invention may in at least one embodiment be 6 foot wide roll goods sometimes referred to a 6 foot broadloom.
In accordance with at least selected embodiments, gravitational forces should dominate the sum of other process induced forces. Examples of these other forces are tensions or thermal contractions from cooling.
The gravity model on a cantilever beam:
Eqn. 1 qL4 ~B 8EI
This can be simplified for carpet tile applications by:
Eqn. 2 - WL4 SB 864Et3 Where:
W = the carpet weight (lbs/yd 2) L Length of overhang (use 6" as a constant) E Young's Modulus (Q / s) for the composite t the bound thickness (in.) - do not include the pile height 8= the maximum deflection of the beam (in.) One can measure the weight (W), deflection (in.), and thickness (in.) in order to calculate the modulus (psi or pounds per square inch).
Assume W is held constant at 8 Ibs/yd2 (or 128 oz/yd2). Further assume t is held constant at 0.20 in. One can then see the relationship between 8 and E.
If we now hold the Modulus constant (e.g., E=1,000 psi), one can illustrate the relationship between 8 and t.
Finally, one can hold thickness and modulus constant and illustrate the
In accordance with at least selected embodiments, gravitational forces should dominate the sum of other process induced forces. Examples of these other forces are tensions or thermal contractions from cooling.
The gravity model on a cantilever beam:
Eqn. 1 qL4 ~B 8EI
This can be simplified for carpet tile applications by:
Eqn. 2 - WL4 SB 864Et3 Where:
W = the carpet weight (lbs/yd 2) L Length of overhang (use 6" as a constant) E Young's Modulus (Q / s) for the composite t the bound thickness (in.) - do not include the pile height 8= the maximum deflection of the beam (in.) One can measure the weight (W), deflection (in.), and thickness (in.) in order to calculate the modulus (psi or pounds per square inch).
Assume W is held constant at 8 Ibs/yd2 (or 128 oz/yd2). Further assume t is held constant at 0.20 in. One can then see the relationship between 8 and E.
If we now hold the Modulus constant (e.g., E=1,000 psi), one can illustrate the relationship between 8 and t.
Finally, one can hold thickness and modulus constant and illustrate the
35 PCT/US2007/021430 relationship of 8 and W.
Note that in each of these examples the equations assume that the angle of deflection is small such that the trigonometric approximation of sin (Y) = Y.
In this case, we want large deflections, so these become qualitative rather than quantitative figures.
In accordance with at least one aspect of the present invention, we want to increase weight, reduce thickness, and reduce modulus of the composite.
The combination of a thin and heavy backing requires that the backing materials are characterized by higher density. This may be achieved by the selection of dense raw materials such as dense fillers. For example, CaCO3 is a common filler used in floor covering products. It has a specific gravity (SG) of 2.6.
If a filler is selected with a SG greater than 5 and the concentration by weight remained the same (>50%), then a significant shift in the compound density would occur.
If the choice was Iron (Fe) with a SG of 7.8 and with a concentration of 70%, then the density could be nearly tripled resulting in a 2/3 reduction in thickness at the same backing weight.
In accordance with at least another aspect of the present invention, we want to increase weight, reduce thickness, increase flexibility, increase resilience, and reduce modulus of the composite. The combination of a thin and heavy backing may require that the backing materials are characterized by higher density. This may be achieved by the selection of dense raw materials such as dense fillers. For example, CaCO3 is a common filler used in floor covering products. It has a specific gravity (SG) of 2.6. If a filler is selected with a SG greater than 5 and the concentration by weight remained the same (>50%), then a significant shift in the compound density would occur. If the choice was Iron (Fe) with a SG of 7.8 and with a concentration of 70%, then the density could be nearly tripled resulting in a 2/3 reduction in thickness at the same backing weight.
If a ferromagnetic material is selected as the filler, it creates the option of selectively creating permanent magnetic properties in the backing. A magnetron located on or after the production range could be switched on/off to produce the
Note that in each of these examples the equations assume that the angle of deflection is small such that the trigonometric approximation of sin (Y) = Y.
In this case, we want large deflections, so these become qualitative rather than quantitative figures.
In accordance with at least one aspect of the present invention, we want to increase weight, reduce thickness, and reduce modulus of the composite.
The combination of a thin and heavy backing requires that the backing materials are characterized by higher density. This may be achieved by the selection of dense raw materials such as dense fillers. For example, CaCO3 is a common filler used in floor covering products. It has a specific gravity (SG) of 2.6.
If a filler is selected with a SG greater than 5 and the concentration by weight remained the same (>50%), then a significant shift in the compound density would occur.
If the choice was Iron (Fe) with a SG of 7.8 and with a concentration of 70%, then the density could be nearly tripled resulting in a 2/3 reduction in thickness at the same backing weight.
In accordance with at least another aspect of the present invention, we want to increase weight, reduce thickness, increase flexibility, increase resilience, and reduce modulus of the composite. The combination of a thin and heavy backing may require that the backing materials are characterized by higher density. This may be achieved by the selection of dense raw materials such as dense fillers. For example, CaCO3 is a common filler used in floor covering products. It has a specific gravity (SG) of 2.6. If a filler is selected with a SG greater than 5 and the concentration by weight remained the same (>50%), then a significant shift in the compound density would occur. If the choice was Iron (Fe) with a SG of 7.8 and with a concentration of 70%, then the density could be nearly tripled resulting in a 2/3 reduction in thickness at the same backing weight.
If a ferromagnetic material is selected as the filler, it creates the option of selectively creating permanent magnetic properties in the backing. A magnetron located on or after the production range could be switched on/off to produce the
36 PCT/US2007/021430 optional magnetic property. If the ferromagnetic material is an oxide, such as ferrite, then the material will not only be dense and magnetizable, but will also starve a fire event from oxygen and self extinguish.
In accordance with at least selected embodiments, an exemplary surface covering such as a lay flat flooring product or tile has an upper show surface and a backing. It is preferred that the show surface such as a carpet or textile material be bonded to the backing during manufacture of the surface covering.
The backing preferably has a very low bending modulus (very flexible), a high density, is thin, and is resilient. Flexibility (low modulus) and high density (heavy) may be the two most important factors that effect tile flatness.
The face or upper show surface is preferably an aesthetically pleasing carpet or textile material. For example, a graphics tufted, printed, dyed, or the like decorative carpet or textile (tufted, woven, bonded, nonwoven, flocked, needled, knit, or the like) of natural and/or synthetic fibers such as wool, polyamide (Nylon), polyester, polyolefin, blends, and the like.
Preferably, the face exits the manufacturing process with substantially zero tension and resists growth or shrinkage during product use.
It is contemplated that the lay flat product may be any desired shape and may be in the form of roll goods, modular product, 6-foot broadloom, 12-foot broadloom, carpet, carpet tile, flooring, floor tile, floor covering, floor mat, stabilized broadloom, rug, runner, or the like. For example, a 6-foot wide roll of lay flat composite may be cut into tiles, rugs, mats, runners, and/or the like. The face 12 is not limited to a precoated carpet or greige goods (non-precoated) face material although such a face may be preferred. Also, it may be possibly preferred that the face be range dyed (jet dyed) prior to lamination or backing to further reduce any latent stresses or tensions in the face. Further, lamination or backing of the face may be carried out at a low enough temperature and the face material or materials (for example, primary backing and tufts) may be selected to avoid the addition of stresses or instability (such as shrinkage) during processing, backing, lamination, curing, etc.
In accordance with possibly preferred embodiments, the backing includes one or more stabilizing layers, backing layers, foam or cushion layers, a friction
In accordance with at least selected embodiments, an exemplary surface covering such as a lay flat flooring product or tile has an upper show surface and a backing. It is preferred that the show surface such as a carpet or textile material be bonded to the backing during manufacture of the surface covering.
The backing preferably has a very low bending modulus (very flexible), a high density, is thin, and is resilient. Flexibility (low modulus) and high density (heavy) may be the two most important factors that effect tile flatness.
The face or upper show surface is preferably an aesthetically pleasing carpet or textile material. For example, a graphics tufted, printed, dyed, or the like decorative carpet or textile (tufted, woven, bonded, nonwoven, flocked, needled, knit, or the like) of natural and/or synthetic fibers such as wool, polyamide (Nylon), polyester, polyolefin, blends, and the like.
Preferably, the face exits the manufacturing process with substantially zero tension and resists growth or shrinkage during product use.
It is contemplated that the lay flat product may be any desired shape and may be in the form of roll goods, modular product, 6-foot broadloom, 12-foot broadloom, carpet, carpet tile, flooring, floor tile, floor covering, floor mat, stabilized broadloom, rug, runner, or the like. For example, a 6-foot wide roll of lay flat composite may be cut into tiles, rugs, mats, runners, and/or the like. The face 12 is not limited to a precoated carpet or greige goods (non-precoated) face material although such a face may be preferred. Also, it may be possibly preferred that the face be range dyed (jet dyed) prior to lamination or backing to further reduce any latent stresses or tensions in the face. Further, lamination or backing of the face may be carried out at a low enough temperature and the face material or materials (for example, primary backing and tufts) may be selected to avoid the addition of stresses or instability (such as shrinkage) during processing, backing, lamination, curing, etc.
In accordance with possibly preferred embodiments, the backing includes one or more stabilizing layers, backing layers, foam or cushion layers, a friction
37 PCT/US2007/021430 enhancing coating, magnetic or magnetizable particles, remains flexible at standard operating temperatures, and/or the like. In accordance with one example, the backing is a thin (less than about 5mm, preferably less than about 3mm), very flexible, dense, resilient, polymeric material.
In accordance with one example, the face is a jet dyed, tufted, polyamide (Nylon) 6 or 6,6 carpet face with a stable primary backing of, for example, woven and/or nonwoven polyamide (Nylon), polyester, and/or stabilized polypropylene.
It may be preferred that the carpet face has a tuft lock or precoat of the same material as backing, for example, a polyurethane precoat and a polyurethane backing, a combined single polyurethane coating that serves as both precoat and tiecoat, or precoat and backing, a nonfoam precoat and a foam backing, a nonfoam precoat and tiecoat and a foam backing, and/or the like.
In accordance with another example, a hardback floor tile has a flexible, heavy (dense), thin backing with the following preferred properties:
1. backing density - about 180 to 250 Ibs/ft3 (3-4 g/cc) 2. backing thickness - about 0.15 inch 3. tile drape - about 2 to 4 inches of drape on a 6 inch tile overhang In accordance with at least selected embodiments of other aspects of the present invention, it may be preferred:
1. To use an adhesive to join a greige tufted substrate to a polyurethane (PU) cushion structure that provides above average wet and dry tuft bind, and PU
lamination strength greater than the cohesion of the PU cushion.
1.1. Adhesive Physical Properties 1.1.1. High flexibility, low modulus (<3,000 psi) 1.1.2. non-PVC, non-latex 1.1.3. composite cuts easily with standard carpet knife 1.1.4. resin may be an aqueous emulsion, hot melt, or multipart reaction applied with a coating blade, film lamination, or in-situ extrusion at speeds greater than 50 fpm (feet per minute).
1.2. The adhesive should provide a moisture barrier in the composite structure.
In accordance with one example, the face is a jet dyed, tufted, polyamide (Nylon) 6 or 6,6 carpet face with a stable primary backing of, for example, woven and/or nonwoven polyamide (Nylon), polyester, and/or stabilized polypropylene.
It may be preferred that the carpet face has a tuft lock or precoat of the same material as backing, for example, a polyurethane precoat and a polyurethane backing, a combined single polyurethane coating that serves as both precoat and tiecoat, or precoat and backing, a nonfoam precoat and a foam backing, a nonfoam precoat and tiecoat and a foam backing, and/or the like.
In accordance with another example, a hardback floor tile has a flexible, heavy (dense), thin backing with the following preferred properties:
1. backing density - about 180 to 250 Ibs/ft3 (3-4 g/cc) 2. backing thickness - about 0.15 inch 3. tile drape - about 2 to 4 inches of drape on a 6 inch tile overhang In accordance with at least selected embodiments of other aspects of the present invention, it may be preferred:
1. To use an adhesive to join a greige tufted substrate to a polyurethane (PU) cushion structure that provides above average wet and dry tuft bind, and PU
lamination strength greater than the cohesion of the PU cushion.
1.1. Adhesive Physical Properties 1.1.1. High flexibility, low modulus (<3,000 psi) 1.1.2. non-PVC, non-latex 1.1.3. composite cuts easily with standard carpet knife 1.1.4. resin may be an aqueous emulsion, hot melt, or multipart reaction applied with a coating blade, film lamination, or in-situ extrusion at speeds greater than 50 fpm (feet per minute).
1.2. The adhesive should provide a moisture barrier in the composite structure.
38 PCT/US2007/021430 1.3. The adhesive may optionally contain recycled content.
1.3.1. >50% recycled content 1.3.2. preferably post consumer recycled content 1.4. The adhesive may optionally provide enhanced flammability resistance to meet vertical flammability tests.
1.4.1. IMO certification (cruise ships) 1.5. The adhesive may become an after life cycle "zipper" to separate the tufted substrate from the PU cushion structure.
1.5.1. zipper may be thermal 1.5.2. zipper may be mechanical 1.5.3. zipper may be chemical 1.6. The adhesive used above should be commercially competitive.
2. The composite using the adhesive can be recycled into item 1.3 or into the PU cushion.
2.1. Rather than separating components, carpet composite may be desized and integrated into the filler integral to the adhesive.
3. The PU cushion structure may be substituted with another cushion material that:
3.1. Provides economic advantage.
3.2. Enables an economically viable recyclable composite.
3.3. Possibly needled felt 3.4. Possibly resized end of life (EOL) carpet with binder 4. The PU cushion structure may be substituted with another material that:
4.1. Creates an optional hardback using the same (or expanded) capital investments for the adhesive from item 1.
4.2. Utilizes recycled content.
4.3. Provides a clear EOL recycling process.
4.4. Provides an economic advantage over competitive hardback.
4.5. Standard carpet knives easily cut the composite.
5. The aforementioned options may create improved products.
In accordance with at least certain other embodiments of other aspects of the present invention, it may be preferred:
1.3.1. >50% recycled content 1.3.2. preferably post consumer recycled content 1.4. The adhesive may optionally provide enhanced flammability resistance to meet vertical flammability tests.
1.4.1. IMO certification (cruise ships) 1.5. The adhesive may become an after life cycle "zipper" to separate the tufted substrate from the PU cushion structure.
1.5.1. zipper may be thermal 1.5.2. zipper may be mechanical 1.5.3. zipper may be chemical 1.6. The adhesive used above should be commercially competitive.
2. The composite using the adhesive can be recycled into item 1.3 or into the PU cushion.
2.1. Rather than separating components, carpet composite may be desized and integrated into the filler integral to the adhesive.
3. The PU cushion structure may be substituted with another cushion material that:
3.1. Provides economic advantage.
3.2. Enables an economically viable recyclable composite.
3.3. Possibly needled felt 3.4. Possibly resized end of life (EOL) carpet with binder 4. The PU cushion structure may be substituted with another material that:
4.1. Creates an optional hardback using the same (or expanded) capital investments for the adhesive from item 1.
4.2. Utilizes recycled content.
4.3. Provides a clear EOL recycling process.
4.4. Provides an economic advantage over competitive hardback.
4.5. Standard carpet knives easily cut the composite.
5. The aforementioned options may create improved products.
In accordance with at least certain other embodiments of other aspects of the present invention, it may be preferred:
39 PCT/US2007/021430 1. To use an adhesive to join a greige tufted substrate to a polyurethane (PU) cushion structure that provides above average wet and dry tuft bind, and PU lamination strength greater than the cohesion of the PU cushion.
1.1. The adhesive may provide a moisture barrier in the composite structure.
1.2. The adhesive may optionally contain recycled content.
1.3. The adhesive may optionally provide enhanced flammability resistance to meet vertical flammability tests.
1.4. The adhesive may become an after life cycle "zipper" to separate the tufted substrate from the PU cushion structure.
1.5. The adhesive should be commercially competitive.
2. The composite using the adhesive can be recycled into item 1.2.
3. The PU cushion structure may be substituted with another material that:
3.1. Provides economic advantage.
3.2. Enables an economically viable recyclable composite.
4. The PU cushion structure may be substituted with another material that:
4.1. Creates an optional hardback using the same (or expanded) capital investments for the adhesive from item 1.
4.2. U EV824804738UStilizes recycled content.
4.3. Provides a clear recycling process.
4.4. Provides an economic advantage over competitive hardback.
5. The aforementioned options may create improved products.
6. The aforementioned options should meet customer expectations of fitness for use including installation.
In accordance with yet another example, a lay flat flooring product has a backing that is flexible, dense, thin, and resilient, flexible - product drape greater than about 2 inches of drape on a 6-inch product overhang or a bending modulus less than about 2000 psi;
dense - backing density of greater than about 20 Ibs/ft3;
thin - backing height (thickness) of less than about 10 mm;
1.1. The adhesive may provide a moisture barrier in the composite structure.
1.2. The adhesive may optionally contain recycled content.
1.3. The adhesive may optionally provide enhanced flammability resistance to meet vertical flammability tests.
1.4. The adhesive may become an after life cycle "zipper" to separate the tufted substrate from the PU cushion structure.
1.5. The adhesive should be commercially competitive.
2. The composite using the adhesive can be recycled into item 1.2.
3. The PU cushion structure may be substituted with another material that:
3.1. Provides economic advantage.
3.2. Enables an economically viable recyclable composite.
4. The PU cushion structure may be substituted with another material that:
4.1. Creates an optional hardback using the same (or expanded) capital investments for the adhesive from item 1.
4.2. U EV824804738UStilizes recycled content.
4.3. Provides a clear recycling process.
4.4. Provides an economic advantage over competitive hardback.
5. The aforementioned options may create improved products.
6. The aforementioned options should meet customer expectations of fitness for use including installation.
In accordance with yet another example, a lay flat flooring product has a backing that is flexible, dense, thin, and resilient, flexible - product drape greater than about 2 inches of drape on a 6-inch product overhang or a bending modulus less than about 2000 psi;
dense - backing density of greater than about 20 Ibs/ft3;
thin - backing height (thickness) of less than about 10 mm;
40 PCT/US2007/021430 resilient - product can be rolled or folded at least once and will go back to a lay flat position.
In accordance with still another example, a lay flat hardback flooring product has a backing that is flexible, dense, thin, and resilient, flexible - product drape greater than about 3 inches of drape on a 6-inch product overhang or a bending modulus less than about 1000 psi;
dense - backing density of greater than about 50 Ibs/ft3;
thin - backing height (thickness) of less than about 5 mm;
resilient - product can be rolled or folded several times and will go back to a lay flat position.
In accordance with still another example, a lay flat cushion back flooring product has a backing that is flexible, dense, thin, and resilient, flexible - product drape greater than about 2 inches of drape on a 6-inch product overhang or a bending modulus less than about 3000 psi;
dense - backing density of greater than about 15 Ibs/ft3;
thin - backing height (thickness) of less than about 15 mm;
resilient - product can be rolled or folded at least once and will go back to a lay flat position.
In accordance with a possibly preferred example, a lay flat hardback flooring product has a backing that is flexible, dense, thin, and resilient, flexible - product drape greater than about 4 inches of drape on a 6-inch product overhang or a bending modulus less than about 500 psi;
dense - backing density of greater than about 200 Ibs/ft3;
thin - backing height (thickness) of less than about 3 mm;
resilient - product can be rolled or folded many times and will go back to a lay flat position.
In accordance with yet another example, a lay flat carpet tile product has a backing that is flexible, dense, thin, and resilient, flexible - product drape greater than about 2 inches of drape on a 6-inch product overhang;
dense - backing density of greater than about 25 Ibs/ft3;
thin - backing height (thickness) of less than about 5 mm;
In accordance with still another example, a lay flat hardback flooring product has a backing that is flexible, dense, thin, and resilient, flexible - product drape greater than about 3 inches of drape on a 6-inch product overhang or a bending modulus less than about 1000 psi;
dense - backing density of greater than about 50 Ibs/ft3;
thin - backing height (thickness) of less than about 5 mm;
resilient - product can be rolled or folded several times and will go back to a lay flat position.
In accordance with still another example, a lay flat cushion back flooring product has a backing that is flexible, dense, thin, and resilient, flexible - product drape greater than about 2 inches of drape on a 6-inch product overhang or a bending modulus less than about 3000 psi;
dense - backing density of greater than about 15 Ibs/ft3;
thin - backing height (thickness) of less than about 15 mm;
resilient - product can be rolled or folded at least once and will go back to a lay flat position.
In accordance with a possibly preferred example, a lay flat hardback flooring product has a backing that is flexible, dense, thin, and resilient, flexible - product drape greater than about 4 inches of drape on a 6-inch product overhang or a bending modulus less than about 500 psi;
dense - backing density of greater than about 200 Ibs/ft3;
thin - backing height (thickness) of less than about 3 mm;
resilient - product can be rolled or folded many times and will go back to a lay flat position.
In accordance with yet another example, a lay flat carpet tile product has a backing that is flexible, dense, thin, and resilient, flexible - product drape greater than about 2 inches of drape on a 6-inch product overhang;
dense - backing density of greater than about 25 Ibs/ft3;
thin - backing height (thickness) of less than about 5 mm;
41 PCT/US2007/021430 resilient - product can be rolled or folded at least once and will go back to a lay flat position.
In accordance with still another example, a lay flat roll goods product has a backing that is flexible, dense, thin, and resilient, flexible - product drape greater than about 4 inches of drape on a 6-inch product overhang;
dense - backing density of greater than about 100 Ibs/ft3;
thin - backing height (thickness) of less than about 5 mm;
resilient - product can be rolled or folded several times and will go back to a lay flat position.
In accordance with yet another example, a lay flat floor mat product has a backing that is flexible, dense, thin, and resilient, flexible - product drape greater than about 2 inches of drape on a 6-inch product overhang;
dense - backing density of greater than about 50 Ibs/ft3;
thin - backing height (thickness) of less than about 5 mm;
resilient - product can be rolled or folded at least once and will go back to a lay flat position.
In accordance with a possibly preferred embodiment, a lay flat flooring product includes a face material and a backing bonded thereto during product manufacture.
In accordance with another example, a lay flat flooring product is a laminated composite of a face, a backing, and an adhesive layer there between.
The adhesive may be the same material as the backing, may be less filled or unfilled, or may be of a different material. Preferably, the adhesive is flexible, resilient, and thin.
In accordance with one object of the present invention, there is provided a lay flat flooring product comprising an upper show surface disposed in overlying relation to a single or multi-layer, flexible, heavy, thin backing, said backing having at least one of a bending modulus of less than about 3,000 psi, a thickness of less than about 15 mm, and a density of greater than about 15 Ibs/ft3.
In accordance with still another example, a lay flat roll goods product has a backing that is flexible, dense, thin, and resilient, flexible - product drape greater than about 4 inches of drape on a 6-inch product overhang;
dense - backing density of greater than about 100 Ibs/ft3;
thin - backing height (thickness) of less than about 5 mm;
resilient - product can be rolled or folded several times and will go back to a lay flat position.
In accordance with yet another example, a lay flat floor mat product has a backing that is flexible, dense, thin, and resilient, flexible - product drape greater than about 2 inches of drape on a 6-inch product overhang;
dense - backing density of greater than about 50 Ibs/ft3;
thin - backing height (thickness) of less than about 5 mm;
resilient - product can be rolled or folded at least once and will go back to a lay flat position.
In accordance with a possibly preferred embodiment, a lay flat flooring product includes a face material and a backing bonded thereto during product manufacture.
In accordance with another example, a lay flat flooring product is a laminated composite of a face, a backing, and an adhesive layer there between.
The adhesive may be the same material as the backing, may be less filled or unfilled, or may be of a different material. Preferably, the adhesive is flexible, resilient, and thin.
In accordance with one object of the present invention, there is provided a lay flat flooring product comprising an upper show surface disposed in overlying relation to a single or multi-layer, flexible, heavy, thin backing, said backing having at least one of a bending modulus of less than about 3,000 psi, a thickness of less than about 15 mm, and a density of greater than about 15 Ibs/ft3.
42 PCT/US2007/021430 In accordance with yet another object of the present invention, there is provided a method of producing a lay flat flooring product such as a lay flat tile or roll goods product with a carpet or textile face and a flexible, heavy, thin, resilient backing, comprising the steps of: preparing a backing composition; depositing the backing composition in a layer; placing a carpet or textile face material on the deposited backing layer to form a multi-layer structure; setting or curing the backing so that the backing composition forms a flexible, heavy, thin, resilient backing, and wherein the carpet or textile face material is bonded to the backing.
In accordance with at least one embodiment, a surface covering such as a lay flat flooring product comprises an upper show surface disposed in overlying relation to a single or multi-layer, flexible, heavy, thin backing.
The surface covering above further comprising a fibrous backing sheet disposed across an underside portion of the backing.
The surface covering above, wherein the surface covering is a tile or roll goods.
The surface covering above, wherein the show surface is a decorative textile or carpet layer.
The surface covering above, wherein the carpet or textile is formed of polyester, Nylon, polyolefin, and combinations thereof.
The surface covering above, wherein the carpet or textile is knit, woven, tufted, bonded, nonwoven, needled, and the like.
The surface covering above, wherein the backing is resilient.
The surface covering above, wherein the show surface is disposed in overlying relation to a multi-layer backing.
The surface covering above, wherein the backing includes at least one stabilizing layer.
The surface covering above, wherein said stabilizing layer is at least one of woven or nonwoven glass.
The surface covering above, further comprising a fibrous backing sheet disposed across an underside portion of the backing.
In accordance with at least one embodiment, a surface covering such as a lay flat flooring product comprises an upper show surface disposed in overlying relation to a single or multi-layer, flexible, heavy, thin backing.
The surface covering above further comprising a fibrous backing sheet disposed across an underside portion of the backing.
The surface covering above, wherein the surface covering is a tile or roll goods.
The surface covering above, wherein the show surface is a decorative textile or carpet layer.
The surface covering above, wherein the carpet or textile is formed of polyester, Nylon, polyolefin, and combinations thereof.
The surface covering above, wherein the carpet or textile is knit, woven, tufted, bonded, nonwoven, needled, and the like.
The surface covering above, wherein the backing is resilient.
The surface covering above, wherein the show surface is disposed in overlying relation to a multi-layer backing.
The surface covering above, wherein the backing includes at least one stabilizing layer.
The surface covering above, wherein said stabilizing layer is at least one of woven or nonwoven glass.
The surface covering above, further comprising a fibrous backing sheet disposed across an underside portion of the backing.
43 PCT/US2007/021430 In accordance with at least one embodiment, a method of producing a surface covering such as a lay flat flooring product with a carpet or textile surface and a flexible, heavy, thin, resilient backing, comprises the steps of:
preparing a backing composition; depositing the backing composition in a layer; placing a carpet or textile surface material on the deposited backing layer to form a multi-layer structure; pressing the multi-layer structure while setting the backing with, for.example, heat so that the backing composition forms a flexible, heavy, thin, resilient backing, and wherein the carpet or textile surface material is bonded to the backing.
The method above wherein the carpet or textile surface material is at least one of graphics tufted, printed or dyed.
The method above wherein one or more additional layers are added in, over or under the backing composition layer.
In at least one embodiment, there is provided a surface covering such as a lay flat flooring product having an upper show surface disposed in overlying relation to a single or multi-layer, flexible, heavy, thin, resilient backing.
A fibrous backing sheet may be disposed across an underside of the backing. The surface covering may be a tile or roll goods. The show surface may be a decorative textile or carpet layer.
In accordance with at least one example, a lay flat flooring product comprises an upper show surface disposed in overlying relation to a single or multi-layer, flexible, heavy, thin backing, said backing having at least one of a bending modulus of less than about 3,000 psi, a thickness of less than about mm, and a density of greater than about 15 Ibs/ft3.
The product above further comprises a flexible fibrous backing sheet disposed at a position below an underside of the backing.
The product above, wherein the flooring product is one of a tile and roll goods.
The product above, wherein the show surface is a decorative textile or carpet layer.
preparing a backing composition; depositing the backing composition in a layer; placing a carpet or textile surface material on the deposited backing layer to form a multi-layer structure; pressing the multi-layer structure while setting the backing with, for.example, heat so that the backing composition forms a flexible, heavy, thin, resilient backing, and wherein the carpet or textile surface material is bonded to the backing.
The method above wherein the carpet or textile surface material is at least one of graphics tufted, printed or dyed.
The method above wherein one or more additional layers are added in, over or under the backing composition layer.
In at least one embodiment, there is provided a surface covering such as a lay flat flooring product having an upper show surface disposed in overlying relation to a single or multi-layer, flexible, heavy, thin, resilient backing.
A fibrous backing sheet may be disposed across an underside of the backing. The surface covering may be a tile or roll goods. The show surface may be a decorative textile or carpet layer.
In accordance with at least one example, a lay flat flooring product comprises an upper show surface disposed in overlying relation to a single or multi-layer, flexible, heavy, thin backing, said backing having at least one of a bending modulus of less than about 3,000 psi, a thickness of less than about mm, and a density of greater than about 15 Ibs/ft3.
The product above further comprises a flexible fibrous backing sheet disposed at a position below an underside of the backing.
The product above, wherein the flooring product is one of a tile and roll goods.
The product above, wherein the show surface is a decorative textile or carpet layer.
44 PCT/US2007/021430 The product above, wherein the show surface is formed of a material selected from polyester, polyamide (Nylon), polyolefin, and combinations thereof.
The product above, wherein the show surface is one of knit, woven, tufted, bonded, nonwoven, needled, graphics tufted, printed, dyed, and combinations thereof.
The product above, wherein the backing is resilient.
The product above, wherein the show surface is disposed in overlying relation to a multi-layer backing.
The product above, wherein the backing includes at least one stabilizing layer.
The product above, wherein said stabilizing layer is at least one of woven or nonwoven glass.
The product above, wherein said backing has a bending modulus of less than about 3,000 psi, a thickness of less than about 15 mm, and a density of greater than about 15 Ibs/ft3.
The product above, wherein said backing preferably has a bending modulus of less than about 2,000 psi, a thickness of less than about 10 mm, and a density of greater than about 20 Ibs/ft3.
The product above, wherein said backing has a bending modulus of less than about 1,000 psi, a thickness of less than about 5 mm, and a density of greater than about 50 Ibs/ft3.
The product above, wherein said backing has a bending modulus of less than about 1,000 psi, a thickness of less than about 4 mm, and a density of greater than about 100 Ibs/ft3.
The product above, wherein said backing has a bending modulus of less than about 500 psi, a thickness of less than about 3 mm, and a density of greater than about 200 Ibs/ft3.
In accordance with at least one embodiment, a method of producing a lay flat flooring product such as a lay flat tile or roll goods product with a carpet or textile face and a flexible, heavy, thin, resilient backing, comprising the steps of:
The product above, wherein the show surface is one of knit, woven, tufted, bonded, nonwoven, needled, graphics tufted, printed, dyed, and combinations thereof.
The product above, wherein the backing is resilient.
The product above, wherein the show surface is disposed in overlying relation to a multi-layer backing.
The product above, wherein the backing includes at least one stabilizing layer.
The product above, wherein said stabilizing layer is at least one of woven or nonwoven glass.
The product above, wherein said backing has a bending modulus of less than about 3,000 psi, a thickness of less than about 15 mm, and a density of greater than about 15 Ibs/ft3.
The product above, wherein said backing preferably has a bending modulus of less than about 2,000 psi, a thickness of less than about 10 mm, and a density of greater than about 20 Ibs/ft3.
The product above, wherein said backing has a bending modulus of less than about 1,000 psi, a thickness of less than about 5 mm, and a density of greater than about 50 Ibs/ft3.
The product above, wherein said backing has a bending modulus of less than about 1,000 psi, a thickness of less than about 4 mm, and a density of greater than about 100 Ibs/ft3.
The product above, wherein said backing has a bending modulus of less than about 500 psi, a thickness of less than about 3 mm, and a density of greater than about 200 Ibs/ft3.
In accordance with at least one embodiment, a method of producing a lay flat flooring product such as a lay flat tile or roll goods product with a carpet or textile face and a flexible, heavy, thin, resilient backing, comprising the steps of:
45 PCT/US2007/021430 preparing a backing composition; depositing the backing composition in a layer;
placing a carpet or textile face material on the deposited backing layer to form a multi-layer structure; setting or curing the backing so that the backing composition forms a flexible, heavy, thin, resilient backing, and wherein the carpet or textile face material is bonded to the backing.
The method above wherein the carpet or textile face material is at least one of graphics tufted, printed or dyed.
The method above further comprising the step of adding one or more additional layers in, over or under the backing composition.
In accordance with at least one embodiment, a method of producing a lay flat flooring product such as a lay flat tile or roll goods product with a carpet or textile face, and a flexible, heavy, thin, resilient backing, comprising the steps of:
preparing a backing composition; inverting a carpet or textile face material;
depositing the backing composition on the inverted face material to form a multi-layer structure; setting or curing the backing so that the backing composition forms a flexible, heavy, thin, resilient backing, and wherein the carpet or textile face material is bonded to the backing.
The method above, wherein the carpet or textile face material is at least one of graphics tufted, printed, and dyed.
The method above further comprising the step of adding one or more additional layers in, over or under the backing composition layer.
A lay flat flooring product produced by one of the methods above.
In accordance with at least selected examples, the preferred backing is filled polyurethane (greater than 50% by weight filled). Although less preferred, other materials which will provide a relatively heavy, thin, flexible, and resilient backing may be used. For example, rubber, latex, extruded polymers, hot melts, adhesives, films, acrylics, and the like may be used.
In accordance with at least selected examples, the preferred adhesive is an unfilled or lightly filled polyurethane (less than 20% by weight filled).
Although polyurethane adhesive is preferred, other known adhesives may be used. For
placing a carpet or textile face material on the deposited backing layer to form a multi-layer structure; setting or curing the backing so that the backing composition forms a flexible, heavy, thin, resilient backing, and wherein the carpet or textile face material is bonded to the backing.
The method above wherein the carpet or textile face material is at least one of graphics tufted, printed or dyed.
The method above further comprising the step of adding one or more additional layers in, over or under the backing composition.
In accordance with at least one embodiment, a method of producing a lay flat flooring product such as a lay flat tile or roll goods product with a carpet or textile face, and a flexible, heavy, thin, resilient backing, comprising the steps of:
preparing a backing composition; inverting a carpet or textile face material;
depositing the backing composition on the inverted face material to form a multi-layer structure; setting or curing the backing so that the backing composition forms a flexible, heavy, thin, resilient backing, and wherein the carpet or textile face material is bonded to the backing.
The method above, wherein the carpet or textile face material is at least one of graphics tufted, printed, and dyed.
The method above further comprising the step of adding one or more additional layers in, over or under the backing composition layer.
A lay flat flooring product produced by one of the methods above.
In accordance with at least selected examples, the preferred backing is filled polyurethane (greater than 50% by weight filled). Although less preferred, other materials which will provide a relatively heavy, thin, flexible, and resilient backing may be used. For example, rubber, latex, extruded polymers, hot melts, adhesives, films, acrylics, and the like may be used.
In accordance with at least selected examples, the preferred adhesive is an unfilled or lightly filled polyurethane (less than 20% by weight filled).
Although polyurethane adhesive is preferred, other known adhesives may be used. For
46 PCT/US2007/021430 example, hot melts, polymers, polyolefins, extruded polymers, acrylics, or the like.
In accordance with at least selected examples, the preferred fillers are dense fillers having, for example, a specific gravity (SG) greater than 2.
Exemplary fillers include magnetite, iron oxides, ferrite, iron, steel, nickel, metals, recycled metals, barite, sand, foundry sand, used foundry sand, glass, recycled glass, recycled soda lime glass, glass particles, glass fibers, gypsum, recycled gypsum, coal fly ash, calcium carbonate, blends and combinations thereof.
Fillers are typically added in amounts by weight totaling from 0% to about 95%.
In accordance with at least one embodiment, fillers with a specific gravity (SG) over 5 are preferred (such as iron oxide).
In accordance with at least one other embodiment, magnetic or magnetizable filler materials are preferred. Such ferromagnetic fillers may be added at 5% by weight or greater filler loads, preferably 10% or greater by weight.
In accordance with at least one example, a method of producing a lay flat product includes the steps of:
1. Producing a substantially tensionless face;
2. Treating the face to remove stresses;
3. Laminating or backing the face;
4. Selectively magnetizing the composite; and 5. Rolling or cutting the composite to form lay flat products.
In accordance with at least one object of the present invention, there is provided a floor covering product comprising a textile face structure disposed in overlying contacting relation to at least one layer of polyurethane backing composition filled with at least one filler selected from calcium carbonate, sand, used foundry sand, recycled gypsum, recycled glass, glass particles, glass fibers, cork, coal fly ash, recycled metal, rubber, recycled rubber, and combinations thereof.
In accordance with at least selected examples, the preferred fillers are dense fillers having, for example, a specific gravity (SG) greater than 2.
Exemplary fillers include magnetite, iron oxides, ferrite, iron, steel, nickel, metals, recycled metals, barite, sand, foundry sand, used foundry sand, glass, recycled glass, recycled soda lime glass, glass particles, glass fibers, gypsum, recycled gypsum, coal fly ash, calcium carbonate, blends and combinations thereof.
Fillers are typically added in amounts by weight totaling from 0% to about 95%.
In accordance with at least one embodiment, fillers with a specific gravity (SG) over 5 are preferred (such as iron oxide).
In accordance with at least one other embodiment, magnetic or magnetizable filler materials are preferred. Such ferromagnetic fillers may be added at 5% by weight or greater filler loads, preferably 10% or greater by weight.
In accordance with at least one example, a method of producing a lay flat product includes the steps of:
1. Producing a substantially tensionless face;
2. Treating the face to remove stresses;
3. Laminating or backing the face;
4. Selectively magnetizing the composite; and 5. Rolling or cutting the composite to form lay flat products.
In accordance with at least one object of the present invention, there is provided a floor covering product comprising a textile face structure disposed in overlying contacting relation to at least one layer of polyurethane backing composition filled with at least one filler selected from calcium carbonate, sand, used foundry sand, recycled gypsum, recycled glass, glass particles, glass fibers, cork, coal fly ash, recycled metal, rubber, recycled rubber, and combinations thereof.
47 PCT/US2007/021430 In accordance with at least one object of the present invention, there is provided a method of forming combinations of floor covering products selected from carpet, carpet tiles, area rugs, floor tiles, runners, mats, and floor mats on a single processing line, the method comprising the steps of:
(a) delivering a mass of polyurethane forming composition onto an endless belt;
(b) leveling the polyurethane forming composition to a desired thickness;
(c) placing a preformed textile face structure into overlying contacting relation with the leveled polyurethane forming composition;
(d) curing the polyurethane forming composition in place across the underside of the textile face structure; and (e) cutting the composite of textile face structure with cured polyurethane to at least two different sizes.
In accordance with at least one object of the present invention, there is provided a system of polyurethane backed floor covering products such as tiles, mats, roll goods, and the like produced on a single polyurethane range.
The system of floor covering products above wherein each such product includes at least 10% by weight recycled content.
The system of floor covering products above wherein each such product includes at least 10% by weight post consumer recycled content.
In accordance with at least one embodiment, a surface covering such as a floor covering comprises a textile face structure disposed in overlying contacting relation to a layer of filled polyurethane.
The surface covering above further comprising a backing disposed across a side of the layer of polyurethane facing away from the textile face structure.
The surface covering above further comprises a structural support layer disposed in embedded relation within the layer of polyurethane.
(a) delivering a mass of polyurethane forming composition onto an endless belt;
(b) leveling the polyurethane forming composition to a desired thickness;
(c) placing a preformed textile face structure into overlying contacting relation with the leveled polyurethane forming composition;
(d) curing the polyurethane forming composition in place across the underside of the textile face structure; and (e) cutting the composite of textile face structure with cured polyurethane to at least two different sizes.
In accordance with at least one object of the present invention, there is provided a system of polyurethane backed floor covering products such as tiles, mats, roll goods, and the like produced on a single polyurethane range.
The system of floor covering products above wherein each such product includes at least 10% by weight recycled content.
The system of floor covering products above wherein each such product includes at least 10% by weight post consumer recycled content.
In accordance with at least one embodiment, a surface covering such as a floor covering comprises a textile face structure disposed in overlying contacting relation to a layer of filled polyurethane.
The surface covering above further comprising a backing disposed across a side of the layer of polyurethane facing away from the textile face structure.
The surface covering above further comprises a structural support layer disposed in embedded relation within the layer of polyurethane.
48 PCT/US2007/021430 The surface covering above, further comprises a structural support layer disposed in embedded relation within the layer of polyurethane and a backing disposed across a side of the layer of polyurethane facing away from the textile face structure.
The surface covering above, wherein the surface covering is a carpet tile, an area rug, or a floor mat.
In accordance with at least one embodiment, a method of forming combinations of the group consisting of carpet, carpet tile, area rugs and floor mats on a single processing line, the method comprises the steps of:
(a) delivering a mass of polyurethane forming composition onto an endless belt;
(b) leveling the polyurethane forming composition to a desired thickness;
(c) placing a preformed textile face structure into overlying contacting relation with the leveled polyurethane forming composition;
(d) curing the polyurethane forming composition in place across the underside of the textile face structure; and (e) cutting the composite of textile face structure with cured polyurethane to at least two different sizes.
In accordance with at least selected embodiments, there is provided a surface covering such as a carpet, carpet tile, area rug, floor mat or the like incorporating a textile face disposed in contacting overlying relation to at least a polyurethane layer. One or more optional intermediate structure layers may be disposed within, on, over, or under the polyurethane and one or more optional backing layers may be disposed across the underside of the polyurethane.
In accordance with at least one embodiment, a floor coveririg product comprises a textile face structure disposed in overlying contacting relation to at least one layer of polyurethane backing composition filled with at least one filler selected from calcium carbonate, sand, used foundry sand, recycled gypsum,
The surface covering above, wherein the surface covering is a carpet tile, an area rug, or a floor mat.
In accordance with at least one embodiment, a method of forming combinations of the group consisting of carpet, carpet tile, area rugs and floor mats on a single processing line, the method comprises the steps of:
(a) delivering a mass of polyurethane forming composition onto an endless belt;
(b) leveling the polyurethane forming composition to a desired thickness;
(c) placing a preformed textile face structure into overlying contacting relation with the leveled polyurethane forming composition;
(d) curing the polyurethane forming composition in place across the underside of the textile face structure; and (e) cutting the composite of textile face structure with cured polyurethane to at least two different sizes.
In accordance with at least selected embodiments, there is provided a surface covering such as a carpet, carpet tile, area rug, floor mat or the like incorporating a textile face disposed in contacting overlying relation to at least a polyurethane layer. One or more optional intermediate structure layers may be disposed within, on, over, or under the polyurethane and one or more optional backing layers may be disposed across the underside of the polyurethane.
In accordance with at least one embodiment, a floor coveririg product comprises a textile face structure disposed in overlying contacting relation to at least one layer of polyurethane backing composition filled with at least one filler selected from calcium carbonate, sand, used foundry sand, recycled gypsum,
49 PCT/US2007/021430 recycled glass, glass particles, glass fibers, cork, coal fly ash, recycled metal, rubber, recycled rubber, and combinations thereof.
The product above further comprises a backing material disposed at a position below an underside of the layer of polyurethane and operatively bonded thereto.
The product above further comprises at least one structural support layer disposed in, on or over said layer of polyurethane.
The product above further comprises a structural support layer disposed in embedded relation within the layer of polyurethane and a backing material disposed across an underside of the layer of polyurethane.
The product above, wherein the floor covering product is a product selected from carpet, carpet tiles, floor tiles, rugs, mats, floor mats, modular product, roll goods, broadloom carpet, 6 foot broadloom, 12 foot broadloom, runners, and area rugs.
The product above, wherein at least one filler in said layer of polyurethane is post consumer recycled soda lime glass, said recycled soda lime glass having a pH in deionized water of greater than 8.4 and an average particle size of greater than 325 mesh.
The product above, wherein the floor covering product is an outdoor product.
The product above, wherein the floor covering product is an indoor/outdoor product.
The product above, wherein an underside of said layer of polyurethane is at least one of embossed, textured, and treated to enhance at least the sliding friction of said floor covering product with a floor or subfloor.
In accordance with at least one embodiment, a method of forming combinations of floor covering products selected from carpet, carpet tiles, area rugs, floor tiles, runners, mats, and floor mats on a single processing line, the method comprises the steps of:
The product above further comprises a backing material disposed at a position below an underside of the layer of polyurethane and operatively bonded thereto.
The product above further comprises at least one structural support layer disposed in, on or over said layer of polyurethane.
The product above further comprises a structural support layer disposed in embedded relation within the layer of polyurethane and a backing material disposed across an underside of the layer of polyurethane.
The product above, wherein the floor covering product is a product selected from carpet, carpet tiles, floor tiles, rugs, mats, floor mats, modular product, roll goods, broadloom carpet, 6 foot broadloom, 12 foot broadloom, runners, and area rugs.
The product above, wherein at least one filler in said layer of polyurethane is post consumer recycled soda lime glass, said recycled soda lime glass having a pH in deionized water of greater than 8.4 and an average particle size of greater than 325 mesh.
The product above, wherein the floor covering product is an outdoor product.
The product above, wherein the floor covering product is an indoor/outdoor product.
The product above, wherein an underside of said layer of polyurethane is at least one of embossed, textured, and treated to enhance at least the sliding friction of said floor covering product with a floor or subfloor.
In accordance with at least one embodiment, a method of forming combinations of floor covering products selected from carpet, carpet tiles, area rugs, floor tiles, runners, mats, and floor mats on a single processing line, the method comprises the steps of:
50 PCT/US2007/021430 (a) delivering a mass of polyurethane forming composition onto an endless belt;
(b) leveling the polyurethane forming composition to a desired thickness;
(c) placing a preformed textile face structure into overlying contacting relation with the leveled polyurethane forming composition;
(d) curing the polyurethane forming composition in place across the underside of the textile face structure; and (e) cutting the composite of textile face structure with cured polyurethane to at least two different sizes.
The method above further comprising the step of adding a release layer, material, or film over the belt prior to the delivering step.
At least two different floor covering products produced by the method above.
A system of polyurethane backed floor covering products as described above such as tiles, mats, roll goods, and the like produced on a single polyurethane range.
The system above, wherein each such product includes at least 10% by weight recycled content.
The system above, wherein.each such product includes at least 10% by weight post consumer recycled content.
If face material 20 must be dyed or printed, it is preferred that it be dyed prior to addition of polyurethane 14.
Polyurethane 14 may include a polyol component, an isocyanate component, a catalyst, and other agents, fillers, additives, and the like. It has been discovered that the catalyst may be eliminated, that the polyol may be replaced with castor oil, or both.
The surface coverings of the present invention may be hardback or cushion back products. One can increase the cushion or resilience of the
(b) leveling the polyurethane forming composition to a desired thickness;
(c) placing a preformed textile face structure into overlying contacting relation with the leveled polyurethane forming composition;
(d) curing the polyurethane forming composition in place across the underside of the textile face structure; and (e) cutting the composite of textile face structure with cured polyurethane to at least two different sizes.
The method above further comprising the step of adding a release layer, material, or film over the belt prior to the delivering step.
At least two different floor covering products produced by the method above.
A system of polyurethane backed floor covering products as described above such as tiles, mats, roll goods, and the like produced on a single polyurethane range.
The system above, wherein each such product includes at least 10% by weight recycled content.
The system above, wherein.each such product includes at least 10% by weight post consumer recycled content.
If face material 20 must be dyed or printed, it is preferred that it be dyed prior to addition of polyurethane 14.
Polyurethane 14 may include a polyol component, an isocyanate component, a catalyst, and other agents, fillers, additives, and the like. It has been discovered that the catalyst may be eliminated, that the polyol may be replaced with castor oil, or both.
The surface coverings of the present invention may be hardback or cushion back products. One can increase the cushion or resilience of the
51 PCT/US2007/021430 backing by adding more air, more blowing agent, felt, thickness, or the like.
It is possibly preferred that a polyurethane hardback or cushion back product such as a polyurethane hardback or cushion back carpet tile have the structure of one of FIGS. 2 - 5, 7- 10, 12 - 15, 17 - 20, and 21 - 26. It may also be preferred that a polyurethane backed area rug, roll goods, or floor mat of the present invention have the structure of one of FIGS. 2 - 5, 21, and 25.
In accordance with a particular example of an indoor/outdoor polyurethane backed area rug having a structure like that of FIG. 2, a tufted face greige carpet material (no precoat) had a cut pile, Nylon 6,6, jet dyed, 20 oz/yd2 face yarn, 8th gauge, tufted through a 4 oz/yd2 non-woven, polyester primary backing, was laid over a mechanically frothed, MDI based polyurethane at a 750 gram cup weight and an average add-on of 27 oz/yd2. The uncured polyurethane composition was poured onto a belt, doctored and then joined to the carpet greige goods under a marriage roll. The polyurethane was cured under heat.
In accordance with another example, an indoor/outdoor polyurethane backed area rug had an overall average height of about 7458.03Nm (micrometers), an average polyurethane backing height of about 1507.64 pm (micrometers), and a total weight of about 51.79 oz/yd2.
In accordance with at least selected embodiments of the present invention, a nip, marriage, or gauge roll 62 (FIG. 1), 162, (FIG. 6), 262 (FIG. 11), 362 (FIG. 16) presses the face material 20, 120, 220, 320 into the uncured polyurethane composition and sets the height of the total product (prior to any chemical blowing).
The surface covering of the present invention may in at least one embodiment be 6 foot wide roll goods sometimes referred to a 6 foot broadloom.
It has been discovered that unmodified castor oil which has preferably been filtered and/or dried (otherwise not chemically modified) serves as an excellent natural oil polyol (or major polyol), reduces or eliminates the need for an additional surfactant, wetting agent, or the like, and facilitates the addition of high filler loads.
It is possibly preferred that a polyurethane hardback or cushion back product such as a polyurethane hardback or cushion back carpet tile have the structure of one of FIGS. 2 - 5, 7- 10, 12 - 15, 17 - 20, and 21 - 26. It may also be preferred that a polyurethane backed area rug, roll goods, or floor mat of the present invention have the structure of one of FIGS. 2 - 5, 21, and 25.
In accordance with a particular example of an indoor/outdoor polyurethane backed area rug having a structure like that of FIG. 2, a tufted face greige carpet material (no precoat) had a cut pile, Nylon 6,6, jet dyed, 20 oz/yd2 face yarn, 8th gauge, tufted through a 4 oz/yd2 non-woven, polyester primary backing, was laid over a mechanically frothed, MDI based polyurethane at a 750 gram cup weight and an average add-on of 27 oz/yd2. The uncured polyurethane composition was poured onto a belt, doctored and then joined to the carpet greige goods under a marriage roll. The polyurethane was cured under heat.
In accordance with another example, an indoor/outdoor polyurethane backed area rug had an overall average height of about 7458.03Nm (micrometers), an average polyurethane backing height of about 1507.64 pm (micrometers), and a total weight of about 51.79 oz/yd2.
In accordance with at least selected embodiments of the present invention, a nip, marriage, or gauge roll 62 (FIG. 1), 162, (FIG. 6), 262 (FIG. 11), 362 (FIG. 16) presses the face material 20, 120, 220, 320 into the uncured polyurethane composition and sets the height of the total product (prior to any chemical blowing).
The surface covering of the present invention may in at least one embodiment be 6 foot wide roll goods sometimes referred to a 6 foot broadloom.
It has been discovered that unmodified castor oil which has preferably been filtered and/or dried (otherwise not chemically modified) serves as an excellent natural oil polyol (or major polyol), reduces or eliminates the need for an additional surfactant, wetting agent, or the like, and facilitates the addition of high filler loads.
52 PCT/US2007/021430 In accordance with selected embodiments, polyurethane compositions are formed of castor oil together with one or more optional additional polyols, an isocyanate, an optional filler or fillers, an optional catalyst, and other optional agents, fillers, extenders, coating agents, lubricants, or the like.
In accordance with at least selected embodiments, a carpet tile has a textile face structure disposed in overlying contacting relation to at least one layer of flexible, polyurethane backing composition consisting essentially of castor oil as major polyol, isocyanate, filler, and an optional catalyst, and an optional minor polyol, wherein the filler is at least 42% by weight of the composition and is selected from coal fly ash, recycled gypsum, recycled glass, and combinations thereof.
The carpet tile above, wherein the layer of flexible, polyurethane backing composition is at least one of a precoat, tiecoat, and backing.
The carpet tile above, further including at least one structural support layer disposed in, on, under, or over the layer of flexible, polyurethane backing composition.
In accordance with at least certain embodiments, a carpet tile has a textile face structure disposed in overlying contacting relation to at least one layer of flexible, polyurethane backing composition, the polyurethane composition being the reaction product of (i) a polyol component in which castor oil is the predominant reactive polyol; and (ii) an isocyanate component, and the polyurethane composition further comprising a filler, the filler being at least 42% by weight of the polyurethane composition and preferably being selected from coal fly ash, recycled gypsum, recycled glass, and combinations thereof.
The carpet tile above, wherein substantially the entire polyol component is castor oil, wherein the polyurethane composition is substantially free of surfactant, wherein the polyurethane composition is substantially free of catalyst,
In accordance with at least selected embodiments, a carpet tile has a textile face structure disposed in overlying contacting relation to at least one layer of flexible, polyurethane backing composition consisting essentially of castor oil as major polyol, isocyanate, filler, and an optional catalyst, and an optional minor polyol, wherein the filler is at least 42% by weight of the composition and is selected from coal fly ash, recycled gypsum, recycled glass, and combinations thereof.
The carpet tile above, wherein the layer of flexible, polyurethane backing composition is at least one of a precoat, tiecoat, and backing.
The carpet tile above, further including at least one structural support layer disposed in, on, under, or over the layer of flexible, polyurethane backing composition.
In accordance with at least certain embodiments, a carpet tile has a textile face structure disposed in overlying contacting relation to at least one layer of flexible, polyurethane backing composition, the polyurethane composition being the reaction product of (i) a polyol component in which castor oil is the predominant reactive polyol; and (ii) an isocyanate component, and the polyurethane composition further comprising a filler, the filler being at least 42% by weight of the polyurethane composition and preferably being selected from coal fly ash, recycled gypsum, recycled glass, and combinations thereof.
The carpet tile above, wherein substantially the entire polyol component is castor oil, wherein the polyurethane composition is substantially free of surfactant, wherein the polyurethane composition is substantially free of catalyst,
53 PCT/US2007/021430 wherein said layer of flexible, polyurethane backing composition is at least one of a precoat, tiecoat, backing, combined precoat/tiecoat, combined precoat/backing, combined tiecoat/backing, combined precoat/tiecoat/backing, and combinations thereof, further including at least one structural support layer disposed in, on, under, or over the layer of flexible, polyurethane backing composition, further comprising at least one backing layer disposed across the underside of said layer of flexible, polyurethane backing composition, wherein the filer component is at least 50% by weight of the polyurethane composition, further comprising a minor polyol component which is not castor oil, wherein the minor polyol component is selected from the group consisting of other natural and/or petrochemical polyols and combinations thereof, wherein the minor polyol component is present in an amount of less than about 50% by weight of the polyol component of the polyurethane composition, wherein the minor polyol component is present in an amount of less than about 10% by weight of the polyurethane composition, wherein the minor polyol component is present in an amount of less than about 7% by weight of the polyurethane composition, and/or wherein the minor polyol component is present in an amount of less than about % by weight of the polyurethane composition.
In accordance with at least one embodiment, a polyurethane for application to a tufted, woven, non-woven, bonded, needled, flocked, needle punched, or knit textile face structure, includes a polyol component, an isocyanate component, a catalyst and other agents, fillers, additives, and the like wherein the catalyst is eliminated, the polyol is replaced with castor oil, or both.
In at least one embodiment of a cured flexible polyurethane material, the polyurethane material is the reaction product of (i) a polyol component in which castor oil is the predominant reactive polyol; and (ii) an isocyanate component, and the polyurethane material further comprising a filler, the filler being at least 42% by weight of the polyurethane material.
In accordance with at least one embodiment, a polyurethane for application to a tufted, woven, non-woven, bonded, needled, flocked, needle punched, or knit textile face structure, includes a polyol component, an isocyanate component, a catalyst and other agents, fillers, additives, and the like wherein the catalyst is eliminated, the polyol is replaced with castor oil, or both.
In at least one embodiment of a cured flexible polyurethane material, the polyurethane material is the reaction product of (i) a polyol component in which castor oil is the predominant reactive polyol; and (ii) an isocyanate component, and the polyurethane material further comprising a filler, the filler being at least 42% by weight of the polyurethane material.
54 PCT/US2007/021430 In accordance with at least one embodiment of a cured flexible polyurethane material, the polyurethane material is the reaction product of (i) a polyol component; and (ii) an isocyanate component, and the polyurethane material further comprising a filler, the filler being at least 42% by weight of the polyurethane material and the cured flexible material being formed substantially in the absence of catalyst.
In accordance with at least one embodiment of a cured flexible polyurethane material, the polyurethane material is the reaction product of (i) a polyol component; and (ii) an isocyanate component, and the polyurethane material further comprising a filler, the filler being at least 42% by weight of the polyurethane material and the cured flexible material being formed substantially in the absence of surfactant, wetting agent, or both.
In accordance with at least one embodiment of a cured flexible reactive elastomer or reactive elastomeric material, the elastomer or elastomeric material is the reaction product of (i) a polyol component; and (ii) an isocyanate component, and the elastomer or elastomeric material further comprising a filler, the filler being at least 42% by weight of the elastomer or elastomeric material and the cured flexible material being formed substantially in the absence of surfactant, wetting agent, or both. The elastomer or elastomeric material may be used as a precoat, tiecoat and/or backing. The preferred reactive elastomer or elastomeric material may be polyurethane.
In accordance with at least selected embodiments, the polyol component is preferably a polyol component in which castor oil is the predominant reactive polyol.
In accordance with at least selected embodiments, a floor covering*
product has a textile face structure disposed in overlying contacting relation to at
In accordance with at least one embodiment of a cured flexible polyurethane material, the polyurethane material is the reaction product of (i) a polyol component; and (ii) an isocyanate component, and the polyurethane material further comprising a filler, the filler being at least 42% by weight of the polyurethane material and the cured flexible material being formed substantially in the absence of surfactant, wetting agent, or both.
In accordance with at least one embodiment of a cured flexible reactive elastomer or reactive elastomeric material, the elastomer or elastomeric material is the reaction product of (i) a polyol component; and (ii) an isocyanate component, and the elastomer or elastomeric material further comprising a filler, the filler being at least 42% by weight of the elastomer or elastomeric material and the cured flexible material being formed substantially in the absence of surfactant, wetting agent, or both. The elastomer or elastomeric material may be used as a precoat, tiecoat and/or backing. The preferred reactive elastomer or elastomeric material may be polyurethane.
In accordance with at least selected embodiments, the polyol component is preferably a polyol component in which castor oil is the predominant reactive polyol.
In accordance with at least selected embodiments, a floor covering*
product has a textile face structure disposed in overlying contacting relation to at
55 PCT/US2007/021430 least one layer of polyurethane backing composition filled with at least one filler selected from calcium carbonate, sand, used foundry sand, recycled gypsum, recycled glass, glass particles, glass fibers, cork, coal fly ash, recycled metal, rubber, recycled rubber, and combinations thereof.
The floor covering product above, further comprising a backing material disposed at a position below an underside of the layer of polyurethane and operatively bonded thereto, further comprising at least one structural support layer disposed in, on, under, or over said layer of polyurethane, further comprising a structural support layer disposed in embedded relation within the layer of polyurethane and a backing material disposed across an underside of the layer of polyurethane, wherein the floor covering product is a product selected from carpet, carpet tiles, floor tiles, rugs, mats, floor mats, modular product, roll goods, broadloom carpet, 6 foot broadloom, 12 foot broadloom, runners, and area rugs, wherein at least one filler in said layer of polyurethane is post consumer recycled soda lime glass, said recycled soda lime glass having a pH in deionized water of greater than 8.4 and an average particle size of greater than 325 mesh, wherein the floor covering product is an outdoor product, wherein the floor covering product is an indoor/outdoor product, and/or wherein an underside of said layer of polyurethane is at least one of embossed, textured, and treated to enhance at least the sliding friction of said floor covering product with a floor or subfloor.
In accordance with at least one embodiment, a method of forming combinations of floor covering products selected from carpet, carpet tiles, area rugs, floor tiles, runners, mats, and floor mats on a single processing line, includes the steps of:
(a) delivering a mass of polyurethane forming composition onto an endless belt;
(b) leveling the polyurethane forming composition to a desired thickness;
(c) placing a preformed textile face structure into overlying contacting relation with the leveled polyurethane forming composition;
The floor covering product above, further comprising a backing material disposed at a position below an underside of the layer of polyurethane and operatively bonded thereto, further comprising at least one structural support layer disposed in, on, under, or over said layer of polyurethane, further comprising a structural support layer disposed in embedded relation within the layer of polyurethane and a backing material disposed across an underside of the layer of polyurethane, wherein the floor covering product is a product selected from carpet, carpet tiles, floor tiles, rugs, mats, floor mats, modular product, roll goods, broadloom carpet, 6 foot broadloom, 12 foot broadloom, runners, and area rugs, wherein at least one filler in said layer of polyurethane is post consumer recycled soda lime glass, said recycled soda lime glass having a pH in deionized water of greater than 8.4 and an average particle size of greater than 325 mesh, wherein the floor covering product is an outdoor product, wherein the floor covering product is an indoor/outdoor product, and/or wherein an underside of said layer of polyurethane is at least one of embossed, textured, and treated to enhance at least the sliding friction of said floor covering product with a floor or subfloor.
In accordance with at least one embodiment, a method of forming combinations of floor covering products selected from carpet, carpet tiles, area rugs, floor tiles, runners, mats, and floor mats on a single processing line, includes the steps of:
(a) delivering a mass of polyurethane forming composition onto an endless belt;
(b) leveling the polyurethane forming composition to a desired thickness;
(c) placing a preformed textile face structure into overlying contacting relation with the leveled polyurethane forming composition;
56 PCT/US2007/021430 (d) curing the polyurethane forming composition in place across the underside of the textile face structure; and (e) cutting the composite of textile face structure with cured polyurethane to at least two different sizes.
The method above, further comprising the step of adding a release layer, material, or film over the belt prior to the delivering step, producing at least two different floor covering products, producing a system of polyurethane backed floor covering products such as tiles, mats, roll goods, and the like produced on a single polyurethane range, wherein each such product includes at least 10%
by weight recycled content, and/or wherein each such product includes at least 10% by weight post consumer recycled content.
In at least selected embodiments, a carpet tile includes a textile face structure disposed in overlying contacting relation to at least one layer of flexible, polyurethane backing composition, the polyurethane composition being the reaction product of (i) a polyol component in which castor oil is the predominant reactive polyol (preferably greater than about 50% of the reactive polyol by weight or by reactivity, more preferably greater than about 60% of the reactive polyol by weight or by reactivity, and most preferably greater than about 75% of the reactive polyol by weight or by reactivity); and (ii) an isocyanate component, and the polyurethane composition further comprising a filler, the filler being at least about 42% by weight of the polyurethane composition.
The carpet tile above, wherein the filler is selected from coal fly ash, recycled gypsum, recycled glass, and combinations thereof, wherein substantially the entire polyol component is unmodified castor oil (preferably greater than about 85% by weight of the entire polyol component, more preferably greater than about 95% by weight of the entire polyol component, and
The method above, further comprising the step of adding a release layer, material, or film over the belt prior to the delivering step, producing at least two different floor covering products, producing a system of polyurethane backed floor covering products such as tiles, mats, roll goods, and the like produced on a single polyurethane range, wherein each such product includes at least 10%
by weight recycled content, and/or wherein each such product includes at least 10% by weight post consumer recycled content.
In at least selected embodiments, a carpet tile includes a textile face structure disposed in overlying contacting relation to at least one layer of flexible, polyurethane backing composition, the polyurethane composition being the reaction product of (i) a polyol component in which castor oil is the predominant reactive polyol (preferably greater than about 50% of the reactive polyol by weight or by reactivity, more preferably greater than about 60% of the reactive polyol by weight or by reactivity, and most preferably greater than about 75% of the reactive polyol by weight or by reactivity); and (ii) an isocyanate component, and the polyurethane composition further comprising a filler, the filler being at least about 42% by weight of the polyurethane composition.
The carpet tile above, wherein the filler is selected from coal fly ash, recycled gypsum, recycled glass, and combinations thereof, wherein substantially the entire polyol component is unmodified castor oil (preferably greater than about 85% by weight of the entire polyol component, more preferably greater than about 95% by weight of the entire polyol component, and
57 PCT/US2007/021430 most preferably greater than about 99% by weight of the entire polyol component), wherein the polyurethane composition is substantially free of surfactant, wetting agent, or both (preferably less than about 3% by weight of the polyurethane composition, more preferably less than about 1% by weight of the polyurethane composition, and most preferably less than about 0.01 % by weight of the polyurethane composition), wherein the polyurethane composition is substantially free of catalyst (preferably less than about 3% by weight of the polyurethane composition, more preferably less than about 1% by weight of the polyurethane composition, and most preferably less than about 0.01 % by weight of the polyurethane composition), wherein said at least one layer of flexible, polyurethane backing composition is at least one of a precoat, tiecoat, backing, combined precoat/tiecoat, combined precoat/backing, combined tiecoat/backing, combined precoat/tiecoat/backing, and combinations thereof, further comprising at least one structural support layer disposed in, on, under, or over said layer of flexible, polyurethane backing composition, at least one backing layer may be disposed across the underside of said layer of flexible, polyurethane backing composition, or both, and/or wherein said textile face structure is at least one of tufted, bonded, woven, non-woven, needled, flocked, knit, and needle punched.
Although it may be preferred that the backing is a single layer combined precoat/backing or combined precoat/tiecoat on the back of greige goods, it is contemplated that in accordance with at least selected embodiments that each of the precoat, tiecoat and/or backing layers may be of the same or of different formulations, may be foam or nonfoam, may be filled or not filled, and/or the like.
For example, the precoat may be a nonfoam, nonfilled formulation A, while the tiecoat is a nonfoam, filled formulation B, and the backing is a foam, filled formulation C. In another example, the combined precoat/tiecoat is a nonfoam, filled formulation D while the backing is a foam, filled formulation E. In yet another example, the combined precoat/tiecoat is a nonfoam, filled, castor oil polyol based polyurethane layer, while the backing is a foam, filled petroleum polyol based polyurethane layer.
Although it may be preferred that the backing is a single layer combined precoat/backing or combined precoat/tiecoat on the back of greige goods, it is contemplated that in accordance with at least selected embodiments that each of the precoat, tiecoat and/or backing layers may be of the same or of different formulations, may be foam or nonfoam, may be filled or not filled, and/or the like.
For example, the precoat may be a nonfoam, nonfilled formulation A, while the tiecoat is a nonfoam, filled formulation B, and the backing is a foam, filled formulation C. In another example, the combined precoat/tiecoat is a nonfoam, filled formulation D while the backing is a foam, filled formulation E. In yet another example, the combined precoat/tiecoat is a nonfoam, filled, castor oil polyol based polyurethane layer, while the backing is a foam, filled petroleum polyol based polyurethane layer.
58 PCT/US2007/021430 It is contemplated that in accordance with at least selected embodiments that the filler for the precoat, tiecoat and/or backing may be recycled precoat, tiecoat, backing, face material, flooring product, or the like. It may be preferred to recycle the entire flooring product by grinding or densifying it and using it as filler in the precoat, tiecoat and/or backing.
While the present invention has been illustrated and described in relation to certain potentially preferred embodiments and practices, it is to be understood that the illustrated and described embodiments and practices are illustrative only and that the present invention includes such embodiments but is not limited thereto. Rather, it is fully contemplated that modifications and variations to the present invention will no doubt occur to those of skill in the art upon reading the above description and/or through practice of the invention. It is therefore intended that the present invention shall extend to all such modifications and variations as may incorporate the broad principles of the present invention within the full spirit and scope thereof.
While the present invention has been illustrated and described in relation to certain potentially preferred embodiments and practices, it is to be understood that the illustrated and described embodiments and practices are illustrative only and that the present invention includes such embodiments but is not limited thereto. Rather, it is fully contemplated that modifications and variations to the present invention will no doubt occur to those of skill in the art upon reading the above description and/or through practice of the invention. It is therefore intended that the present invention shall extend to all such modifications and variations as may incorporate the broad principles of the present invention within the full spirit and scope thereof.
Claims (22)
1. A carpet tile comprising:
a textile face structure disposed in overlying contacting relation to at least one layer of flexible, polyurethane backing composition, the polyurethane composition being the reaction product of (i) a polyol component in which castor oil is the predominant reactive polyol; and (ii) an isocyanate component, and the polyurethane composition further comprising a filler, the filler being at least about 42% by weight of the polyurethane composition.
a textile face structure disposed in overlying contacting relation to at least one layer of flexible, polyurethane backing composition, the polyurethane composition being the reaction product of (i) a polyol component in which castor oil is the predominant reactive polyol; and (ii) an isocyanate component, and the polyurethane composition further comprising a filler, the filler being at least about 42% by weight of the polyurethane composition.
2. The carpet tile of claim 1, wherein the filler is selected from coal fly ash, recycled gypsum, recycled glass, and combinations thereof.
3. The carpet tile of claim 1, wherein substantially the entire polyol component is unmodified castor oil.
4. The carpet tile of claim 1, wherein the polyurethane composition is substantially free of surfactant, wetting agent, or both.
5. The carpet tile of claim 1, wherein the polyurethane composition is substantially free of catalyst.
6. The carpet tile of claim 1, wherein said at least one layer of flexible, polyurethane backing composition is at least one of a precoat, tiecoat, backing, combined precoat/tiecoat, combined precoat/backing, combined tiecoat/backing, combined precoat/tiecoat/backing, and combinations thereof.
7. The carpet tile of claim 1, further comprising at least one structural support layer disposed in, on, under, or over said layer of flexible, polyurethane backing composition, at least one backing layer may be disposed across the underside of said layer of flexible, polyurethane backing composition, or both.
8. The carpet tile of claim 1, wherein said textile face structure is at least one of tufted, bonded, woven, non-woven, needled, flocked, knit, and needle punched.
9. The carpet tile of claim 8, wherein said textile face structure is at least one of greige goods, backed, unbacked, precoated, and nonprecoated.
The carpet tile of claim 8, wherein said textile face structure is tufted greige goods and said at least one layer of flexible, polyurethane backing composition is a combined precoat/backing.
11. The carpet tile of claim 1, wherein the filer component is at least 50% by weight of the polyurethane composition.
12. The carpet tile of claim 1, further comprising a minor polyol component which is not castor oil.
13. The carpet tile of claim 12, wherein the minor polyol component is selected from the group consisting of natural polyols, petroleum based polyols, polyols with functionality of 2 or 3 and a molecular weight of about 750 to about 7500, PPG polyols, PEG polyols, PPG-PEG copolymer polyols, and combinations thereof.
14. The carpet tile of claim 12, wherein the minor polyol component is present in an amount of less than about 50% by weight of the polyol component of the polyurethane composition.
15. The carpet tile of claim 12, wherein the minor polyol component is present in an amount of less than about 10% by weight of the polyurethane composition.
16. The carpet tile of claim 12, wherein the minor polyol component is present in an amount of less than about 5 % by weight of the polyurethane composition.
17. A polyurethane for application to a tufted, woven, non-woven, bonded, needled, flocked, needle punched, or knit textile face structure, including a polyol component, an isocyanate component, a catalyst and other agents, fillers, additives, and the like wherein the catalyst is eliminated, the polyol is replaced with castor oil, or both.
18. The polyurethane of claim 17, wherein the polyurethane forms at least one of a combined precoat/backing and combined precoat/tiecoat of at least one of a tile, rug, mat, and indoor/outdoor area rug.
19. A cured flexible polyurethane material, the polyurethane material being the reaction product of (i) a polyol component in which castor oil is the predominant reactive polyol; and (ii) an isocyanate component, and the polyurethane material further comprising a filler, the filler being at least 42% by weight of the polyurethane material.
20. A cured flexible polyurethane material, the polyurethane material being the reaction product of (i) a polyol component; and (ii) an isocyanate component, and the polyurethane material further comprising a filler, the filler being at least 42% by weight of the polyurethane material, and the cured flexible material being formed substantially in the absence of at least one of catalyst, surfactant, and wetting agent.
21. The polyurethane material of claim 20, wherein the polyol component is preferably a polyol component in which castor oil is the predominant reactive polyol.
22. The polyurethane material of claim 20, wherein the polyurethane material is used as a precoat, tiecoat, backing, or combinations thereof.
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KR100680097B1 (en) * | 2004-02-23 | 2007-02-09 | 이비덴 가부시키가이샤 | Honeycomb structural body and exhaust gas purifying apparatus |
US20090029097A1 (en) * | 2007-06-11 | 2009-01-29 | Riddle Dennis L | Flooring products and methods |
US20090110869A1 (en) * | 2007-10-31 | 2009-04-30 | Streeton Amy B | Polyurethane backed products and methods |
US20100267304A1 (en) * | 2008-11-14 | 2010-10-21 | Gregory Fowler | Polyurethane foam pad and methods of making and using same |
MX341382B (en) * | 2008-11-14 | 2016-08-18 | Shaw Ind Group Inc | Polyurethane foam pad and methods of making and using same. |
US8863347B2 (en) * | 2009-04-17 | 2014-10-21 | Tietex International Ltd | Cleaning system incorporating stitch bonded cleaning pad with multi-filament stitches |
US8728581B2 (en) | 2009-07-17 | 2014-05-20 | Columbia Insurance Company | Embossed carpet backing |
PL3484969T3 (en) | 2016-07-14 | 2023-12-11 | Michelman, Inc. | Aqueous based polyurethane/acrylate hybrid dispersions |
WO2020214794A1 (en) * | 2019-04-17 | 2020-10-22 | Shaw Industries Group, Inc. | Cross-ply backing materials and carpet compositions comprising same |
IT202100010754A1 (en) * | 2021-04-28 | 2022-10-28 | Consorzio Interuniversitario Per Lo Sviluppo Dei Sistemi A Grande Interfase Csgi | ORGANIC-INORGANIC COMPOSITE MATERIAL BASED ON CASTOR OIL FOR THE REMOVAL OF VOCs |
Family Cites Families (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
BE793159A (en) * | 1971-12-21 | 1973-06-21 | Ici Ltd | FLOORING |
DE2748085A1 (en) * | 1976-11-04 | 1978-05-18 | Mobay Chemical Corp | PROCESS FOR THE PRODUCTION OF CARPET BACKING COATINGS |
US4522857A (en) * | 1984-09-24 | 1985-06-11 | Milliken Research Corporation | Carpet tile with stabilizing material embedded in adhesive layer |
US6096401A (en) * | 1996-08-28 | 2000-08-01 | The Dow Chemical Company | Carpet backing precoats, laminate coats, and foam coats prepared from polyurethane formulations including fly ash |
US5908701A (en) * | 1996-12-10 | 1999-06-01 | The Dow Chemical Company | Preparation of filled reactive polyurethane carpet backing formulations using an in-line continuous mixing process |
US20060111506A1 (en) * | 2004-11-22 | 2006-05-25 | Bedri Erdem | Filled polyurethane dispersions |
US20090029097A1 (en) * | 2007-06-11 | 2009-01-29 | Riddle Dennis L | Flooring products and methods |
-
2006
- 2006-10-06 US US11/539,537 patent/US20080085391A1/en not_active Abandoned
- 2006-12-21 WO PCT/US2006/049020 patent/WO2008041999A1/en active Application Filing
-
2007
- 2007-10-05 CA CA002663809A patent/CA2663809A1/en not_active Abandoned
Also Published As
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US20080085391A1 (en) | 2008-04-10 |
WO2008041999A1 (en) | 2008-04-10 |
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Legal Events
Date | Code | Title | Description |
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FZDE | Discontinued |