WO2006127837A1 - Revetements de surface et leurs procedes - Google Patents

Revetements de surface et leurs procedes Download PDF

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Publication number
WO2006127837A1
WO2006127837A1 PCT/US2006/020129 US2006020129W WO2006127837A1 WO 2006127837 A1 WO2006127837 A1 WO 2006127837A1 US 2006020129 W US2006020129 W US 2006020129W WO 2006127837 A1 WO2006127837 A1 WO 2006127837A1
Authority
WO
WIPO (PCT)
Prior art keywords
backing
carpet
binder
particles
particle
Prior art date
Application number
PCT/US2006/020129
Other languages
English (en)
Inventor
Kenneth Benjamin Higgins
Peter Charles Brazier
Flemming Bojstrup
William Tippett
Dennis L. Riddle
Original Assignee
Milliken & Company
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Milliken & Company filed Critical Milliken & Company
Priority to GB0722863A priority Critical patent/GB2440729A/en
Publication of WO2006127837A1 publication Critical patent/WO2006127837A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/30—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being formed of particles, e.g. chips, granules, powder
    • 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
    • D06N7/0005—Floor covering on textile basis comprising a fibrous substrate being coated with at least one layer of a polymer on the top surface
    • D06N7/0036—Floor covering on textile basis comprising a fibrous substrate being coated with at least one layer of a polymer on the top surface characterised by their backing, e.g. secondary backing, back-sizing
    • 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
    • D06N7/0005—Floor covering on textile basis comprising a fibrous substrate being coated with at least one layer of a polymer on the top surface
    • D06N7/0039—Floor covering on textile basis comprising a fibrous substrate being coated with at least one layer of a polymer on the top surface characterised by the physical or chemical aspects of the layers
    • D06N7/0057—Layers obtained by sintering or glueing the granules together
    • 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
    • D06N7/0081—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 with at least one extra fibrous layer at the backing, e.g. stabilizing fibrous layer, fibrous secondary 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
    • D06N7/0084—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 with at least one layer obtained by sintering or bonding granules together
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/02—Synthetic macromolecular particles
    • B32B2264/0207—Particles made of materials belonging to B32B25/00
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/70—Scrap or recycled material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/716—Degradable
    • B32B2307/7163—Biodegradable
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2471/00—Floor coverings
    • 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
    • D06N2203/04—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D06N2203/042—Polyolefin (co)polymers
    • 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
    • D06N2203/04—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D06N2203/045—Vinyl (co)polymers
    • D06N2203/048—Polyvinylchloride (co)polymers
    • 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

Definitions

  • the present invention relates to surface coverings such as floor coverings having a carpet face or show surface in overlying relation to a backing of adjoined particle elements.
  • a surface covering such as a carpet, carpet tile, modular flooring, runner, rug, roll goods, stabilized broadloom, and/or the like incorporating a carpet surface or carpet face, such as a tufted, bonded, flocked, needled, needle punched, woven, non-woven, knit, or the like carpet material, having, for example, a pile surface such as a loop pile, cut pile, cut and loop pile, level pile, multi-level pile, textured pile, sculpted pile, nap, and/or the like.
  • the carpet has a tuft bind or precoat layer, such as a urethane precoat disposed in overlying relation to a resilient backing formed from a mass, mixture, or slurry, for example, of virgin, recycled, recyclable, renewable, biodegradable, and/or other environmentally friendly and/or environmentally responsible particles or crumbs, for example, foam and/or rubber and/or cork and/or carpet particles bonded together in adjoined relation by an adhesive or binder, such as an MDI urethane binder.
  • One or more optional stabilizing and/or backing layers may be disposed above, within and/or across the underside of the particle backing. Friction enhancing, adhesive, or installation facilitation materials may be added to and/or on the underside of the backing.
  • the particle backing may include voids which increase lateral grip, reduce creep, and the like. Methods of making such surface coverings are also provided.
  • Patents 4,522,857, 5,545,276; 5,948,500; 6,203,881 ; and 6,468,623 each hereby fully incorporated by reference herein.
  • Such rebond foam carpet constructions are disclosed for example in British Patent GB 2 369 294B and in U.S. patent applications 09/721 ,871 , filed November 24, 2000; 09/910,085, filed July 20, 2001 ; 09/960,114, filed September 21, 2001; 09/993,158, filed November 16, 2001 (U.S. Published Application US 2002/0132085); 10/118,059, filed April 8, 2002; 10/154,187, filed May 23, 2002; 10/198,238, filed July 18, 2002; 10/209,050, filed July 31 , 2002 (U.S. Published Application US 2004/0022991); and, 10/313,169, filed December 6, 2002 each of which are hereby incorporated by reference as if fully set forth herein.
  • virgin foam carpet constructions described above tend to be rather expensive, owing to the relatively high cost of the virgin backing material.
  • product manufacturers or purchasers to increase the recycled content of manufactured products, to recycle products, and to purchase products that can be recycled.
  • the present invention provides advantages and/or alternatives over the prior art or addresses the desires for recycled content, recyclable products, or the like, by providing a surface covering such as a floor covering, for example, carpet, carpet tile, modular flooring, runner, rug, roll goods, stabilized broadloom, or the like incorporating a carpet surface or face defining a show surface and a particle or crumb backing of particles, crumbs, powder, granular, chips, pieces, and/or the like of, for example, virgin materials, recycled materials, renewable materials, recyclable materials, biobased materials, biodegradable materials, low volatile organic compound (VOC) materials, other environmentally friendly or environmentally responsible materials, and/or the like, including, for example, particles of rubber, foam, cork, wood, carpet, carpet tile, resilient flooring, hard surface flooring, textile, fabric, floor sweepings, waste products, or the like and at least one optional adhesive or binder, with one or more optional additives, and with one or more optional stabilizing and/or backing layers. Friction enhancing, adhesive, or installation facilitating materials or treatments may be added
  • the adhesive or binder may be comprised of any of several different materials.
  • the binder may be a liquid, fiber or powder binder material such as a polyurethane diphenylmethane diisocyanate (MDI) binder.
  • MDI polyurethane diphenylmethane diisocyanate
  • the binder is selected from the group consisting of 4,4-methylene di-p-phenylene isocyanate (4,4'-MDI) polyurethane one- and two-component adhesives.
  • the binder is a solvent-free, one component (moisture curing) polyurethane adhesive.
  • Such binder may typically be present at a level of from about 2 to 40% by weight.
  • the binder may be a hot melt binder and is desirably present at a level of from about 2 to 40% by weight.
  • the binder level preferably lies in the range of about 2 to 20% by weight. Although 2 to 40% binder levels are preferred, binder levels of less than 2% and greater than 40% by weight may be employed as may be determined by experimentation.
  • the backing may also include other additives selected, for example, from the group of anti-microbial additives, anti- flammability additives, pigments, such as iron oxide, and anti-static additives, such as carbon fibers, as well as other fillers, fibers, colorants, dyes, particles and/or the like.
  • the binder may be reduced or eliminated if the particles or crumbs are made of, contain or are covered by a material, such as a hot melt adhesive, which when processed, such as under heat and pressure, binds or bonds the particles together (self-binding particles).
  • a material such as a hot melt adhesive, which when processed, such as under heat and pressure, binds or bonds the particles together (self-binding particles).
  • the decorative face of such surface coverings is preferably formed from a carpet material such as tufted, bonded, flocked, needled, needle punched, knit, woven, nonwoven, or the like construction.
  • the carpet face may be a solid color or shade, heathered, patterned, or the like, formed of colored yarns, printed or dyed in broadloom form, printed or dyed in piece or tile form, and/or the like.
  • the surface covering is jet dyed by a Millitron® jet dye machine by Milliken & Company of Spartanburg, South Carolina, U.S.A. If desired, the surface covering may include one or more stabilizing layers.
  • a glass mat may be embedded within the carpet face, below the carpet face, in the precoat, below the precoat, in an adhesive or tiecoat layer, above or below an adhesive layer, above the particle or crumb backing, in the crumb backing, below the crumb backing, as a secondary backing, above or below a secondary backing, in a secondary backing, and/or the like.
  • a secondary backing such as a coating film and/or textile backing layer may also be applied across the underside of the particle backing.
  • one or more friction enhancing coating or adhesive layers may be added above and/or below the secondary backing or may be the secondary backing.
  • a friction enhancing coating may be added below the crumb backing or a secondary backing.
  • One such friction enhancing coating material is TractionBack coating offered by Milliken & Company of LaGrange, Georgia, U.S.A.
  • an environmentally friendly and/or environmentally responsible surface covering with a carpet surface and a crumb or particle backing preferably having a substantial percentage of, for example, recycled, recyclable, biobased, biodegradable, renewable, environmentally friendly, and/or environmentally responsible material.
  • the method includes mixing particles or crumbs of virgin, recycled and/or renewable materials of, for example, rubber and/or foam and/or cork and/or carpet (such as recycled waste carpet tile) with binder material and one or more additives, fillers, agents or compounds, depositing the particle/ binder mixture in a layer, placing a carpet surface material on the particle/binder layer to form a multi-layer structure, pressing the multi-layer structure while setting the binder with, for example, time, pressure, heat and/or catalyst (such as water) so that the particles are consolidated to form a particle or crumb backing that may include voids between the pressed particles with the carpet surface material bonded to the particle backing.
  • binder material for example, rubber and/or foam and/or cork and/or carpet (such as recycled waste carpet tile)
  • additives, fillers, agents or compounds depositing the particle/ binder mixture in a layer, placing a carpet surface material on the particle/binder layer to form a multi-layer structure, pressing the multi-layer structure while setting the binder with
  • the composite product of the present invention can be made by either placing the carpet on top of the particle/binder mixture or by inverting the carpet and then placing the crumb/binder mixture on top of the inverted carpet.
  • the carpet or show surface may be dyed or printed before and/or after the addition of the backing.
  • the terms “particle”, “crumb”, “particles”, “crumbs”, “powder”, granules”, or “chips” are used to designate elements of, for example, virgin, recycled, renewable, recyclable, biobased, biodegradable, or other environmentally friendly or environmentally responsible materials, and/or the like materials, such as, cork, foam, rubber, wood, carpet, carpet tile, resilient flooring, hard surface flooring, textiles, fabrics, floor sweepings, waste particles, and/or the like that may have been "broken down” by chopping, crushing, pulverizing, reducing, particalizing, grinding, shattering, screening, meshing, sizing, milling, densifying, masticating, mechanical grinding, cryogenic grinding, ambient grinding, granulating, hammer milling, attrition milling, classification grinding, roll milling, and/or other known suitable single or combination techniques as will be known to those of skill in the art.
  • a particle or crumb of, for example, cork, foam, carpet, or rubber utilized within the contemplated practices can be any size in a range that includes powder, granules and chips.
  • the term “powder” or “powders” means particles or crumbs that will pass a 2mm mesh or with a maximum dimension of 2mm in at least one dimension, as the context requires.
  • "Granule” or “granules” means particles or crumbs that will pass a 6mm mesh or with a maximum dimension of 6mm in at least one dimension, as the context requires.
  • Granules may include some powder but are generally larger than powder and have a weight average size that is near to the maximum of the size specification for the granule.
  • Chip or “chips” means particles or crumbs that are larger than granules. That is, larger than 6mm in at least one dimension, as the context requires.
  • environmentally friendly materials or “environmentally responsible” materials refer to materials considered to inflict little or no harm on the environment, being friendly to the environment, favourably reducing negative- environmental impact, and the like.
  • being friendly to the environment includes: reducing the amount of materials to be land filled (disposed of in a landfill), to be incinerated, or to be otherwise dumped; using materials that would typically be discarded (recycling); using bio-based or biodegradable materials; encapsulating waste or toxic materials; and the like.
  • the particles or crumbs are preferably a mixture of sizes with at least 25% of the particles larger than 325 mesh, more preferably at least 25% of the particles larger than 100 mesh, and most preferably at least 25% of the particles at least 50 mesh.
  • the particles or crumbs may be characterized by substantially fractal irregular surface configuration, but may also be spherical, oval, elliptical, polygonal, rectangular, cylindrical, conical, cigar shaped, pear shaped, or the like.
  • the particles may be solid, resilient, hollow, perforated, mesh, foam, fibers, and/or the like.
  • any batch of particles normally contains a proportion smaller than the nominal particle size.
  • rubber particles made using a granulator with a 1.5mm screen i.e. having holes of diameter 1.5mm
  • had a distribution of sizes measured by using standard "Endecott” test sieves (ISO3310-1 :2200, BE410-1 :2000, ASTM E11 :95), comprising by weight 72.82% in the range 1.0-2.0mm, 17.45% of 0.71 -1.0mm, 6.90% of 0.5-0.71 mm, 2.65% of 0.25-0.5mm, and 0.18% of 0-0.25mm. Therefore, in the present specification, where we refer to 1.5mm crumb or particle size, it is meant that the particles are generated using a granulator with a
  • the binder may be selected from the group including thermosetting and water curable polymeric materials, adhesives, and mixtures thereof.
  • the binder may alternatively be selected from the group including thermoplastic polymeric materials, hot melt binders, adhesives, and mixtures thereof.
  • the assembled layers are pressed at a temperature of from about 50 0 C to 200 0 C, preferably from about 11O 0 C to 180 0 C, and most preferably approximately from about 125 0 C to 177 "C.
  • the assembled layers may be pressed at high pressure, medium pressure, low pressure, extremely low pressure, or at no added pressure while being set, cured, hardened, fixed, and/or the like.
  • the composite may be pressed together in a double belt laminator (opposing compressive belts) at a pressure of between about 0.10 pounds per square inch (psi) and 100 psi, preferably between about 1 psi and 50 psi, and most preferably between about 2 psi and 20 psi.
  • psi pounds per square inch
  • at least the crumb backing is passed through a set gap to precisely doctor or set the height of the crumb backing.
  • the assembly or composite may be pressed in a plurality of stages including one or more low temperature and high temperature stages. Depending on requirements, the low temperature stage may be employed first with a later higher temperature stage or vice versa. For example, if the binder is selected from the group including thermosetting and water curable polymeric materials and mixtures thereof, the assembly may be pressed in a single high temperature stage, or in a plurality of stages including at least one low temperature stage followed by at least one higher temperature stage.
  • the assembly may be pressed in a single low temperature stage or in a plurality of stages including at least one high temperature stage followed by at least one lower temperature or cooling stage.
  • the assembly may be pressed, for example, between a roller and a platen, a roller and a belt, two rollers, a blanket and a belt, a blanket and a platen, a weighted blanket and a belt, a progressively weighted blanket and a belt, progressively weighted rollers and a belt, a compressive belt and a fixed belt, a pair of opposing compressive belts, and/or the like.
  • a continuous process is preferred, other step wise, two stage, multi-stage, incremental indexing, or batch type process or equipment such as a heated press having an inflatable diaphragm may likewise be used when it is desired to cure the assembly under pressure.
  • a continuous sheet, web or piece of carpet, carpet face, carpet material, grey (or greige) goods, precoated carpet, backed carpet, or the like may be laid on the particle/binder layer.
  • a continuous sheet or web is preferred, separate carpet pieces may be laid on the particle/binder layer.
  • the particle/binder layer may be laid on an inverted continuous sheet, web or piece of carpet or on inverted discrete carpet pieces (for example, tile sized pieces).
  • a layer of adhesive, primer, prepolymer, binder, or the like such as a resilient urethane or hot melt adhesive, may be disposed between the carpet face and the particle/binder layer, between the carpet face and a stabilizing layer or material, and/or between a stabilizing layer or material and the particle/binder backing to facilitate adhesion.
  • the carpet face has a precoat or tuft bind layer or coating which not only holds the tufts in place, but also facilitates adhesion of the carpet face to the adhesive layer and/or to the particle/binder layer.
  • the product may include, for example, a urethane precoat and a urethane binder, a latex precoat and urethane binder, a PVC precoat and a PVC binder, a hot melt precoat and a hot melt binder, an EVA precoat and an EVA binder, an EVA precoat and a PVC binder, or the like.
  • the underside of the carpet may be coated, sprayed or treated, with a material such as a primer, prepolymer, binder, or the like to promote adhesion to the particle/binder mixture or particle/binder/additive mixture.
  • EPDM is a term used to designate a rubber mixture of which the main polymeric content is an ethylene propylene diene rubber monomer. It may also have fillers, plasticizers and other ancillary components as will be known in the rubber compounding industry.
  • the EPDM particles may be either foam or solid particles.
  • the EPDM particles or crumbs are recycled weather stripping material.
  • Nitrile rubber may also be used and is a term used to describe a compounded rubber mixture of which the main polymeric content is an acrylonitrile butadiene copolymer.
  • the nitrile rubber crumbs are recycled floor mat material.
  • SBR is a term used to designate a rubber mixture of which the main polymeric content is styrene-butadiene rubber.
  • Tires may be mainly SBR rubber but may also include some natural rubber, filler, platicizers, and ancillary components.
  • Other rubber materials such as SBR rubber particles, for example, recycled tires, may also be used.
  • Other rubber or elastomer particles such as butyl, natural, fluorocarbon, neoprene, and/or the like, may be used.
  • foam particles such foam is preferably a urethane foam or an EPDM foam.
  • foams and in particular urethane foams, may be mechanically frothed and/or chemically blown and may be of either open or closed cell construction.
  • foam particles may be polyurethane foam particles or chips or crumbs typically used in rebond polyurethane foam or bonded urethane foam.
  • Other foams including rebond foam, waste rebond foam, nitrile foam, SBR, EVA, PVC, polyethylene, and/or other resilient materials or foam may be used.
  • the particle/binder backing of the present invention has a density of less than about 1g/cm 3 , preferably a density in the range of from about 0.5 to 0.9 g/cm 3 , more preferably in the range of from about 0.7 to 0.9g/cm 3 .
  • the particle backing of the present invention exhibits a tear resistance strength of at least about 0.8N/mm 2 , more preferably, about 1.5N/mm 2 or higher.
  • the carpet surface or face may include or be made up of white and/or light colored yarn and/or fiber, such as synthetic or natural fibers or blends thereof, for example, Nylon 6, Nylon 6,6, wool, wool/Nylon blends, polyester, polypropylene, polyolefin, sisal, polyester, cotton, polyamide, and/or the like.
  • white and/or light colored yarn and/or fiber such as synthetic or natural fibers or blends thereof, for example, Nylon 6, Nylon 6,6, wool, wool/Nylon blends, polyester, polypropylene, polyolefin, sisal, polyester, cotton, polyamide, and/or the like.
  • Such materials may be printed or dyed with decorative surface designs, patterns, colors, shades, and/or the like.
  • carpet or carpet tiles having a white yarn face may be pattern jet dyed.
  • One exemplary object of the present invention is the provision of a surface covering having a carpet face and a particle backing.
  • Another object of the present invention is the provision of a surface covering having a carpet face, a particle backing layer and a secondary backing.
  • Yet another object of the present invention is the provision of a method of making a surface covering having a carpet face and a particle backing.
  • a more particular object of the present invention is the provision of a carpet tile having a carpet face and a particle backing.
  • Another more particular object of the present invention is the provision of a carpet tile having a carpet face and a particle cushion backing.
  • Yet another object of the present invention is the provision of an aesthetically pleasing, environmentally friendly, and/or environmentally responsible surface covering, floor covering, carpet tile, or the like.
  • Still another object of the present invention is the provision of a method of making a carpet tile having a carpet face and a particle backing.
  • Still yet another object of the present invention is a method of making an aesthetically pleasing, environmentally friendly, and/or environmentally responsible surface covering, floor covering, carpet tile, or the like.
  • FIG. 1 is a partial cross-sectional side elevation illustration of an exemplary surface covering having a tufted carpet surface and a particle backing;
  • FIG. 2 is a partial cross-sectional side elevation view like FIG. 1 illustrating another exemplary surface covering having a carpet surface and layered backing;
  • FIG. 3 is a partial cross-sectional side elevation of yet another exemplary surface covering having a carpet surface and a layered backing;
  • FIG. 4 is a partial cross-sectional side elevation of still yet another exemplary surface covering having a carpet surface and layered backing;
  • FIG. 5 is a partial cross-sectional side elevation of another exemplary surface covering having a carpet surface and a layered backing;
  • FIG. 6 is a partial cross-sectional side elevation of yet another exemplary surface covering having a carpet surface and a layered backing;
  • FIG. 7 is a partial cross-sectional side elevation of still yet another exemplary surface covering having a carpet surface and a particle backing
  • FIG. 8 is a partial cross-sectional side elevation like FIG. 7 of another exemplary surface covering having a carpet surface and a layered backing;
  • FIG. 9 is a schematic side elevation view of a process line for manufacturing a surface covering incorporating a carpet surface and a particle backing or layered backing, such as shown, for example, in any of FIGS. 1 - 8, 10, 11 , 13 - 22, or 25;
  • FIG. 9A is a schematic side elevation view similar to FIG. 9 illustrating an alternative process line for manufacturing a surface covering incorporating a carpet surface and a preformed particle backing layer;
  • FIG. 9B is a schematic side elevation view similar to FIG. 9 illustrating an alternative process line for manufacturing a surface covering having a carpet face and a particle backing or layered backing;
  • FIG. 10 is a partial cross-sectional side elevation view illustrating an exemplary surface covering having a carpet surface bonded to a stabilized particle backing with an underlying backing sheet;
  • FIG. 11 is a partial cross-sectional side elevation view similar to FIG. 10 illustrating another exemplary surface covering having a carpet surface bonded to a stabilized particle backing with an underlying backing sheet and a lower coating or material;
  • FIG. 12 is a schematic side elevation view of a process line for manufacturing a surface covering such as a floor covering having the layered construction illustrated in any of FIGS. 10, 11 , 14, 18, or 19 and incorporating a carpet surface bonded to a stabilized particle backing;
  • FIG. 12A is a schematic side elevation view similar to FIG. 12 illustrating an alternative process line for manufacturing a surface covering having, for example, the layered construction illustrated in any of FIGS. 10, 11 , or 19 and incorporating a carpet surface bonded to stabilized particle backing including preformed particle backing layers;
  • FIG. 13 is a partial cross-sectional side elevation view of another exemplary surface covering having a woven carpet surface and layered backing;
  • FIG. 14 is a partial cross-sectional side elevation view similar to FIG. 13 illustrating still another exemplary surface covering having a carpet surface bonded to a stabilized particle backing with an underlying backing sheet;
  • FIG. 15 is a partial cross-sectional side elevation view similar to FIG. 13 illustrating still yet another exemplary surface covering having a carpet surface adhesively bonded to a particle backing with an underlying backing sheet;
  • FIG. 16 is a partial cross-sectional side elevation view of yet another exemplary surface covering similar to FIG. 13, incorporating a layer of adhesive bonding a fibrous backing sheet;
  • FIG. 17 is a partial cross-sectional side elevation view of another exemplary surface covering similar to FIG. 16 incorporating a layer of adhesive on either side of a particle backing layer;
  • FIG. 18 is a partial cross-sectional side elevation view of still another exemplary surface covering similar to FIG. 14, incorporating an additional stabilizing or reinforcement layer;
  • FIG. 19 is a partial cross-sectional side elevation view of yet another exemplary surface covering similar to FIG. 13, incorporating a stabilized particle backing;
  • FIG. 20 is a partial cross-sectional side elevation view like FIGS. 3 or 13 illustrating another exemplary surface covering having a bonded carpet surface and a layered backing;
  • FIG. 21 is a top plan view illustrating a carpet product of the present invention, such as a carpet tile, incorporating a decorative show surface;
  • FIG. 22 is a side view taken along line 22-22 in FIG. 21 ;
  • FIG. 23 is a top plan view of another carpet product of the present invention, such as a carpet tile, incorporating a decorative show surface with outboard border zones;
  • FIG. 24 is a side view taken along line 24-24 in FIG. 23;
  • FIG. 25 is a partial cross-sectional side elevation view of an exemplary construction of the present invention illustrating an alternative manufacturing process wherein the particle backing is added over an inverted carpet structure.
  • a surface covering 10 such as a floor covering such as a carpet, carpet tile, modular flooring, runner, rug, roll goods, stabilized broadloom, or the like is illustrated in cross section.
  • a surface covering 10 such as a floor covering such as a carpet, carpet tile, modular flooring, runner, rug, roll goods, stabilized broadloom, or the like is illustrated in cross section.
  • the various layers and elements are illustrated with enhanced dimensions.
  • the illustrated dimensions do not necessarily correspond to, for example, relative thickness levels in the final construction or to actual size of the particles or crumbs.
  • the surface covering 10 includes a tufted, level cut pile carpet, primary carpet, carpet surface, or carpet face 12 preferably having tufts 14, a tufting substrate or primary backing 16, and a precoat or tuft bind layer or coating 18.
  • the tufts are tufted through the primary backing and then held in place by the precoat.
  • the carpet face or exterior carpet layer 12 is disposed in overlying relation to a single or multi-layer particle backing structure 20 as will be described further hereinafter incorporating a mass of particles or crumbs, for example, particles or crumbs of virgin, recycled, recyclable, natural, biobased, biodegradable, renewable, other environmentally friendly or environmentally responsible materials, and/or the like materials such as foam and/or rubber and/or cork and/or carpet particles or crumbs together with at least one optional adhesive or binder and may also include other additives fillers, agents, particles, fibers, and/or the like.
  • a mass of particles or crumbs for example, particles or crumbs of virgin, recycled, recyclable, natural, biobased, biodegradable, renewable, other environmentally friendly or environmentally responsible materials, and/or the like materials such as foam and/or rubber and/or cork and/or carpet particles or crumbs together with at least one optional adhesive or binder and may also include other additives fillers, agents, particles, fibers, and/or the like.
  • the term "carpet" used in reference to the carpet surface or carpet face 12 of the present invention is intended to refer to carpet in its general meaning including, for example, tufted, woven, bonded, nonwoven, flocked, needled, needle punched, knit, and/or the like having, for example, a pile or nap surface such as pile yarns or fibers, for example, loop pile, cut pile, cut and loop pile, level pile, multi-level pile, textured pile, sculpted pile, treated pile, and/or the like.
  • the carpet, carpet tile, rug, runner, roll goods, carpet face, or the like may be or may include, for example, flat yarn, twisted yarn, textured yarn, level loop, multi-level loop, Berber, broadloom, bulked continuous filament non-texturized yarn, bulked continuous filament texturized yarn, cut pile, cut and loop pile, wool, Nylon, olefin, polyester, filament fiber, staple fiber, frieze yam, heat-set yarn, heat-set Nylon, heat-set olefin, heat-set polyester, indoor, indoor/outdoor, outdoor, loop pile, fiber pile, yarn pile, nap, single ply yarn, multiple ply yam, plush, velvet-plush, Saxony, natural Sisal, synthetic sisal, wool sisal, sisal like, Nylon/wool blend sisal, tufted, woven, nonwoven, knit, needle punched, bonded, fusion bonded, latex bonded, hot melt bonded, non-heat-set yarn, spun yarn,
  • carpets carpet products, carpet types, faces, yarns, fibers, finishes, etc.
  • the carpet of the present invention is not limited to any particular formation technique, yarn type, product, or the like.
  • carpet may include any number of textiles, fabrics, materials, floorings, and/or the like commonly referred to as carpet, used as carpet, known as carpet, or the like.
  • at least one process for forming a bonded carpet is disclosed in, for example, U.S. Patents 5,443,881 and 5,567,257 the contents of which are each incorporated herein by reference.
  • the carpet 12 is preferably a pile face carpet, such as loop pile, cut pile, or cut and loop pile.
  • a pile face carpet such as loop pile, cut pile, or cut and loop pile.
  • one contemplated carpet is a tufted cut pile carpet.
  • Another contemplated carpet is a loop pile tufted carpet.
  • Still another contemplated carpet is a cut pile bonded carpet.
  • Still yet another carpet is an Axminster woven carpet.
  • Another exemplary carpet is a Wilton woven carpet.
  • the carpet 12 may be either of solid coloration, heather and/or may have a decorative coloration, image, pattern or design woven, tufted, formed, printed and/or dyed thereon.
  • a pattern, design, color, shade, or the like may be formed by using colored yarns such as yarn dyed or solution dyed yarn, formed by piece dyeing, formed by printing, or may be jet dyed on a carpet made, for example, from white or light colored yarn or fiber Any printing, dyeing or other coloration may be done prior to carpet formation, during carpet formation, following carpet formation, prior to product formation, during product formation, and/or after product formation.
  • the precoat 18 preferably penetrates, encapsulates, or covers the exposed bottom of the tufts 14 and the exposed bottom of the primary backing 16 to hold the tufts 14 in place and to serve as a bond promoting agent for bonding the carpet 12 to the crumb or particle backing 20, and more particularly to bond to and be compatible with the binder or binders 24 in the backing 20.
  • the precoat 18 is preferably compatible with the binder 24 or binders in backing 20.
  • precoat 18 may be, for example, a latex or urethane based precoat, such as a polyurethane precoat, compatible with a urethane based binder, such as, an MDI binder.
  • the binder may be comprised of any of several different materials.
  • the binder may be a liquid, fiber or powdered binder material such as a polyurethane diphenylmethane diisocyanate (MDI) binder.
  • MDI polyurethane diphenylmethane diisocyanate
  • the binder is selected from the group consisting of 4,4-methylene di-p-phenylene isocyanate (4,4'- MDI) polyurethane one- and two- component adhesives.
  • MDI polyurethane diphenylmethane diisocyanate
  • the binder is a solvent-free, one component (moisture curing) polyurethane adhesive.
  • the binder may be or may include resins, polymers, plastics, prepolymers, primers, or the like. Such binder may typically be present at a level of from about 2 to 40%.
  • the binder may be a hot melt binder and is desirably present at a level of from about 2 to 40%.
  • the binder level preferably lies in the range from about 5 to 20%. Binder levels of less than about 2% and greater than about 40% may be employed as may be determined by routine experimentation.
  • the backing may also include one or more additives such as anti-microbial additives, anti-flammability additives, pigments, such as iron oxide, and anti-static additives, such as carbon fibers, fillers, fibers, colorants, dyes, and/or the like.
  • FIGS. 1 - 6, 10, 11 , 13 - 20, and 25 show a precoat 18, a precoat 18 may not be required (see FIGS. 7 and 8).
  • the binder 24 or binders in backing 20 may be added in sufficient quantity to not only bind the particles or crumbs 22 of backing 20 to one another and make backing 20 cohesive but to also bond the backing 20 to the lower surface of carpet 12 and the binder may also serve a tuft lock function.
  • carpet 12 may or may not include a precoat layer 18.
  • Carpet 12 may also include multiple backings or tufting substrates, composite tufting substrates, multiple precoats or precoat layers, stabilizing layers, different piles, loop pile, textured piles, over stitching, secondary backings below the precoat such as natural or synthetic materials, for example, woven or nonwoven polypropylene or jute, urethane secondary, or the like.
  • the precoat 18 may be a resilient thermoset or thermoplastic adhesive such as a polyurethane adhesive, latex adhesive, a bitumen hot melt adhesive, or the like applied in liquid, powder, thin film, or the like form, and which serves to not only lock the tufts 14 in place in primary backing 16, but also as a tiecoat to adhere or bond the carpet 12 to the crumb backing 20.
  • An exemplary bitumen hot melt adhesive is described, for example, in U.S. Patent 5, 929,145 hereby incorporated by reference herein.
  • the adhesive or binder 24 on crumbs or particles 22 of particle backing 20 of FIGS. 1 and 7, may form a skin 26 of binder 24 on the bottom of the crumbs 22 of backing 20.
  • the add on weights of a precoat layer are usually less than the add on weights of a tiecoat or adhesive layer.
  • a typical precoat add on is about 2 to 20 oz/yd 2 and a typical tiecoat add on is from about 15 to 50 oz/yd 2 .
  • the precoat 18 of the present invention may be one or more layers of precoat material. If the precoat 18, 60 is to act as both a precoat and tiecoat, a heavier add on of precoat may be used. Also, the precoat composition or chemistry may be more like a tiecoat or adhesive when the precoat is used as a tiecoat.
  • the backing structure 20 preferably is formed from a mass of crumbs or particles 22, such as renewable materials, recycled materials, and/or virgin materials, for example, such as cork and/or foam and/or rubber particles, preferably recycled cork and/or recycled foam and/or recycled rubber particles attached together using a binder material 24 such as a resilient or hard binder that bonds each particle to adjacent particles alone or together with other materials, agents, fillers, additives, and/or the like.
  • the crumbs or particles 22 are preferably of a substantially irregular fractal surface geometry so as to provide a high surface area for bonding. However, cylindrical, cigar, polygonal, spheroidal, pellet, disc, rod, and/or other relatively smooth surface geometries may be used if desired.
  • the crumbs 22 may be solid, resilient, hollow, perforated, mesh, foam, fibrous, or the like.
  • crumbs 22 may be compressible and/or noncompressible spherical particles such as rubber or ceramic spheres may be employed.
  • the binder 24 also bonds the backing structure 20 to the precoat 18 on the underside of carpet layer 12.
  • interstitial voids exist between the crumbs or particles, some of which may be partially or fully filled with the binder, fillers, additives, etc. If desired, maintaining voids and/or using a resilient binder may provide substantial resiliency and cushioning.
  • a certain number of voids may also reduce mass, reduce cost, increase flexibility, enhance lateral grip, reduce creep, and/or the like.
  • each of the particles of the backing be encapsulated with at least a thin layer of binder. This aids in bonding the particles together and in bonding the backing 20 to the face composite 12.
  • the particles 22 of the backing structure 20 are rubber, recycled SBR rubber, recycled nitrile rubber, or recycled EPDM rubber or polymer may be preferred, and recycled EPDM rubber or polymer may be most preferred.
  • one contemplated source of EPDM polymer is recycled weather stripping. Such EPDM may be either of hard or resilient (foam) character.
  • one contemplated source for nitrile rubber is from recycled industrial mats. The rental industrial mat segment is an ideal source of raw material for the rubber crumbs or particles because it ensures that low bleed, low staining nitrile rubber is used as the starting point for the production of the surface coverings. Recycled SBR rubber from recycled tires may also be used if desired.
  • foam Other rubber materials (solid or foam) may be used.
  • particles of the backing structure are foam
  • recycled EPDM foam or cellular polyurethane foam may be preferred.
  • Resilient materials other than foam may be used.
  • compressible or resilient materials such as cork (which is also a renewable material), hollow particles like hollow spheres, rubber, gel particles, gel filled particles or spheres, and/or the like may be used.
  • EPDM particles may need to use up to 10% by weight binder; if one uses a mixture of EPDM particles and cork particles, then they may need to use up to 15% by weight binder; while, if one uses an equal mixture by volume of recycled EPDM particles, cork particles, and recycled carpet tile waste particles, then they may need up to 20% by weight binder to fully cover each particle, bind the particles together, and to bind the particle backing to the carpet and to any secondary backing.
  • a particle backing 20 is made up of a mixture of particles of 1/3 cork crumb, 1/3 recycled EPDM rubber crumb, and 1/3 recycled carpet tile crumb based on volume as the densities of these materials varies greatly together with about 5% to about 15% polyurethane MDI binder by weight.
  • a particle backing has an aesthetically pleasing appearance due to the mixture of, for example, tan colored cork particles, black colored rubber particles, and brown colored recycled carpet tile particles.
  • the binder coats the surfaces of the particles but does not fill all of the voids between the coated particles in the particle backing.
  • the size of backing structure particles or crumbs 22, for example, recycled material particles, renewable resource particles, and/or virgin particles, such as recycled foam, carpet, rubber and/or cork particles, utilized preferably range from about 0.01 to about 15 mm, more preferably from about 0.04 mm to about 12 mm, still more preferably from about 0.15 mm to about 10 mm, and yet more preferably from about 0.3 mm to about 8 mm, and most preferably from about 0.5 mm to about 6 mm.
  • the particle backing is to be about 1 /2 inch thick, then the crumbs should preferably be sized about VA inch or less. If the particle backing is to be about % inch thick, the crumbs should preferably be sized about 1/8 inch or less.
  • a low fines crumb may be preferred. However, smaller and/or larger particle sizes may be used if desired.
  • the size of particle is selected to be as large as possible for the use and properties required.
  • the particular particle backing may include a majority of particles of the preferred size or range of size but may also include a certain amount of particles below and above the preferred size or range of size.
  • the screen or mesh only sets an upper limit on particle size in one dimension of the particles. For instance, cylindrical particles may have a small diameter but a long length. Also, smaller particles will fit through the mesh or screen. It has been found that particle size can be chosen to give different amounts of resilience in the product. Larger particles generally provide greater resilience. Particles of a desired size may be mixed with powder of the same material or a different material to provide a greater tear resistance.
  • Powder may increase the tensile strength for a given binder level.
  • Suitable additives include, but are not limited to, anti-microbial materials, anti-flammability additives, odorants, colorants or pigments such as iron oxide powder, anti-static additives such as carbon fibers, fillers, such as calcium carbonate, fly ash, sand, used foundry sand, silica, fibers, such as natural or synthetic fibers, for example, glass or Nylon, polymers, plastics, resins, adhesives, carbon black, charcoal, and/or other generally known agents, fillers, additives and/or the like.
  • the adhesive or binder 24 used to adjoin the particles 22 of backing 20 may be one or more of a variety of binding, bonding, adhering, and the like materials, systems, mixtures, prepolymers, blends, components, and the like.
  • the binder may be a water curing, heat setting or thermoplastic type material.
  • the binder can be, for example, in liquid, fiber, pellet, particle, or powder form.
  • the binder is selected from one of the following types: water based adhesives, polyurethane reactive hot melts, copolyester or copolyamide reactive and thermoplastic hot melts, urethane MDI binder, and 4,4-methylene di-p- phenylene isocyanate (4,4'- MDI) polyurethane one- or two-component adhesives.
  • the binder 24 may be EVA, PVC, SBR, other thermoset adhesives, resins, plastics, polymers, low melts, fibers, particles, pellets, and/or the like which bond or fuse the particles or crumbs 22 to one another.
  • the binder 24 has good adhesive properties to ensure that the particles 22 are well bound, and it may be additionally desirable that sufficient free binder is provided to be capable of forming a physical or chemical bond to the lower exterior surface of carpet 12, precoat 18, tufts 14, or backing 16, to any secondary backings (for example, 50 in FIG. 2, 52 in FIG. 3), to any adhesive or tiecoat layers (for example, 260 in FIG. 15, 264 in FlG. 17), to any stabilizing or reinforcement layers or materials (for example, 162 in FIGS. 10 and 11 , 257, 262 in FIG. 18), and the like.
  • the binder should also desirably exhibit sufficient cohesive strength to give the backing 20 sufficient strength.
  • the binder 24 may contain any of the known cross linkers or curing accelerators, water, catalysts, and/or the like to suit the process and the desired properties of the product being manufactured and the particles being used.
  • carpet tiles especially commercial carpet tiles, require dimensional stability and durability, roll goods require flexibility, runners that are adapted for stairs require flexibility, etc.
  • certain carpet products have not only stability and/or flexibility, but also cushion or resiliency.
  • the binder may be a resilient adhesive, at least some of the particles may be compressible, and voids may be left between particles to allow for the cushion effect. Underfoot comfort may dictate that the carpet product be at least slightly compressible under load, but that it not bottom out (fully compress) under typical load.
  • the binder 24 performs the dual function of holding together the particles 22 to form a backing 20 and bonding the backing 20 to the bottom of the carpet 12 (the precoat 18).
  • binder levels should preferably be in the range of from about 2% to 40% by weight of the particles, more preferably from about 2% to 20% by weight.
  • Use of lower particle sizes or use of particles with high surface area may dictate the use of higher percentages of binder due to greater surface area.
  • the use of fine powders of size less than 0.5mm may require about 20% binder by weight or more.
  • the crumbs or particles 22 of backing 20 are made from or coated with a material that will bind the particles together during particle backing formation, then addition of binder 24 may not be required.
  • the particles 22 are recycled waste carpet tile particles including or coated with hot melt adhesive or hot melt adhesive components during particle formation, then the hot melt components of particles 22 may be sufficient to bond the particles 22 together and to carpet 12 (precoat 18).
  • the particles may be self-binding or the binder may form part of the particles or crumbs 22.
  • binder content there is an inverse relationship between the binder content and size of the particles 22 and between the binder content and pressure applied to the binder/particle mixture while forming the backing structure 20. Therefore, as the particle size and the pressure increase, the binder content normally decreases.
  • the binder content also depends on other factors, such as the type of binder, the particle material or materials used, the type of carpet, desired resiliency, and the like, and can be determined by routine experimentation. As binder is usually an expensive material, one would not use more binder than necessary.
  • the binder may be a liquid polyurethane MDI binder, in which case it is preferably present at a level of from about 2% to 20% by weight, more preferably from about 2% to 12% by weight if, for example, the backing consists primarily of chips or granules.
  • the binder may, for example, contain further additives or materials that are in liquid form and are compatible with the binder, such as water, catalyst, colorants, plasticizers, perfumes, and/or the like.
  • the binder may also contain other additives provided that they are suitable for addition in a liquid medium.
  • the binder may alternatively be a thermoplastic or thermosetting powder, such as an adhesive or hot melt powder, in which case it is preferably present at a level from about 2% to 20% by weight, more preferably from about 2% to 12% by weight if the backing consists primarily of chips or granules.
  • a powdered binder may also contain other additives provided that they are suitable for addition in a powder medium.
  • the preferred ranges for binder content may thus be summarized as follows:
  • binder content in range from about 2% to 20% by weight, preferably from about 2% to 12% by weight with, for example, an MDI binder or preferably from about 2% to 12% by weight with, for example, a hot melt binder.
  • binder content in range from about 2% to 40% by weight, preferably from about 9% to 20% by weight.
  • a binder content of less than about 2% or more than about 40% by weight may be employed. High binder contents may lead to the formation of a skin, reduction or elimination of voids, higher cost, longer set times, slower processing speeds, higher processing temperatures, and/or the like.
  • a very heavy (dense) particle or crumb material (or materials) may be used with a very light (for example, powder) binder or adhesive. Hence, about 1% or more by volume binder may be sufficient.
  • a hardback flooring product may have a dense particle/binder backing with a low binder content.
  • very light particles or crumbs with a relatively heavy binder or adhesive.
  • the ratio of binder to particles may vary between about 0/100 binder to particles (no binder, self-binding particles) by weight or by volume to about 90/10 ratio of binder to particles by weight or by volume, preferably from about 5/95 to 25/75 ratio of binder to particles by weight.
  • FIG. 9 is a schematic of an integrated processing line and process.
  • particles 22 such as a mixture of particles, crumbs, or chips, of, for example, foam, rubber, and/or cork is mixed or blended with a desired binder or binders 24 and any additives or fillers 28 in mixer 44.
  • each of the particles 22 and binders 24 may be premixed or preblended upstream of mixer 44.
  • multiple types of particles 22 may be premixed and fed to mixer 44, water and/or catalyst may be premixed with a urethane binder, the two components of a two-component binder may be premixed upstream of mixer 44, and/or powdered additives 28 may be premixed with particles 22 upstream of mixer 44.
  • a plurality of mixers 44 may be used.
  • the contents of mixer 44 are fed to a deposit head 45 which delivers the binder/particle/additive mixture to a conveyor belt or carrier belt 38 upstream of a doctor blade 46 or other doctoring device.
  • Mixer 44, deposit head 45 and doctor blade 46 form a deposit station that deposits the particles and binder onto the motor driven carrier belt 38.
  • the particle/binder/additive mixture may be deposited directly onto belt 38, onto a release material, layer, film, textile sheet, or the like on belt 38, onto a secondary backing on belt 38, onto a stabilizing or reinforcement layer or material on belt 38, on top of one or more other backings on belt 38, or the like.
  • the doctor blade 46 or other suitable levelling device is positioned downstream of the deposit station.
  • the doctor blade 46 or other levelling device such as a doctor roll, knife, air knife, or the like may reciprocate, oscillate, have a moving polymer film cover, and/or the like to help set the level of particles on the belt, to flatten and/or compress the particles on the belt, to keep the doctor blade or roller clean (for example, to prevent build-up of particles, binder and/or additives on the blade), and the like.
  • binder 24, particles 22, and additives 28 are all in particle, powder or granular form (rather than liquid form), one may not be as concerned with keeping the blade 46 or roller clean.
  • FIG. 9A shows a preformed particle backing 20' from a roll 74' being let down onto belt 38'.
  • FIG. 9B shows a hopper 92 feeding a binder/particle/additive mixture down on to belt 38" between a wall or stop 94 and a mating roll 37".
  • Deposit head 45 of FIG. 9 may be reciprocated back and forth across a selected width of belt 38 in order to deliver a constant supply of particle/binder/additive mixture across the necessary width of belt 38 upstream of doctor blade 46.
  • deposit head 45 may include a screw extruder or feed and a flexible hose, the end of which can be reciprocated back and forth across the belt.
  • Mixer 44 may be a paddle mixer, rotary mixer, or the like.
  • Doctor blade 46 may doctor the level of the particle/binder/additive mixture to about 1.0 inch, 0.5 inch, 0.25 inch, or the like. Walls or stops (not shown) running along the length of the belt 38 in the area of doctor blade 46 may serve to keep the particle/binder/additive mixture within set boundaries on the belt.
  • the mixer 44, deposit head 45, other feeds, doctor blade 46, and the like may need to be cleaned to remove any particle, binder, or additive build-up.
  • Water, cleaning agents and/or solvents may need to be used to clean these items depending on the particles, binder, and/or additives in use. Also, when switching from one mixture to another, these items may be cleaned.
  • the carrier belt 38 like belt 36, is made, for example, of hardened rubber, metal, glass, non-stick polytetrafluoroethylene (PTFE)-coated woven glass fabric, or the like.
  • the belt may be coated with, for example, PTFE, silicone, latex, acrylics, textiles, films, and/or other materials or release agents to prevent the applied materials from sticking to it.
  • the carrier belt 38 advances in the direction of the arrows (clockwise rotation). This movement may be either stepwise or continuous depending upon the nature of the product being formed.
  • the carrier belt 38 is disposed in opposing relation to motor driven compression belt 36 which moves in reverse angular relation to the carrier belt 38 to establish a nip zone between the belts in the vicinity of heating and/or cooling elements 40. Materials deposited on the carrier belt 38 thus undergo a degree of compression between the carrier belt 38 and the compression belt 36 while simultaneously being heated or cooled.
  • a carpet forming the carpet surface 12 is conveyed from a roll 30 through coater 32 such as a roll coater, reverse roll coater, sprayer, extruder, or the like wherein the precoat or film forming composition 18 is applied to the back of carpet 12.
  • the film-forming composition 18 may be added in one or more steps and is preferably a liquid latex or urethane such as is readily available for precoating the back of greige (grey) goods and the like although acrylics and other suitable tuft lock, tuft bind, adhesives, binders, or compositions may likewise be utilized if desired.
  • suitable precoat compositions are believed to be urethane, polyurethane, latex, nitrile latex, natural latex, diphenylmethane diisocyanate (MDI) 1 polymeric MDI (PMDI), 4,4'- MDI, 2,4'- MDI, 2,2'- MDI, non-isomer- specific MDI, water dispersion urethane precoat system, thermoset adhesive, thermoplastic adhesive, MDI binding adhesive, binder, hot melt adhesive, bitumen hot melt, polyurethane adhesive, urethane reactive hot melt, SBR, EVA, PVC, water based adhesive, and/or the like.
  • MDI diphenylmethane diisocyanate
  • PMDI polymeric MDI
  • EPVC polymeric MDI
  • suitable precoat compositions are believed to be urethane, polyurethane, latex, nitrile latex, natural latex, diphenylmethane diisocyanate (MDI) 1 polymeric MDI (PMD
  • the precoat 18 be compatible with and bind to binder 24 of backing 20, especially when there are no adhesive or tiecoat layers between the precoat 18 and binder 24.
  • precoat, binder, adhesive, tiecoat, secondary coating, and/or the like be environmentally friendly, environmentally responsible, low VOC, water based, biobased, biodegradable, natural, renewable, recyclable, recycled, moisture cured, non-toxic, ambient temperature cured, nonfugitive, non-volatile, nonreactive, zero risk environment, resilient, elastomeric, formaldehyde free, solvent free, PVC-free, and/or the like if possible or desirable.
  • the precoated carpet 12 is then passed through a curing station 34 such as a heater, oven, fan, dryer, other curing equipment, or the like to cure the applied precoat composition to form the lower exterior carpet surface 18 as previously described.
  • the carpet 12 with the cured precoat 18 is then delivered in overlying relation to the particle/binder composition on the carrier belt 38 for subsequent compression and heating and/or cooling between the carrier belt 38 and the compression belt 36.
  • a curing station 34 such as a heater, oven, fan, dryer, other curing equipment, or the like to cure the applied precoat composition to form the lower exterior carpet surface 18 as previously described.
  • the carpet 12 with the cured precoat 18 is then delivered in overlying relation to the particle/binder composition on the carrier belt 38 for subsequent compression and heating and/or cooling between the carrier belt 38 and the compression belt 36.
  • the coating or precoating of the carpet or greige goods need not be carried out in the same processing line as the setting (heated compression) of the particle backing 20. In fact, such steps are likely to
  • precoat 18 may not be required as shown in FIGS. 7 and 8.
  • Precoat 18 may be replaced with tiecoat or adhesive 60 supplied by roll coater or other coating device 90. If precoat 18 or tiecoat 60 is a hot melt adhesive, then curing station 34 may be a cooling station. Similarly, a pre-heating device such as infrared heaters may be added just upstream of belt 36.
  • the pressure and heat (and/or cooling) applied between the opposing belts 36, 38 causes the binder to bond or fuse the particles 22 together thereby forming a stable backing structure 20 of desired thickness and resilience.
  • the applied pressure is preferably in the range of from about 0.01 to about 50 pounds per square inch or greater, more preferably from about 1 to 10 pounds per square inch, and the temperature is preferably from about 250 to about 375 degrees Fahrenheit although higher or lower temperatures may be used depending upon the materials of construction and pressure utilized.
  • the heating or cooling platen 40 is preferably divided into a plurality of sections, for example, 4OA, 4OB, and 40C as shown in FIG. 9.
  • the sections can be heating or cooling sections, such as low heat, high heat, low cool, very low cool, and/or the like. If the binder is a heat set binder (heat sets or accelerates setting of the binder), it is preferred that section 40A be a low heat section, section 40B be a high heat section and that section 4OC be a cooling section. If the binder is a cool set (hot melt) binder, it is preferred that section 4OA be a high heat section, 4OB be a low cool section and section 4OC be a very cool section. If all of sections 4OA - 4OC are heating sections, then heating platen 40 and at least a portion of belts 36 and 38 may be located in an oven or steamer. If sections 4OA - 4OC are cooling sections, then cooling platen 40 and at least a portion of belts 36 and 38 may be located in a cooler or chiller.
  • platen 40 is shown in FIGs. 9, 9A and 9B and only platen 140 is shown in FIGS. 12 and 12A, it is contemplated that there may be a plurality of platens below belt 38 and/or above belt 36 to provide the desired heating and/or cooling.
  • the carpet and particle backing construction may be subjected to other heating and cooling means such as infrared (IR), microwave (MW), radio frequency (RF), steam, super heated steam, forced heating, hot fluid, hot air, oven, forced cooling, cold fluid, cold air, cooler, ambient cooling, and/or the like.
  • belts 36 and/or 38 may be heated and/or cooled as desired.
  • the particle/binder/additive layer may be pre-cured or partially cured upstream of belts 36, 38 using, for example, heating or cooling elements.
  • the combination of the precoat 18 and the binder 24 in the backing structure 20 may concurrently bond the carpet 12 to the backing structure 20.
  • the layered structure formed has the configuration illustrated in FIG. 1. As will be appreciated, a percentage of the lower surface of carpet 12 may be depressed into and below the surface of the backing structure 20 if desired.
  • the resultant structure may be delivered to a tile cutter 42 (or rug cutter) if it is to be used in a modular installation (or as a rug) or accumulated on a roll (not shown) if it is to be used in extended length segments, such as broadloom, roll goods, runners, attached cushion broadloom, stabilized attached cushion broadloom, 6 foot wide broadloom, or to be cut later.
  • coater 32 as well as supplies 48, 80, 84 and 86 are not used or, alternatively, a belt release agent is applied at, for example, supply 80 or 86, to belt 38 (and stays on belt 38, does not become part of product 10F).
  • products 10A and 10G are similar to products 10 and 1OF, respectively, with the addition of a lower layer, coating, film, release layer, or secondary backing 50 applied to belt 38 upstream of the application of the particle/binder/additive mixture.
  • the lower layer 50 may be, for example, a belt release agent, coating, skin, composition, or the like, such as a latex, acrylic, silicone, or other belt release or mold release agent that sticks to the particle backing 20 and prevents the particle backing 20 from sticking to the belt 38.
  • layer or coating or film or skin 50 may be added to belt 38, 38', 38", upstream of the particle/binder/additive mixture by, for example, at least one of supply 48, 80, 84, 86, 48', 80', 84', 86', 48", 80", 84", 86" depending on if the coating, layer, film, or the like 50 is a liquid, preformed film, thin film, or the like.
  • a liquid and/or powder coating 50 may be applied to belt 38 by supply, hopper, mixer, or feed 86 and doctored by a doctor blade 88, air knife, or the like.
  • the doctor blade 88 may be covered by a protective polymer film to keep the doctor blade clean.
  • a liquid and/or powder coating 50 may be applied to belt 38 by supply, hopper, mixer, or feed 80 and doctored by a doctor blade, air knife, or the like 82. It is understood that supplies 80 and 86 may also be spray heads or the like depending on the composition, thickness, and the like of coating, film, or layer 50.
  • layer 50 is a preformed film, such as a thin polypropylene film, acrylic film, latex film, urethane film, or the like
  • preformed film 50 may be added to belt 38 by supply, roll, feed, let off, or the like 48 or 84 upstream of the addition of the particle/binder/additive mixture.
  • a thin polypropylene film such as a black or clear film may be preferred to keep binder 24 from contacting and sticking to belt 38.
  • the carpet 12 tends to keep the binder 24 from contacting the belt 36.
  • layer 50, 54, 60, 150, 160, or the like may be or may be covered by a thin, friction enhancing coating material which may provide enhanced lateral grip and/or vertical stick to the floor or sub-floor.
  • friction enhancing materials or layers may optionally be added to the bottom of the surface coverings.
  • Such friction enhancing materials are described, for example, in US patent application 10/209,050 (US Published Application US 2004/0022991) incorporated by reference herein.
  • such friction enhancing materials provide additional lateral grip and some vertical stick.
  • backing 20 and/or the other backing layers or materials may include magnetic or magnetizable particles or material to provide a magnetic attraction to, for example, metal raised access flooring.
  • the friction enhancing material may be covered with a releasable, removable, cover sheet to provide a peel-n-stick surface covering product. The friction enhancing material may be added before, during or after product formation.
  • a secondary backing, release layer, lower textile or fabric layer, 52, 52', 52", 252, 452 is added to or laid on belt 38, 38', 38" upstream of the particle/binder/additive mixture and bonded to particle backing 20.
  • the secondary backing 52, 52', 52", 252, 452 may be, for example, a woven or nonwoven textile such as a woven polypropylene, nonwoven polypropylene, nonwoven polyester, nonwoven polyester/polypropylene, felt, mesh, scrim, mat, glass mat, nonwoven glass, flocked, needled, fabric, natural fiber or yarn, synthetic fiber or yarn, blend of natural and synthetic fibers or yarns, jute, sisal, cotton, and/or the like. It is preferred that layer 52 is a nonwoven textile or felt of polypropylene, polyester and/or acrylic fibers, with at least a portion thereof of recycled fibers, low melt fibers, low melt clad fibers, or the like. In one example, secondary backing or release layer 52 is a blend of polyester and polypropylene fibers ranging from 100% polyester to 100% polypropylene. The backing 52 can be used to balance the face 12 and provide for a flat product.
  • Secondary backing or release layer or textile 52 may be added to or laid on belt 38 via supply, feed, let off, or roll 48, 84, 48", 84', 48", 84" of FIGS. 9, 9A of 9B upstream of addition of the particle/binder/additive mixture.
  • Backing 52 is bound to particle backing 20 by, for example, binder 24, binder or adhesive in layer 52, low melt or fuse fibers in layer 52, and/or the like
  • layer 52 of product 1OC of FIG. 4 may be added to or laid on layer 50 on belt 38 by supply 48 or 84 and similar to layer 50 of product 10A of FIG. 2, layer 50 of product 10C of FIG. 4 may be added to belt 38 by supply 80, 84 or 86. If layer 50 of product 10C is added by supply 80, then layer 52 of product 10C is added by supply 48.
  • Layer 50 is bound, bonded, attached, or adhered to layer 52 of product 10C of FIG. 4 by, for example, binder 24 which passes through layer or fabric 52, the material of layer 50 adhering to layer 52, binder, low melt, or fuse materials in layer 52, and/or the like. Also, layers 50 and 52 may be preformed as a composite and supplied via roll 48 or 84.
  • layer 50 of product 10D of FIG. 5 may be added or laid on to layer 52 by, for example, supply 48 or 80 and layer 52 of product 10D of FIG. 5 may be added to or laid on belt 38 by supply or roll 84. Also, if layers 50 and 52 of product 10D are a preformed composite, then the composite can be added to or laid on belt 38 via supply or roll 48 or 84.
  • Layer or backing 52 of product 10D of FIG. 5 is bonded, bound, adhered, attached, or the like to the particle backing 20 via layer 50.
  • Layer 52 of FIG. 5 is bonded to layer 50 by the material or composition of layer 50, binder, low melt or fuse materials in layer 52, or the like. If, for example, layer 50 of FIG. 5 is a hot melt material, then the heat supplied by platen 40 may melt or soften layer 50 so that it binds to layer 52.
  • the release layer, coating, material, film, skin, or the like 54 is supplied to belt 38 upstream of the layer 52 by supply, feed, or the like 86.
  • the layer 52 is added over or laid on layer 54 by supply or roll 84.
  • the coating, layer, film, or the like 50 of FIG. 6 is added to or laid on layer 52 by supply, roll, feed, or the like 48 or 80.
  • 50, 52, 54 may be a preformed composite and supplied over belt 38 by supply or roll 48 or 84.
  • Layer 54 of product 1OE, like layer 50 of product 1OC is bonded, bound, adhered, or attached to layer 52 by the material of layer 54, binder, low melt, fuse, or the like materials in layer 52, material of layer 50 that passes through layer 52, and/or the like.
  • Layers, coating, backings, or the like 50, 150, of FIGS. 2, 4, 8, and 11 , and layer, coating, backing, or the like 54 of FIG. 6, may be a friction enhancing, releasable adhesive, or adhesive material such as TractionBack friction enhancing coating by Milliken & Company of LaGrange, Georgia, U.S.A.
  • a friction enhancing coating 50, 150, 54 preferably provides for lateral grip but limited vertical stick and is described, for example, in U.S. Published Applications 2003/0072911 , 2004/0022991 , 2003/0203152, and 2004/0022985 each of which are hereby incorporated by reference herein.
  • products 10F and 10G do not include a separate precoat layer, but instead rely upon the binder 24 of backing 20 to serve as the precoat and the adhesive or binder for joining the carpet 12 to the particle backing 20.
  • An especially high addition of binder 24, gravity, high pressure in the double belt laminator (36, 38, 40), and/or the like can produce a thick skin 26 of binder 24 on the bottom of particle backing 20.
  • Certain enhanced tufting substrates or primary backings 16 can reduce or eliminate the need for a precoat or tuft lock layer. If desired, a very thin primer material or layer can be added to the base of carpet 12 to enhance the bond between carpet 12 and backing 20.
  • FIGS. 1 - 8, 10 - 11 , and 25 schematically illustrate a tufted, level, cut pile surface covering
  • the carpet 12 of the present invention is not limited to level, cut pile, tufted substrates.
  • the present invention encompasses not only level cut pile carpets, but also multilevel cut pile, textured cut pile, loop pile, cut and loop pile, multi-level loop, multilevel cut and loop, needled, needle punched, woven (FIGS. 13 - 19), bonded (FIGS. 20), nonwoven, knit, plush, nap, textured nap, textured loop, treated loop, non-pile, and/or the like.
  • an additional layer of adhesive such as a thermoset or thermoplastic resilient adhesive, for example, a thermoset urethane, a hot melt urethane, polyester, polyamide, or the like may be added at the intersection between the particle/binder backing 20 and the lower surface or precoat 18 of carpet 12.
  • a thermoset or thermoplastic resilient adhesive for example, a thermoset urethane, a hot melt urethane, polyester, polyamide, or the like may be added at the intersection between the particle/binder backing 20 and the lower surface or precoat 18 of carpet 12.
  • an adhesive 60 may further stabilize the structure and provide enhanced protection against delamination.
  • an adhesive or tiecoat layer 60 such as a urethane hot melt, reactive urethane hot melt, thermoset urethane, or the like, may be added in place of precoat 18, between precoat 18 and particle backing 20 (FIG. 15), between particle backing 20 and a secondary backing (FIGS. 5 and 16), below a secondary backing 52 (FIGS. 6 and 11 ), and/or the like
  • adhesive or tiecoat material or layer 60 can be added at applicator 90, thin film adhesive 6OC can be added at supply roll 48, adhesive 6OA can be added at supply 80, thin film adhesive 6OD can be added at supply roll 84, and adhesive 6OB can be added at supply 86.
  • Adhesive 6OA and 6OB can be doctored by doctor blades 82 and 88, respectively. If used, such an adhesive layer 60, 160, 260, 264 may be applied in line such as on the bottom of the carpet 12 or precoat 18 using coating techniques such as roll coaters or the like. Alternatively, it may also be applied to the top of the backing structure 20 if desired.
  • FIG. 9A illustrates an exemplary processing line for the incorporation of such preformed particle backings, such as, crumb rubber or rebond foam into a layered structure as described in relation to FIG. 1.
  • preformed particle backings such as, crumb rubber or rebond foam
  • FIG. 9A elements corresponding to those described in relation to FIG. 9 are designated by corresponding reference numerals with a prime.
  • FIG. 9A The process illustrated in FIG. 9A is substantially identical to that described in relation to FIG. 9 with the exception that the deposited mass of particles, binder and additives (if any) is replaced by a roll 74' of a preformed sheet 20' of particle backing, for example, particles or crumbs and binder, particles or crumbs, binder and additives, particles and additives, and the like such as rubber, cork, carpet, foam or other particles plus binder and any additives.
  • a roll 74' of a preformed sheet 20' of particle backing for example, particles or crumbs and binder, particles or crumbs, binder and additives, particles and additives, and the like such as rubber, cork, carpet, foam or other particles plus binder and any additives.
  • a coater 90' is used to apply a layer of adhesive or tiecoat 60' such as a thermoset or thermoplastic resilient adhesive, such as a hot melt urethane, polyester, polyamide, or the like to the underside of the carpet 12' prior to mating with the preformed particle backing sheet 20'.
  • adhesive or tiecoat 60' such as a thermoset or thermoplastic resilient adhesive, such as a hot melt urethane, polyester, polyamide, or the like
  • the carpet 12' is concurrently bonded to the backing structure 20' by the intermediate adhesive layer 60', any reactive binder in backing 20', heat, pressure, moisture, and the like.
  • the resultant structure may be delivered to a tile cutter 42' if it is to be used in a modular installation or accumulated on a roll (not shown) if it is to be used in extended length segments, as roll goods, or cut later.
  • a tile cutter 42' if it is to be used in a modular installation or accumulated on a roll (not shown) if it is to be used in extended length segments, as roll goods, or cut later.
  • any of devices, supplies, coaters, doctoring devices, and/or the like for example, 32', 34', 90', 48', 80', 84', 86', or the like may or may not be used in the production of particular products such as shown, for example, in any of FIGS. 1 - 8, 10, 11 , and 13 - 25 and variations thereof preferably incorporating a carpet face and a particular backing or particle backing layer plus any additional layers, elements, skins, coatings, or the like.
  • FIG. 9B An alternative exemplary process for use in forming the illustrated and described structures is shown in FIG. 9B.
  • elements corresponding to those described in relation to FIG. 9 are designated by corresponding reference numerals with a double prime.
  • the particle/binder/additive composition 22", 24", 28" is delivered onto the carrier belt 38" from deposit station 92" to form a build-up or puddle 93 of the particle/binder/additive composition between a wall, stop, or dam 94 and the nip between a doctor or compression roll 37" and the carrier belt 38".
  • the compression roll 37" presses the bottom of the carpet 12" into the particle/binder/additive mass while simultaneously controlling the thickness of the overall construction.
  • the underlying portion of heating or cooling elements 40" raises or lowers the temperature of the layers to initiate bonding.
  • the formed structure thereafter passes between the carrier belt 38" and a downstream compression belt 36" to complete joinder.
  • the resultant structure may be delivered to a tile cutter 42" if it is to be used in a modular installation or accumulated on a roll (not shown) if it is to be used in extended length segments, as roll goods, or cut later.
  • any of devices, supplies, coaters, doctoring devices, and/or the like for example, 32", 34", 90", 48", 80", 84", 86", or the like may or may not be used in the production of a particular product such as shown, for example, in any of FIGS. 1 - 8, 10, 11 , and 13 - 25 and variations thereof preferably incorporating a carpet face and a particular backing or particle backing layer plus any additional layers, elements, skins, coatings, or the like.
  • the present invention is also readily adaptable to structures requiring substantial levels of internal dimensional stability such as, for example, free lay carpet tile, cushion back carpet tile, stabilized broadloom, and the like.
  • One exemplary structure for a surface covering 110 intended to have such internal dimensional stability is illustrated in FIG. 10 wherein elements corresponding to those in earlier figures such as FIGS. 1 - 6 are designated by corresponding reference numerals increased by 100. As shown, in the embodiment of FIG.
  • the surface covering 110 such as a carpet tile or the like incorporates a multi-layer stabilized backing structure 120 having a stabilizing or reinforcement layer 162 such as a woven or non-woven textile or material, for example, a non woven glass mat disposed between opposing particle backing layers 120A, 120B of virgin, renewable, recycled, or recyclable particles, such as cork, foam, carpet or rubber particles held together with one or more binders and including any additives as previously described.
  • a stabilizing or reinforcement layer 162 such as a woven or non-woven textile or material, for example, a non woven glass mat disposed between opposing particle backing layers 120A, 120B of virgin, renewable, recycled, or recyclable particles, such as cork, foam, carpet or rubber particles held together with one or more binders and including any additives as previously described.
  • one or more layers of adhesive 160 such as a hot melt urethane, polyester, polyamide or the like may be disposed, for example, between the carpet 112 and the upper surface of the backing structure 120.
  • FIG. 12 is a schematic of an integrated exemplary processing line.
  • a backing sheet 152 of, for example, a textile fabric, film or the like, such as a woven or non- woven textile material is delivered from roll 184 in overlying relation to a carrier belt 138.
  • the backing sheet 152 is preferably a non- woven felt material incorporating polyester and/or polypropylene fibers in any desired ratio between 100% polyester to 100% polypropylene and may include acrylic fibers as well.
  • a mixture of foam, rubber and/or cork particles in blended relation with a desired binder is delivered from a first deposit station including a mixer 180 that blends the particles 122, binder 124, and any additives 128 and deposits them onto the backing sheet 152.
  • a doctor blade 182 or other suitable levelling device is positioned downstream of the first deposit station.
  • a layer of stabilizing material 162 such as woven or non-woven glass is thereafter applied from roll 148 in juxtaposed relation across the particle and binder layer.
  • a second mixture of particles, binder and additives in blended relation with a desired binder is delivered from a mixer 144 onto the stabilizing layer 162 from a second deposit station that blends the particles and binder and includes a deposit head 145.
  • a doctor blade 146 or other suitable levelling device is positioned downstream of the second deposit station.
  • the carrier belt 138 like belt 136, is made, for example, of PTFE-coated woven glass fabric to prevent the applied materials from sticking to it.
  • the carrier belt 138 advances in the direction of the arrows (clockwise as shown). This movement may be either stepwise or continuous depending upon the nature of the product being formed.
  • the carrier belt 138 may have a smooth or textured outer surface. A textured surface of the belt 138 may impart a texture to the base of product 110.
  • the carrier belt 138 is disposed in opposing relation to motor driven compression belt 136 which moves in reverse angular relation to the carrier belt (counter clockwise as shown) to establish a nip zone between the belts in the vicinity of heating and/or cooling elements 140.
  • a carpet or carpet fabric 112 is conveyed from a roll 130 to a first coater 132 such as a roll coater or the like wherein the precoat or film forming composition 118 is applied in saturating relation to the bottom of the carpet 112.
  • the precoat composition 118 is preferably a liquid latex or urethane precoat material, binder, primer, or the like although acrylics and other suitable compositions such as SBR, EVA, PVC, or blends may likewise be utilized if desired.
  • the coated carpet fabric is then passed through a curing station 134 such as a heater, cooler, dryer, or the like to cure the applied composition 118 thereby forming the lower exterior of carpet 112.
  • the precoated carpet 112 may then be delivered to a second coater 160 such as a reverse roll coater or the like for application of the adhesive layer 160 to the underside surface of carpet 112.
  • the carpet with the cured coating 118 and applied adhesive 160 is then applied in overlying relation to the upper layer of particle/binder composition for subsequent compression and heating and/or cooling between the carrier belt 138 and the compression belt 136.
  • the coating of the carpet fabric need not be carried out in the same processing line as the heated compression. In fact, such steps are likely to be carried out in separate processing lines to facilitate processing freedom.
  • the carpet with or without precoat 118 and/or adhesive 160 may be supplied in roll form.
  • the pressure, heat, cold, moisture, and/or the like applied between the opposing belts causes the binder to bond or fuse the particles together thereby forming a stable backing structure 120 adhered to both sides of the stabilizing layer 162 and to the carpet 112.
  • the applied pressure is preferably in the range of from about 0.01 to about 50 pounds per square inch, preferably from about 0.1 to about 20 pounds per square inch, and most preferably between about 2 to about 8 pounds per square inch to avoid excess pressure, pile crush, etc.
  • the temperature is preferably in the range of from about 200 to 500 degrees Farenheit, more preferably, about 250 to 375 degrees Fahrenheit.
  • the exterior composite layer 120B is concurrently bonded to the backing structure 152, 150, 160 by the binder in combination with any applied adhesive.
  • the resultant structure may be delivered to a tile cutter 142 if it is to be used in a modular installation or accumulated on a roll (not shown) if it is to be used in extended length segments, as roll goods, or to be cut later.
  • the indexing or continuous movement of belts 136, 138 depends on factors including the product to be produced, the amount of compression required, the speed of setting or curing of the binder, additives, adhesives, precoats, films, coatings, and/or the like.
  • a section or increment of product composite can sit between belts 136, 138 under pressure and heat for, for example, anywhere from about 1 to 60 minutes, preferably 2 to 30 minutes, more preferably less than 5 minutes.
  • the time to set or cure can be reduced by, for example, adding water and/or other catalyst or accelerators to the binder, particle/binder/additive mix, particle/binder mix, particles, additives, and/or the like.
  • increases in pressure, temperature can reduce set time.
  • belts 136, 138 can be driven in increments or steps, it is preferred that they are run continuously for an in-line, continuous operation.
  • belts 136, 138 may form part of a continuous double belt laminator system and may be run, for example, at 10 feet per minute, 20 feet per minute, 40 feet per minute, or the like.
  • the carpet face particle backing composite have an overall dwell time, for example, under heat and pressure of between about 1 to 20 minutes, more preferred 2 to 10 minutes, most preferred about 3 to 8 minutes.
  • the product 110 include a lower or bottom coating, film, layer, and/or the like such as 150, 160, or 120C. It may be most preferred that product 110 have a lower coating of a friction enhancing composition.
  • surface coverings of the present invention may incorporate preformed particle backing structures of such virgin, renewable, recyclable, recycled, natural, synthetic, and/or the like particles, for example, preformed particle/binder/additive backings or backing layers, such as so- called "rebond” or "bonded” foam, such as rebond polyurethane foam, wherein relatively small pieces of scrap foam are formed into sheets with resilient binder between the foam pieces.
  • FIG. 12A illustrates an exemplary processing line for the incorporation of such preformed particle backing such as crumb rubber, rebond foam or other bonded particles into a layered structure as described in relation to, for example, FIGS. 10 and 11.
  • elements corresponding to those described in relation to FIGS. 10, 11 and 12 are designated by corresponding reference numerals with a prime.
  • the exemplary process illustrated in FIG. 12A is substantially identical to that described in relation to FIG. 12 with the exception that the deposited layers of particles and binder 120A, 120B are replaced by preformed sheets 120A', 120B' of preformed particle backing, such as rebond foam.
  • layers of adhesive 160' such as thermoset or thermoplastic adhesive, such as hot melt urethane adhesive or the like are applied between each of the preformed sheets 120A', 120B' of bonded particles and the adjacent layers by coaters 190', 192', 194', 196' to facilitate bonding.
  • the pressure and heat applied causes the bonded particle layers to partially compress.
  • the adhesive and/or binder between the particles may fuse the particles together in the partially compressed state thereby forming a stable backing structure of desired thickness and resilience. In this regard, greater compression may give rise to reduced levels of cushioning resilience.
  • the bottom of carpet 112' is concurrently bonded to the backing structure 120A' by the adhesive 160' and/or binder of the preformed particle backing sheet in combination with the applied adhesive 160'.
  • the resultant structure may be delivered to a tile cutter 142' if it is to be used in a modular installation or accumulated on a roll (not shown) if it is to be used in extended length segments, as roll goods, or cut later.
  • any of devices, supplies, coaters, doctoring devices, and/or the like 132, 132', 134, 134', 190, 190", 148, 148', 176, 180, 184, 184', 186, and/or 186', of FIGS. 12 or 12A, or the like may or may not be used in the production of particular products such as shown, for example, in any of FIGS. 1 - 8, 10, 11 , and 13 - 25 and variations thereof preferably incorporating a carpet face and a particle backing or one or more particle backing layers plus any additional layers, elements, skins, coatings, or the like.
  • the product 110A of FIG. 11 may if desired include one or more additional adhesive layers, for example, adhesive layer 160, 160' between precoat 118 and particle backing 120A, adhesive layer 160A, 160A' between particle backing 120A and stabilizing layer 162, adhesive layer 160B, 160B' between stabilizing layer 162 and particle backing layer 120B, and adhesive layer 160C, 160C between particle backing layer 120B and backing material 152.
  • adhesive layer 160, 160' between precoat 118 and particle backing 120A adhesive layer 160A, 160A' between particle backing 120A and stabilizing layer 162, adhesive layer 160B, 160B' between stabilizing layer 162 and particle backing layer 120B, and adhesive layer 160C, 160C between particle backing layer 120B and backing material 152.
  • FIGS. 13 - 18 show a woven carpet construction and in which elements corresponding to those previously described are designated by like reference numerals within a 200 series.
  • the surface covering 210 in FIG. 13 is of substantially the same construction as described in relation to FIG. 3 but with a woven carpet face 212 including yarns 214 and a precoat 218.
  • a backing sheet 252 is preferably held in place by binder 224 securing particles 222 together in the particle backing layer 220.
  • an additional adhesive layer 260 may be used if desired.
  • such a structure may be formed by a process as illustrated and described in relation to FIG. 9 if the backing structure 220 is of a particle/binder/additive mixture, FIG. 9A if it is a preformed particle backing or FIG. 9B as an alternative process.
  • product 210 may be produced on the same range or process line by merely replacing tufted carpet 12 with woven carpet 212. Also, one need not use feeds or supplies 80, 84, 86, and 90 to make product 210.
  • product 210A can be made on the range or process line of FIG. 9 using feeds or supplies 30, 32, 90, 48, 80 and 84.
  • product 210B can be made on the range or process line of FlG. 9 using feeds or supplies 30, 32, 90, 44, 45, and 48.
  • product 210C can be made on the range or product line of FIG. 9 using feeds or supplies 30, 32, 44, 45, 80, and 84.
  • product 210D can be made on the range or process line of FIG. 9 using feed or supplies 30, 32, 90, 44, 45, 80, and 84.
  • product 210E can be made on the equipment of FIG. 9 using feeds or supplies 30, 32, 90, 48, 80, and 84 if both layers 262 and 257 are let off of roll 48. Alternatively, another roll or let off for layer 257 could be add between roll 48 and feed 80.
  • a stabilizing layer 262 such as woven or nonwoven glass mat or scrim or the like is adhesively bonded below the carpet material 212 by a layer of adhesive 260 such as a hot melt urethane or the like.
  • adhesive 260 such as a hot melt urethane or the like.
  • the resulting structure provides substantial internal dimensional stability and may be particularly suitable for articles such as carpet tile and the like.
  • a particle/binder layer 220 is adhesively bonded below the carpet 212 by a layer of adhesive 260 or such as a hot melt urethane or the like.
  • the secondary backing 52, 252, 352, 452 may include additional layers, coatings, skins, films, and/or the like.
  • a friction enhancing coating 50 or 60 may be added below textile or material 52.
  • a TractionBack friction enhancing coating by Milliken & Company of Spartanburg, South Carolina, U.S.A. may be added.
  • the secondary backing may include a release material, release film, release sheet, or the like.
  • this construction is a modification of that in FIGS. 13 and 15 wherein the adhesive layer 260 is positioned between the backing structure 220 and a fibrous backing sheet 252.
  • Adhesive layer 260 may be helpful in bonding backing 220 to, for example, a polyester or polypropylene nonwoven or felt backing 252.
  • this construction is a modification of that in FIGS. 13, 15, and 16 wherein an adhesive layer 260A is disposed between carpet 212 and particle backing layer 220 and another adhesive layer 260B is disposed between the backing structure 220 and a fibrous backing sheet 252.
  • this construction is a modification of that in FIG. 14 wherein a scrim layer 257 such as a glass, polyester, polypropylene and/or the like woven or nonwoven mesh or net-like material is disposed adjacent to the stabilizing layer 262 such as a nonwoven glass mat.
  • the resulting structure provides substantial internal dimensional stability and may be particularly suitable for articles such as carpet tile and the like.
  • the scrim 257 may balance any shrinkage in the face material 212 or backing 252 to provide for a flat or slightly domed product.
  • the additional stabilizing layer or scrim 257 may facilitate the removal of textile backing 252, use of a lighter face fabric 214, use of less composition 218 or 260, the provision of a more durable, printable product, and/or the like
  • FIG. 19 Another contemplated construction is illustrated in FIG. 19 wherein elements corresponding to those previously described are designated by like reference numerals within a 300 series. As will be appreciated, this construction is a modification of that in FIG. 13 wherein no additional adhesive is disposed between the precoat 318 and underlying layers. It is contemplated that such a structure may be formed by a process as illustrated and described in relation to any of FIGS. 9, 9A, 9B, 12, 12A. For example, product 310 can be made on the range of FIG. 12 using feeds or supplies 130, 132, 144, 148, 180, and 184.
  • FIG. 20 Yet another contemplated construction is illustrated in FIG. 20 with reference numerals in a 400 series.
  • Product 410 of FIG. 20 is like product 10B of FIG. 3 and like product 210 of FIG. 13 except that it has a bonded carpet face 412 in place of a tufted or woven face.
  • the bonded face 412 includes tufts 414, an adhesive 470, a support substrate 472, and a precoat layer 418.
  • Precoat 418 may be eliminated if desired (like in FIGS. 7 and 8) or if adhesive 470 extends below substrate 472 and is compatible with the binder in particle backing 420.
  • Product 410 can be made the same way as products 10B and 210.
  • additional layers of adhesive such as hot melt urethane, polyester and/or polyamide or the like may be added at one or more of the intersections between any of the layers in any of the illustrated embodiments.
  • a layer of adhesive may be added between the backing sheet and the adjacent backing layer and/or between the lower backing layer and the stabilizing layer (if utilized) and/or between the stabilizing layer (if utilized) and the overlying backing layer (if present).
  • the structure may be formed with or without a fibrous backing sheet.
  • additional binder may be added to the surface of any layers, sheets, or the like, such as preformed particle sheets such as crumb rubber or rebond foam, or may be used as an adhesive, tiecoat, etc.
  • One contemplated benefit of the constructions of the present invention is the ability to incorporate large percentages of recycled, renewable, recyclable, natural, biodegradable, biobased, or the like materials such as recycled waste products, such as recycled weather stripping, recycled mats, recycled tires, recycled carpet waste, and the like.
  • recycled waste products such as recycled weather stripping, recycled mats, recycled tires, recycled carpet waste, and the like.
  • renewable resources such as natural products such as cork or wood may be used.
  • recycled particle or crumb materials such as ground up carpet may be blended with the rubber particles and binder prior to being deposited in the desired layered relation. In such a process the carpet waste may not undergo melting but may rather form a constituent of the resilient matrix forming the backing.
  • relatively large amounts of carpet waste may be incorporated without negatively impacting resiliency since the individual rubber particles are not melted, voids remain, etc.
  • the particle binder mixture is made up of one-third cork particles, one-third recycled rubber particles, and one-third recycled surface covering particles.
  • the one-third proportion can be based on either weight or volume.
  • Binder such as MDI binder bonds the three different types of particles together.
  • an exemplary carpet product such as a carpet tile 900 has a decorative show surface 910 defined by an exterior layer such as a pile or nap layer incorporating a decorative appearance, color, shade, pattern, texture, or the like, such as a jet dyed pattern, overlying a particle backing 920.
  • the materials forming the backing structures may themselves be used to provide a portion of an aesthetically pleasing show surface.
  • a surface covering construction such as a carpet tile 1000 is illustrated having a decorative show surface 1010 defined by a composite layer such as a pile or nap layer incorporating a decorative appearance, color, shade, pattern, texture, or the like, such as a jet dyed pattern, overlying a particle backing 1020.
  • a portion of the particle backing 1020 extends outboard or outward of the exterior layer to define a decorative backing border 1030.
  • the particle backing 1020 may have a pleasing appearance. For example, a mixture of rubber and cork chips or a mixture of colored particles, such as colored EPDM particles, may look good on their own.
  • the materials forming the backing structures may also be used to provide a portion of an aesthetically pleasing show surface by using show surface fabric constituents of relatively open weave or knit construction (including mesh or net- like scrims) such that the backing is visible through the show surface fabric.
  • Such open fabrics may be used alone or in combination with outboard borders.
  • bottom surface of any of the structures, constructions, or products of the present invention may also be textured such as by embossing to, for example, enhance surface friction or the like.
  • the construction of a carpet face and a backing of at least one layer of agglomerated, adjoined particles are cured, cut into floor tile blanks, colored, printed or dyed, then cured, sheared, packaged, and the like.
  • a backed floor tile blank (carpet face, particle/binder backing, with or without an additional stabilizing layer, adhesive layer, textile backing, friction enhancing backing, and/or the like) with a light color or white textile face adapted to be colored, printed, dyed, or the like is adapted to be colored, dyed, printed, textured, treated, embossed, and can have, for example, an image, design or pattern applied thereto with relative precision (for example, by placing a square tile blank in a jig) to produce, for example, a floor tile with an image, pattern, or design which will register with an adjacent image, pattern, or design of an abutting floor tile in a floor tile installation.
  • a large image, pattern or design can be split up into a number of parts with each part on a separate tile.
  • a tile pattern that is intended to mate with at least certain elements of an adjacent tile pattern can do so with precision and in registration to provide a very pleasing, seamless, appearance to the overall installation.
  • a tile blank or modular blank with a carpet face of show surface and a particle/binder backing may be cured and then colored, printed, dyed, and/or the like by, for example, a printing process (for example, transfer printing, screen printing, rotary printing, or the like).
  • a printing process for example, transfer printing, screen printing, rotary printing, or the like.
  • the face and/or backing of the surface covering of the present invention meets or exceeds industry standards of, for example, flammability, smoke, toxicity, soil protection, antimicrobial, odour, VOC, smoke density, pill test, lightfastness, crocking, static electricity, dimensional stability, Aachen test, dye fastness, durability, caster chair test, face weight, height, flexibility, size, cup, curl, bow, bias, skew, height variation, dimensional variation, stain protection, soil resistance, stain resistance, cleanability, commercial rating, residential rating, cushion, resilience, drape, seamability, appearance retention, compression, compression set, recycled content, recyclable content, renewable material content, and/or other industry standards, environmental standards, test ratings, and/or the like.
  • industry standards for example, flammability, smoke, toxicity, soil protection, antimicrobial, odour, VOC, smoke density, pill test, lightfastness, crocking, static electricity, dimensional stability, Aachen test, dye fastness, durability, caster chair test, face weight, height
  • floor covering industry standards and/or specifications more particularly, commercial flooring standards, residential flooring standards, institutional flooring standards (such as hospital, education and/or government standards), hospitality flooring standards, retail flooring standards, and/or the like.
  • the surface covering may be PVC-free.
  • the particles and/or crumbs in the particle/binder backing structure or layer be about 6mm or less (powder or granules).
  • the particle/binder backing of at least one embodiment of the present invention is cured at about 100 psi (pounds per square inch) or less, preferably 50 psi or less, more preferably 25 psi or less, most preferably 10 psi or less.
  • lateral grip with smooth and even carpeted surfaces.
  • This lateral grip provides surface coverings, for example, flooring which tends not to creep or walk.
  • Floor tiles of the present invention having this lateral grip tend to stay in place after installed even without full spread adhesive installation, releasable adhesive installation, double sticky tape installation, and even free-lay or adhesive free installation.
  • the particles or crumbs of the particle/binder or particle/binder/additive backing of at least certain embodiments of the present invention may be selected from recycled, recyclable, renewable, waste, by-product, reclaimed, and/or virgin materials.
  • recycled flooring recycled foam, recycled rubber, recycled cork, cork, wood, and combinations thereof, are preferable.
  • Recycled flooring such as recycled carpet, recycled carpet tile, recycled waste carpet, recycled carpet, recycled trim waste, recycled carped production waste, and the like can be processed to produce particles or crumbs of less than about 20 mm, preferably less than about 15mm, more preferably less than about 10mm, and most preferably less than about 6mm (powder or granules).
  • post consumer recycled content may be preferred, post industrial recycled content, renewable material, recyclable material, bio-based, biodegradable, and other environmental friendly or environmentally responsible materials may be used.
  • the constructions of the present invention may be made, processed, manufactured, or the like inverted or upside down to facilitate or simplify construction.
  • the product 10B may be made on the range or process line of FIG. 9 (on a double belt laminator) by precoating the carpet, inverting the carpet (so that is tufts down as shown in FIG.
  • the products of the present invention can be made right side up or upside down as desired.
  • the particle backing of the present invention may be a preformed composite including a particle backing layer, a stabilizing layer attached to one side of the particle backing layer and a backing material attached to the other side of the particle backing layer (see FIG. 14).
  • This three component composite backing may be laminated to a carpet face using an adhesive or tiecoat layer (see FIG. 14). It is therefore intended that the present invention shall extend to all such modifications and variations as may incorporate the broad aspects of the present invention within the full spirit and scope of the following claims and all equivalents thereto.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Carpets (AREA)

Abstract

L'invention concerne des revêtements de surface, tels que des revêtements de sol comprenant une face tapis ou une face présentation en relation de recouvrement avec un support d'éléments particulaires assemblés. Les revêtements de surface sont, notamment, des tapis, des carreaux de tapis, des revêtements de sol modulaires, des tapis de couloir, des petits tapis, des marchandises en rouleau, des moquettes stabilisées ou analogues incorporant une surface ou une face de tapis dotées, par exemple, d'une surface en velours ou non. Dans un mode de réalisation, le tapis comprend une couche d'implantation de touffes ou de préenduction, telle qu'une couche intermédiaire d'uréthanne disposée par recouvrement sur un support résilient formé d'une masse, d'un mélange ou d'une boue, par exemple, de particules ou de granules liées ensemble en relation d'assemblage par un liant. Une ou plusieurs couche(s) de stabilisation et/ou de support facultative(s) peuvent être incluses. L'invention concerne également des procédés permettant de produire ces revêtements de surface.
PCT/US2006/020129 2005-05-24 2006-05-24 Revetements de surface et leurs procedes WO2006127837A1 (fr)

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GB0722863A GB2440729A (en) 2005-05-24 2006-05-24 Surface converings and related methods

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US60/684,250 2005-05-24

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PCT/US2006/020129 WO2006127837A1 (fr) 2005-05-24 2006-05-24 Revetements de surface et leurs procedes

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GB2482240A (en) * 2010-07-19 2012-01-25 Instafibre Ltd Sheet, used as e.g. a removable floor covering, comprising rubber crumb, scrim and adhesive
WO2012010830A3 (fr) * 2010-07-19 2012-06-14 Instafibre Ltd Produits adhésifs en feuille
WO2012010831A3 (fr) * 2010-07-19 2012-06-28 Instafibre Ltd Sous-couche
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CN106193496A (zh) * 2015-04-30 2016-12-07 孙高雷 一种软性建筑装饰板的生产方法
CN104775585A (zh) * 2015-04-30 2015-07-15 孙高雷 一种软性建筑装饰板的生产方法
CN106193494A (zh) * 2015-04-30 2016-12-07 孙高雷 一种软性建筑装饰板的生产方法
CN106193496B (zh) * 2015-04-30 2018-09-11 宁波高新区起兴机电有限公司 一种软性建筑装饰板的生产方法
CN104775585B (zh) * 2015-04-30 2018-01-26 陶健 一种软性建筑装饰板的生产方法
CN106193494B (zh) * 2015-04-30 2018-09-11 宁波高新区起兴机电有限公司 一种软性建筑装饰板的生产方法
CN105249784A (zh) * 2015-11-18 2016-01-20 张继金 利用废旧衣物制作地垫的方法
CN105835463A (zh) * 2016-05-16 2016-08-10 佛山市顺德区琅美地毯制品有限公司 剑麻地毯及其生产方法
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KR102277572B1 (ko) 2019-06-28 2021-07-15 주식회사 금진 플로킹 카펫 타일 및 그 제조 방법
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BE1028924B1 (nl) * 2020-12-21 2022-07-19 Finipur Bvba Verbeterde samengestelde mat, werkwijze voor vervaardiging ervan en gebruik van verbeterde samengestelde mat
GB2617444A (en) * 2022-04-08 2023-10-11 Interfloor Ltd System and method to manufacture foam underlay
WO2023194700A1 (fr) * 2022-04-08 2023-10-12 Interfloor Limited Système et procédé de fabrication de sous-couche en mousse
GB2617444B (en) * 2022-04-08 2024-07-24 Interfloor Ltd System and method to manufacture foam underlay

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WO2006127873A1 (fr) 2006-11-30

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