Note: Descriptions are shown in the official language in which they were submitted.
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POLYURETHANE BACKED PRODUCTS AND METHODS
Technical Field
In accordance with at least one embodiment, the present invention relates
to surface coverings such as floor coverings having a show surface material in
contacting overlying relation to a backing of polyurethane with or without
additional structures, layers, backings, and/or the like. In particular, but
not
exclusively, at least one embodiment of the invention relates to a surface
covering such as a carpet, carpet tile, area rug, floor mat or the like
incorporating
a textile face, such as a tufted, bonded, flocked, needled, needle punched,
woven, non-woven, or knit fabric structure disposed in contacting overlying
relation to at least a polyurethane layer. The polyurethane layer may form a
precoat, tiecoat and/or backing and may be foam or non-foam, and may
preferably be flexible. One or more optional intermediate structure layers may
be disposed over, in, on, or under the polyurethane and one or more optional
backing layers may be disposed across the underside of the polyurethane.
Methods of making such surface coverings, processes, uses, apparatus,
components, materials, and/or products are also provided.
Background to the Invention
It is known to provide carpeting and carpet tile with, for example, tufted or
bonded carpet faces, and with backing layers formed from so-called "virgin" or
"filled" foam, for example, polyurethane foam, or from "rebond" or "bonded"
foam
wherein chips or pieces of recycled foam are held together by a binder. It is
also
known to form mats such as floor mats or entry way mats from tufted or bonded
carpet faces secured in bonded relation to rubber backings.
One disadvantage of prior flooring or floor covering, constructions has
been the relatively complex arrangement of various structural layers to
provide
dimensional stability and wear performance of the products. In this regard,
various prior constructions have relied on the inclusion of various adhesive
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layers, stabilizing layers, and/or on the use of relatively high strength
backing
layers such as PVC or vulcanized rubber to provide a structure that remains
flat
across a floor or sub-floor without deforming over time.
Examples of prior carpet tile constructions are described, for example, in
U.S. Patents 4,522,857; 5,545,276; 5,948,500; 6,203,881; and 6,468,623 each
of which are hereby incorporated by reference herein.
Examples of prior floor mats are described in, for example, U.S. Patents
6,296,919; 6,478,995; and RE38,422 each of which are hereby incorporated by
reference herein.
Summary of the Invention
At least one embodiment of the present invention provides advantages
and/or alternatives over the prior art by providing a surface covering such as
a
carpet, carpet tile, area rug, floor mat, flooring, floor tile, rug, mat,
broadloom
carpet, stabilized broadloom, roll goods, modular flooring, 6-foot broadloom
or
the like incorporating a textile face, such as a tufted, bonded, flocked,
needled,
needle punched, woven, non-woven, or kn'it fabric structure disposed in
contacting overlying relation to at least one polyurethane layer. One or more
optional intermediate structure layers may be disposed over, in, on, or under
the
polyurethane and one or more optional backing layers may be disposed across
the underside of the polyurethane.
According to a potentially preferred feature, the polyurethane is in direct
contacting relation with the underside of the textile face structure without
the
need for any intermediate binder or pre-coat.
According to another potentially preferred feature, the textile face
structure is preferably substantially relaxed such as by steaming, dyeing or
the
like prior to application of the polyurethane so as to substantially avoid
subsequent deformation due to shrinkage.
According to another possibly preferred feature, a polyurethane material
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or layer is the reaction product of castor oil, an isocyanate and an optional
catalyst, an optional filler, and an optional additional polyol.
According to still yet another possibly preferred feature, a polyurethane
material or layer is the reaction product of a chemically unmodified castor
oil
(preferably filtered and dried), an isocyanate, a filler (preferably at least
42% by
weight filler), and an optional catalyst, an optional additional polyol, or
both.
According to still another potentially preferred feature, a cured flexible
polyurethane material is the reaction product of
(i) a polyol component in which castor oil is the predominant reactive
polyol; and
(ii) an isocyanate component,
and the polyurethane material further comprising a filler, the filler
being at least 42% by weight of the polyurethane material.
According to still another potentially preferred feature, a cured flexible
polyurethane material, is the reaction product of
(i) a polyol component; and
(ii) an isocyanate component,
and the polyurethane material further comprising a filler, the filler
being at least 42% by weight of the polyurethane material, and the
cured flexible material being formed substantially in the absence of
catalyst.
According to still another potentially preferred feature, a cured flexible
polyurethane material, is the reaction product of
(i) a polyol component; and
(ii) an isocyanate component,
and the polyurethane material further comprising a filler, the filler
being at least 42% by weight of the polyurethane material, and the
cured flexible material being formed substantially in the absence of
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a surfactant or a wetting agent.
According to yet another possibly preferred feature, a carpet tile has a
textile face structure disposed in overlying contacting relation to at least
one
layer of flexible, polyurethane backing composition, the polyurethane
composition being the reaction product of
(i) a polyol component in which castor oil is the predominant reactive
polyol; and
(ii) an isocyanate component,
and the polyurethane composition further comprising a filler, the
filler being at least 42% by weight of the polyurethane composition
and being preferably selected from coal fly ash, recycled gypsum,
recycled glass, and combinations thereof.
The feature above, wherein substantially the entire polyol component is
castor oil, wherein the polyurethane composition is substantially free of
surfactant, wherein the polyurethane composition is substantially free of
catalyst,
wherein said layer of flexible, polyurethane backing composition is at least
one of
a precoat, tiecoat, and backing, further comprising at least one structural
support
layer disposed in, on, under, or over said layer of flexible, polyurethane
backing
composition, wherein the filler component is at least 50% by weight of the
polyurethane composition, further comprising a minor polyol component which is
not castor oil, wherein the minor polyol component is selected from the group
consisting of petroleum based polyols, natural polyols, polyols with
functionality
of 2 or 3 and a molecular weight of about 750 to about 7500, polypropylene
glycol (PPG) polyols, polyethylene glycol (PEG) polyols, PPG-PEG copolymer
polyols, and combinations thereof, wherein the minor polyol component is
present in an amount of less than about 50% by weight of the polyol component
of the polyurethane composition, wherein the minor polyol component is present
in an amount of less than about 10% by weight of the polyurethane composition,
wherein the minor polyol component is present in an amount of less than about
7% by weight of the polyurethane composition, and/or wherein the minor polyol
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component is present in an amount of less than about 5% by weight of the
polyurethane composition.
According to still yet another potentially preferred feature, a polyurethane
for application to a woven, non-woven, or tufted textile face structure,
including a
polyol component, an isocyanate component, a catalyst and other agents,
fillers,
additives, and the like wherein the catalyst is eliminated, the polyol is
replaced
with castor oil, or both.
According to still another potentially preferred feature, a common
formation unit and process may be used to produce carpet, area rugs, carpet
tile,
floor mats, and the like.
Other features and further scope of the applicability of the present
invention will become apparent from the detailed description to follow, taken
in
conjunction with the accompanying drawings wherein like parts are designated
by like reference numerals in the various views.
Brief Description of the Drawings
The invention will now be further described by way of example only and
with reference to the drawings, which are briefly described as follows:
FIG. 1 is schematic view illustrating apparatus and process for forming
various polyurethane-backed surface coverings.
FIG. 2 is a cross-sectional illustration of an exemplary polyurethane-
backed surface covering incorporating a tufted face structure;
FIG. 3 is a cross-sectional illustration of an exemplary polyurethane-
backed surface covering incorporating a woven face structure;
FIG. 4 is a cross-sectional illustration of an exemplary polyurethane-
backed surface covering incorporating a non-woven face structure;
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FIG. 5 is a cross-sectional illustration of an exemplary polyurethane-
backed surface covering incorporating a bonded pile face structure;
FIG. 6 is schematic view illustrating apparatus and process for forming
various surface coverings incorporating backed polyurethane;
FIG. 7 is a cross-sectional illustration of an exemplary surface covering
incorporating a tufted face structure in contacting relation to a backed
polyurethane layer;
FIG. 8 is a cross-sectional illustration of an exemplary surface covering
incorporating a woven face structure in contacting relation to a backed
polyurethane layer;
FIG. 9 is a cross-sectional illustrational of an exemplary surface covering
incorporating a non-woven face structure in contacting relation to a backed
polyurethane layer;
FIG. 10 is a cross-sectional illustration of an exemplary surface covering
incorporating a bonded pile face structure in contacting relation to a backed
polyurethane layer;
FIG. 11 is schematic view illustrating apparatus and process for forming
various surface coverings incorporating stabilized polyurethane;
FIG. 12 is a cross-sectional illustration of an exemplary surface covering
incorporating a tufted face structure in contacting relation to a stabilized
polyurethane layer;
FIG. 13 is a cross-sectional illustration of an exemplary surface covering
incorporating a woven face structure in contacting relation to a stabilized
polyurethane layer;
FIG. 14 is a cross-sectional illustration of an exemplary surface covering
incorporating a non-woven face structure in contacting relation to a
stabilized
polyurethane layer;
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FIG. 15 is a cross-sectional illustration of an exemplary surface covering
incorporating a bonded pile face structure in contacting relation to a
stabilized
polyurethane layer;
FIG. 16 is schematic view illustrating apparatus and process for forming
various surface coverings incorporating stabilized and backed polyurethane;
FIG. 17 is a cross-sectional illustration of an exemplary surface covering
incorporating a tufted face structure in contacting relation to a stabilized
and
backed polyurethane backing;
FIG. 18 is a cross-sectional illustration of an exemplary surface covering
incorporating a woven face structure in contacting relation to a stabilized
and
backed polyurethane backing;
FIG. 19 is a cross-sectional illustration of an exemplary surface covering
incorporating a non-woven face structure in contacting relation to a
stabilized
and backed polyurethane backing; and
FIG. 20 is a cross-sectional illustration of an exemplary surface covering
incorporating a bonded pile face structure in contacting relation to a
stabilized
and backed polyurethane backing;
FIG. 21 is a cross-sectional illustration of an exemplary surface covering
like that of FIG. 2 with the addition of a backing such as a coating, film, or
the
like;
FIG. 22 is a cross-sectional illustration of an exemplary surface covering
like that of FIG. 7 with the addition of a backing such as a coating, film, or
the
like;
FIG. 23 is a cross-sectional illustration of an exemplary surface-covering
like that of FIG. 12 except that the stabilizing layer or material is adjacent
or
abutting the tufts;
FIG. 24 is a cross-sectional illustration of an exemplary surface covering
like that of FIG. 13 except that the stabilizing layer or material is near or
on the
bottom of the polyurethane backing;
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FIG. 25 is a cross-sectional illustration of an exemplary surface covering
like that of FIG. 3 except that it is inverted as constructed using an
exemplary
apparatus and process as shown in FIG. 27;
FIG. 26 is a cross-sectional illustration of an exemplary surface covering
like that of FIG. 8 except that it is inverted like in FIGS. 25 and 27; and,
FIG. 27 is a schematic illustration of an exemplary apparatus and process
for forming polyurethane backed surface coverings in accordance with another
embodiment of the present invention.
Detailed Description
Referring to FIG. 1 of the drawings, an exemplary formation system 10 is
illustrated for use in the production of surface coverings or polyurethane
backed
products such as carpeting, carpet tile, area rugs, roll goods, and/or floor
mats.
According to the illustrated and potentially preferred embodiment, the
formation
system 10 includes an endless belt 12 formed from a material such as PTFE
woven fiberglass or the like. As shown according to the illustrated process, a
mass of uncured polyurethane composition 14 is preferably deposited directly
onto the belt 12 and then adjusted to a desired height by a leveller 16 such
as a
doctor blade, air knife, or the like. The thickness of the levelled
polyurethane
composition is preferably in the range of about 0.10 inches to about 1.0
inches,
more preferably about 0.16 inches to about 0.60 inches although higher or
lower
thickness levels may likewise be used. While direct application of the
polyurethane composition onto the belt 12 may be preferred, it is likewise
contemplated that a release layer, film, paper or the like (not shown) on or
over
the belt or other deposit surface may likewise be used if desired.
By way of example only, one contemplated polyurethane composition is
believed to be disclosed in U.S. Patent No. 5,104,693 to Jenkines, the
teachings
of which are incorporated herein by reference in their entirety. Fillers,
agents,
additives, extenders, and the like such as calcium carbonate, coal fly ash,
sand,
foundry sand, used foundry sand, crushed glass, crushed recycled glass, post-
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consumer recycled glass, soda lime glass, post-consumer recycled soda lime
glass, glass particles, glass fibers, bone, bone meal, metal, recycled metal,
iron,
steel, ferrite, magnetite, iron oxides, barite, nickel, recycled soda lime
glass
having a pH in deionized water of greater than 8.4, fillers with a specific
gravity
(SG) greater than 2, fillers with a specific gravity greater than 5, inert
oil, rubber,
recycled rubber, SBR particles, mixed fines glass, mixed course glass, crushed
bone meal, crushed gypsum, barium sulphate, castor oil, foam chips, recycled
carpet tile, natural and/or synthetic fibers, colorants, anti-microbial
agents, flame
retardants, blowing agents, catalyst, water, recycled materials, renewable
materials, bio-based materials, post-consumer recycled materials, post-
industrial
recycled materials, blends, combinations thereof, and/or the like. Fillers may
be
added at amounts of about 0.0% to about 99% by weight, most preferably about
10% to about 90% by weight, and more preferably from about 20% to about 80%
by weight. Fillers, agents, additives, extenders, liquids, and/or the like may
be
added in combination with air (or other gases) mixing or frothing and/or
blowing
to provide density levels as desired. In accordance with at least one
particular
example, a polyurethane froth density of about 887 grams per litre has been
found to provide good results.
In accordance with one example of an indoor/outdoor polyurethane
backed area rug having a construction like that of FIG. 2 of the drawings, a
preferred polyurethane backing which serves as precoat and backing (combined
precoat/backing) is a mechanically frothed methyl diphenyl diisocyanate (MDI)
based polyurethane having an about 750 gram cup weight and an about 27
oz/yd2 add on.
Potentially preferred filler examples include (% by weight of the
polyurethane):
Used foundry sand (UFS) - 50% to 80% by weight
Crushed glass - 65% by weight
Calcium carbonate - 50% to 65% by weight
Coal fly ash - 50% by weight
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Blend of used foundry sand (UFS) and calcium carbonate - % by weight
13% UFS and 44% calcium carbonate
21% UFS and 40% calcium carbonate
26% UFS and 37% calcium carbonate
Blend of calcium carbonate and 40 mesh ground tires (SBR) - % by
weight
55% calcium carbonate and 10% SBR
Blend of used foundry sand (UFS) and 40 mesh SBR rubber particles (%
by weight)
60% UFS and 10% SBR
51% UFS and 13% SBR
47% UFS and 12% SBR
Used foundry sand
42%
72%
Crushed glass
72%
Blend of crushed glass with coal fly ash (CFA)
24% crushed glass and 48% CFA
Blend of crushed glass with calcium carbonate
24% crushed glass and 48% calcium carbonate
Blend of crushed glass with used foundry sand (UFS)
24% crushed glass and 48% UFS
Calcium carbonate
42%
72%
40 mesh SBR
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38%
31%
36%
Coal fly ash
42%
69%
72%
75%
Magnetite
76%
Ground bone meal, 30-80%
Ground gypsum, 30-80%
Barium sulphate, 30-80%
Blend of 80x325 mesh mixed course (MC) glass and calcium carbonate
Blend of 80x325 mesh mixed course (MC) glass and used foundry sand
Blend of 100x325 mesh mixed fines (MF) glass and coal fly ash
Blends by grams or parts:
16g glass 100x325 mesh mixed fines (MF) glass
49g coal fly ash (CFA) PV 20A
8g glass 100x325 mesh mixed fines (MF) glass
8g glass 80x325 mesh mixed course (MC) glass
49g coal fly ash (CFA)
16g glass 80x325 mesh mixed course (MC) glass
49g coal fly ash (CFA)
16g glass 80x325 mesh mixed course (MC) glass
49g calcium carbonate
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65g coal fly ash (CFA)
16g glass 80x325 mesh mixed course (MC) glass
49g used foundry sand
32.5g bone
65g bone
65g 40 mesh gypsum from recycled drywall
30g gypsum wet with 15g water
16g glass 100x325 mesh mixed fines (MF) glass
49g calcium carbonate
16g glass 100x325 mesh mixed fines (MF) glass
49g used foundry sand
As illustrated, once the polyurethane composition 14 is set to a desired
level, a textile face structure 20 with a fibrous underside is preferably
delivered
into direct contacting relation with the polyurethane composition. For
polyurethane backed products such as carpet, area rugs and mats, preferably no
intermediate layer is disposed between the polyurethane and the underside of
the textile face structure (see FIGS. 2 - 5). According to one contemplated
practice, the textile face structure 20 may be pre-treated at a steam box 22
to
relieve internal stresses by application of moisture and heat, may be dyed,
may
be range dyed, or the like. Such treatment permits the face structure 20 to
remain substantially tensionless during subsequent curing of the polyurethane
composition 14 as will be described further hereinafter. The elimination of
tension in the face structure 20 facilitates the avoidance of undue levels of
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cupping or curling in the final structure. It is preferred that the
polyurethane
backing be relatively thin, dense, and flexible and that the face material or
fabric
be substantially tensionless. Such a product lies flat on the floor, can be
bent or
rolled, and the like.
Following introduction of the textile face structure 20 across the
polyurethane composition 14, the resulting composite structure may thereafter
be moved through, for example, an elevated temperature curing range 26. The
temperature in the curing range is set to provide substantially complete
curing of
the polyurethane composition 14. By way of example only and not limitation,
such a curing range 26 having, for example, heated platens below belt 12, a
platen temperature setting of about 250 degrees F in a first zone, and with a
setting of about 290 degrees F in subsequent zones has been found to provide
good curing results when the belt 12 is operating at a rate of about 30 feet
per
minute. Of course, these setting may be readily adjusted as desired. For
example, certain polyurethane backings may cure at room temperature.
As shown, upon exiting the curing range 26, the composite structure with
cured polyurethane may thereafter be removed from the belt 12 and sent to a
cutter 30 for segmentation to a length and width as desired based on the final
intended use or rolled to be cut later. Cutter 30 may be a clicker for carpet
tiles,
a cut table for mats or rugs, a slitter, ultrasonic cutter, or the like.
Accordingly,
the formation system 10 may be used to form carpet, carpet tile, area rugs,
roll
goods, and/or floor mats as may be desired. In this regard, it is to be
understood
that the density and thickness levels of polyurethane may be adjusted
depending
upon the product being produced. Specifically, it is contemplated that the
mass
per unit area of polyurethane may be slightly higher for carpeting than for
floor
mats. By way of example only, it has been found that a polyurethane mass per
unit area of about 26 to 28 ounces per square yard with a thickness of about
63
mils may be suitable for carpeting while a mass per unit area of about 25
ounces
per square yard with a thickness of about 100 mils may be more suitable for
dust
control mats.
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As previously noted, the textile face structure 20 may have any number of
suitable constructions. By way of example only, FIGS. 2-5 illustrate a number
of
polyurethane-backed constructions such as may be formed on the system 10
using various face structures.
FIG. 2 illustrates a tufted textile face structure 20 incorporating an
arrangement of yarn elements 36 tufted through a so called "primary backing"
38
such as a woven material, a scrim, a non-woven material, combined woven and
non-woven material, or the like. As shown, the cured polyurethane composition
14 extends substantially to the primary backing 38 thereby aiding in locking
the
yarn elements 36 in place. Although a loop pile is shown, the pile may be
loop,
cut, or cut and loop.
FIG. 3 illustrates a woven textile face structure 20A disposed in contacting
relation to the cured polyurethane composition 14. As shown, the cured
polyurethane composition 14 extends substantially to the surface of the woven
textile face structure 20A and preferably migrates at least partially into the
interstices between yarn elements forming the woven textile face structure 20A
to promote good adhesion.
FIG. 4 illustrates a non-woven textile face structure 20B such as a
needlepunched, flocked, spunbond, wet laid, or other non-woven construction
disposed in contacting relation to the cured polyurethane composition 14. As
shown, the cured polyurethane composition 14 extends substantially to the
surface of the non-woven textile face structure 20B and preferably migrates at
least partially into the interstices between fiber elements forming the non-
woven
textile face structure 20B to promote good adhesion.
FIG. 5 illustrates a bonded yarn textile face structure 20C incorporating an
arrangement of yarn or pile elements 37 bonded in place across a primary
backing or substrate layer 44 by an adhesive 42 disposed across at least the
upper surface of the primary backing layer 44. Although a loop pile is shown,
the
pile may be loop, cut, or cut and loop. As shown, the cured polyurethane
composition 14 preferably extends substantially to the primary backing 44.
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As indicated previously, it is also contemplated that one or more backing
or release layers may be applied across the underside of the cured
polyurethane
facing away from the textile face structure. By way of example only, FIG. 6
illustrates a formation system 110 for production of surface coverings
incorporating backed polyurethane, such as felt or scrim backed polyurethane,
wherein elements corresponding to those previously described are designated
by like reference numerals increased by 100. As will be appreciated, the
formation system 110 is substantially identical to the system illustrated and
described in relation to FIG. 1 but with the addition of backing material,
such as
felt 140 across the belt 112 at a position upstream of the location at which
the
polyurethane composition 114 is deposited.
By way of example only, one felt that may be particularly preferred is a
needle punched felt formed from polyester and/or polypropylene as described in
U.S. Patent 5,540,968 hereby incorporated by reference herein. Of course other
woven and/or non-woven backings may likewise be utilized as desired.
The textile face structure 120 may have any number of suitable
constructions. By way of example only, FIGS. 7-10 illustrate a number of
backed polyurethane constructions such as may be formed on the system 110
using various face structures.
FIG. 7 illustrates a tufted textile face structure 120 incorporating an
arrangement of yarn elements 136 tufted through a primary backing 138 such as
a woven, a non-woven or the like. As shown, the cured polyurethane
composition 114 extends substantially between the backing, such as non-woven
felt or a woven or nonwoven scrim or mesh 140 and the primary backing 138
thereby aiding in locking the yarn elements 136 in place.
FIG. 8 illustrates a woven textile face structure 120A disposed in
contacting relation to the cured polyurethane composition 114. As shown, the
cured polyurethane composition 114 extends substantially between the backing,
such as non-woven felt 140 and the surface of the woven textile face structure
120A and preferably migrates at least partially into the interstices between
yarn
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elements forming the woven textile face structure 120A so as to promote good
adhesion.
FIG. 9 illustrates a non-woven textile face structure 120B such as a
needlepunched, flocked, spun bond or other non-woven construction disposed in
contacting relation to the cured polyurethane composition 114. As shown, the
cured polyurethane composition 114 extends substantially between the felt
backing, such as a non-woven 140 and the surface of the non-woven textile face
structure 120B and preferably migrates at least partially into the interstices
between fiber elements forming the non-woven textile face structure 120B so as
to promote good adhesion.
FIG. 10 illustrates a bonded yarn textile face structure 120C incorporating
an arrangement of yarn elements 137 bonded in place across a primary backing
or substrate layer 144 by an adhesive 142 disposed across the upper surface of
the primary backing layer 144. As shown, the cured polyurethane composition
114 preferably extends substantially between the backing, such as a non-woven
felt 140 and the primary backing 144.
The backings 140 of FIGS. 6 - 10 may be a woven, non-woven, or
combined woven and non-woven material or fabric, a film, a scrim, a mesh, or
combinations thereof. In accordance with one example, the backing 140 is a
non-woven bonded glass scrim material marketed as STABILON TRIAXT"" by
Milliken & Company of Spartanburg, SC. It is preferred that the backing 140 be
a flexible material which prevents growth and which tends to prevent curling
of
the surface covering 120 (such as a carpet tile). A glass scrim, mat, or the
like
may be preferred.
As indicated previously, it is also contemplated that one or more structural
support layers may be placed within, over, or under the cured polyurethane. By
way of example only, FIG. 11 illustrates a formation system 210 for production
of
surface coverings incorporating polyurethane with an intermediate structural
support layer, wherein elements corresponding to those previously described
are
designated by like reference numerals in a 200 series.
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As will be appreciated, the formation system 210 is substantially identical
to the system illustrated and described in relation to FIG. 1 but with the
addition
of a structural support layer 250, such as a glass mat or scrim, between
deposited layers of polyurethane composition 214, 214'. As shown, in the
illustrated practice the structural support layer 250 is placed in contacting
overlying relation to a first layer of polyurethane composition 214 following
a first
leveller 216. A second layer of polyurethane composition 214' is then applied
across the structural support layer 250 followed by a leveller 216' thereby
yielding a sandwich structure for application of the textile face structure
220.
With reference to FIGS. 11 - 15, 23 and 24 of the drawings, the location
of support, stabilizing or reinforcement layer or material 250 can be
determined
by the amount of polyurethane composition added upstream and downstream of
the support layer 250. Although it may be preferred that the support layer 250
be located at the top of, in the middle of, or at the bottom of the
polyurethane
backing (FIGS. 23, 12, and 24, respectively), it may be located anywhere in
between by controlling the add of polyurethane 214 and 214' in the system of
FIG. 11.
By way of example only, one structural support layer 250 is in the form of
woven or non-woven glass, although other materials including polyester,
polypropylene, and the like may also be utilized if desired. The textile face
structure 220 may have any number of suitable constructions. By way of
example only, FIGS. 12-15 illustrate a number of constructions incorporating a
structural support layer 250 such as may be formed on the system 210 using
various face structures.
FIG. 12 illustrates a tufted textile face structure 220 incorporating an
arrangement of yarn elements 236 tufted through a primary backing 238 such as
a scrim, a non-woven or the like. As shown, the upper layer of cured
polyurethane composition 214' extends substantially between the structural
support layer 250 and the primary backing 238 thereby aiding in locking the
yarn
elements 236 in place. The lower layer of cured polyurethane composition 214
extends away from the structural support layer 250 to define a lower surface.
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FIG. 13 illustrates a woven textile face structure 220A disposed in
contacting relation to the upper layer of cured polyurethane composition 214'.
As shown, the upper layer of cured polyurethane composition 214' extends
substantially between the structural support layer 250 and the underside of
the
woven textile face structure 220A and preferably migrates at least partially
into
the interstices between yarn elements forming the woven textile face structure
220A so as to promote good adhesion. The lower layer of cured polyurethane
composition 214 extends away from the structural support layer 250 to define a
lower surface.
FIG. 14 illustrates a non-woven textile face structure 220B such as a
needlepunched, flocked, spun bond or other non-woven construction disposed
in contacting relation to the upper layer of cured polyurethane composition
214'.
As shown, the upper layer of cured polyurethane composition 214' extends
substantially between the structural support layer 250 and the underside of
the
non-woven textile face structure 220B and preferably migrates at least
partially
into the interstices between fiber elements forming the non-woven textile face
structure 220B so as to promote good adhesion. The lower layer of cured
polyurethane composition 214 extends away from the structural support layer
250 to define a lower surface.
FIG. 15 illustrates a bonded yarn textile face structure 220C incorporating
an arrangement of yarn elements 237 bonded in place across a primary backing
or substrate layer 244 by an adhesive 242 disposed across the upper surface of
the primary backing layer 244. As shown, the upper layer of cured polyurethane
composition 214' extends substantially between the structural support layer
250
and the underside of the primary backing layer 244. The lower layer of cured
polyurethane composition 214 extends away from the structural support layer
250 to define a lower surface.
It is also contemplated that combinations of structural support layers and
backings, such as felt backings, may be utilized. By way of example only, FIG.
16 illustrates a formation system 310 for production of surface coverings
incorporating polyurethane with an intermediate structural support layer and
with
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a backing. In this figure and related figures, elements corresponding to those
previously described are designated by like reference numerals within a 300
series. As will be appreciated, the formation system 310 is substantially
identical
to the system illustrated and described in relation to FIG. 11 but with the
addition
of a layer of backing such as felt 340 across the belt 312 at a position
upstream
of the location at which the polyurethane composition 314 is deposited.
As shown, in the illustrated practice a first layer of polyurethane
composition 314 is deposited over the backing material or layer 340 and
levelled
by a first leveller 316. The structural support layer 350 is placed in
contacting
overlying relation to the first layer of polyurethane composition 314
following a
first leveller 316. A second layer of polyurethane composition 314' is then
applied across the structural support layer 350 followed by a leveller 316'
thereby yielding a stabilized and backed sandwich structure for application of
the
textile face structure 320.
The textile face structure 320 may have any number of suitable
constructions. By way of example only, FIGS. 17-20 illustrate a number of
constructions incorporating a structural support layer 350 and a backing 340
such as may be formed on the system 310 using various face structures.
FIG. 17 illustrates a tufted textile face structure 320 incorporating an
arrangement of yarn elements 336 tufted through a primary backing 338 such as
a woven, a non-woven or the like. As shown, the upper layer of cured
polyurethane composition 314' extends substantially between the structural
support layer 350 and the primary backing 338 thereby aiding in locking the
yarn
elements 336 in place. The lower layer of cured polyurethane composition 314
extends away from the structural support layer 350 to the backing layer 340.
FIG. 18 illustrates a woven textile face structure 320A disposed in
contacting relation to the upper layer of cured polyurethane composition 314'.
As shown, the upper layer of cured polyurethane composition 314' extends
substantially between the structural support layer 350 and the underside of
the
woven textile face structure 320A and preferably migrates at least partially
into
the interstices between yarn elements forming the woven textile face structure
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320A so as to promote good adhesion. The lower layer of cured polyurethane
composition 314 extends away from the structural support layer 350 to the
backing layer 340.
FIG. 19 illustrates a non-woven textile face structure 320B such as a
needlepunched, flocked, spun bond or other non-woven construction disposed in
contacting relation to the upper layer of cured polyurethane composition 314'.
As shown, the upper layer of cured polyurethane composition 314' extends
substantially between the structural support layer 350 and the underside of
the
non-woven textile face structure 320B and preferably migrates at least
partially
into the interstices between fiber elements forming the non-woven textile face
structure 320B so as to promote good adhesion. The lower layer of cured
polyurethane composition 314 extends away from the structural support layer
350 to the backirig layer 340.
FIG. 20 illustrates a bonded yarn textile face structure 320C incorporating
an arrangement of yarn elements 337 bonded in place across a primary backing
or substrate layer 344 by an adhesive 342 disposed across the upper surface of
the primary backing layer 344. As shown, the upper layer of cured polyurethane
composition 314' extends substantially between the structural support layer
350
and the underside of the primary backing layer 340. The lower layer of cured
polyurethane composition 314 extends away from the structural support layer
350 to the layer of felt 340.
With reference to FIG. 21, a tufted face surface covering like that of FIG. 2
is shown with a backing 60 such as a coating, film, or the like. For example,
backing 60 may be an adhesive or other friction enhancing coating such as
TractionBack coating offered by Milliken & Company of LaGrange, GA.
The underside or lower surface of polyurethane layer 14 or 214 may be
textured, embossed, cleated, nubbed, ribbed, or the like to, for example,
increase sliding friction with a floor or subfloor. Likewise, the lower
surface of
backing 140, 340, or 250, or of coating or film 60 or 160 may be embossed,
textured, or the like.
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The tufted face surface covering of FIG. 22 is like that of FIG. 7 with the
addition of backing 160 such as a coating, film, or the like.
The tufted face surface covering of FIG. 23 is like that of FIG. 12 except
that the support layer 250 is shown just below tufts 236.
The woven face surface covering of FIG. 24 is like that of FIG. 13 except
that the support layer 250 is shown at the bottom of polyurethane 214.
FIGS. 25 - 27 relate to an alternative production process wherein the face
material 20, 120, 220 is inverted and then laid on the belt 112. Next,
polyurethane composition 114 is poured or applied to the back of the face
material 20A or 120A and doctored by blade 116.
With respect to FIGS. 26 and 27, a backing 140 is added over the
polyurethane 114 and nip or gauge roll 162 presses backing 140 into the
polyurethane 114.
One advantage of the system 110A of FIG. 27 is that the face material
120 tends to keep the belt 112 clean of polyurethane 114.
The face material 20, 20A, 20B, 20C, 120, 120A, ' 120B, 120C, 220,
220A, 220B, 220C, 320, 320A, 320B, and 320C may be formed of natural or
synthetic fibers or materials, or blends thereof. For example, tufts 36 may be
Nylon 6, Nylon 6,6, polyolefin, wool, or blends thereof.
If face material 20 must be dyed or printed, it is preferred that it be dyed
prior to addition of polyurethane 14.
Polyurethane 14 may include a polyol component, an isocyanate
component, a catalyst, and other agents, fillers, additives, and the like. It
has
been discovered that the catalyst may be eliminated, that the polyol may be
replaced with castor oil, or both.
In accordance with at least selected examples, castor oil was used in
place of the polyol component of a two component MDI based polyurethane
system typically having a polyol component and an isocyanate component (in
grams or parts).
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A. 16g 100x325 mesh mixed fines (MF) glass
49g coal fly ash (CFA)
12g castor oil
23g isocyanate
drop dibutyl tin dilaurate (about 0.026g) catalyst
B. 16g 100x325 mesh mixed fines (MF) glass
49g coal fly ash (CFA)
12g castor oil
8g inert oil
23g isocyanate
drop dibutyl tin dilaurate (about 0.026g) catalyst
C. 16g 100x325 mesh mixed fines (MF) glass
49g coal fly ash (CFA)
20g castor oil
23g isocyanate
drop dibutyl tin dilaurate (about 0.026g) catalyst
D. 65g coal fly ash (CFA)
20g castor oil
23g isocyanate
2 drops catalyst
E. 16g 100x325 mesh mixed fines (MF) glass
49g coal fly ash (CFA)
18g castor oil
23g isocyanate
2 drops catalyst
F. 32.5g bone meal
13g castor oil
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13g isocyanate
3 drops catalyst
G. 65g bone meal
26g castor oil
26g isocyanate
0.23 mL catalyst
H. 65g 40 mesh gypsum from recycled drywall
49g castor oil
46g isocyanate
0.46 mL dibutyl tin dilaurate
0.46 mL water
1. 30g gypsum wet with 15g water
lOg castor oil
lOg isocyanate
0.1 mL dibutyl tin dilaurate
J. 16g 100x325 mesh mixed fines (MF) glass
49g coal fly ash (CFA)
17g castor oil
23g isocyanate
0.5 mL dibutyl tin dilaurate
K. 16g 100x325 mesh mixed fines (MF) glass
49g coal fly ash (CFA)
16g castor oil
23g isocyanate
0.5 mL dibutyl tin dilaurate
L. 65 parts 100x325 mesh mixed fines (MF)
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crushed post-consumer glass
23g isocyanate
12 parts castor oil
0.026 parts dibutyl tin dilaurate catalyst
M. 62.5 parts coal fly ash (PV 20A)
parts castor oil
9.93 parts PPG polyol MW 6000 f=3
17.57 parts prepolymer isocyanate
dibutyl tin dilaurate catalyst
N. 62.5 parts coal fly ash (PV 20A)
13.52 parts castor oil
13.43 parts PPG polyol MW 6000 f=3
5.26 parts isocyanate
5.29 parts prepolymer isocyanate
dibutyl tin dilaurate catalyst
0. 62.5 parts coal fly ash (PV 20A)
15.04 parts castor oil
14.94 parts PPG polyol MW 6000 f=3
7.52 parts isocyanate
dibutyl tin dilaurate catalyst
P. 62.5 parts coal fly ash (PV 20A)
13.62 parts castor oil
13.55 parts PPG polyol MW 6000 f=3
4.98 parts isocyanate
5.34 parts prepolymer isocyanate
dibutyl tin dilaurate catalyst
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Polyurethane 14 may include a polyol component, an isocyanate
component, a catalyst, and other agents, fillers, additives, and the like. It
has
been discovered that the petrochemical polyol may be replaced with chemically
unmodified (preferably filtered and dried) castor oil (a natural oil polyol).
In accordance with at least selected examples, castor oil is used in place
of at least the major polyol component of a two component MDI based
polyurethane system typically having a petrochemical or petroleum based polyol
or polyol blend component and an isocyanate component (in grams or parts).
Q. 16g 100x325 mesh mixed fines (MF) glass
49g coal fly ash (CFA)
12g dry, filtered castor oil
23g isocyanate
drop dibutyl tin dilaurate (about 0.026g) catalyst
R. 16g 100x325 mesh mixed fines (MF) glass
49g coal fly ash (CFA)
12g dry, filtered castor oil
8g inert oil
23g isocyanate
S. 69g coal fly ash (CFA)
20g castor oil
23g isocyanate
T. 65g coal fly ash (CFA)
20g dry, filtered castor oil
23g isocyanate
2 drops catalyst
U. 16g 100x325 mesh mixed fines (MF) glass
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49g coal fly ash (CFA)
18g castor oil
6g PPG polyol
29g isocyanate
2 drops catalyst
V. 32.5g bone meal
13g castor oil
5g PEG polyol
18g isocyanate
3 drops catalyst
W. 65g bone meal
26g castor oil
13g PPG-PEG copolymer polyol
39g isocyanate
0.23 mL catalyst
X. 65g 40 mesh gypsum from recycled drywall
49g castor oil
12g minor polyol with functionality of 2 or 3 and a molecular weight
ranging from 750 to 7500
58g isocyanate
0.46 mL dibutyl tin dilaurate
Y. 30g gypsum wet with 15g water
10g dry castor oil
10g isocyanate
Z. 16g 100x325 mesh mixed fines (MF) glass
49g coal fly ash (CFA)
17g polyurethane grade, dry castor oil
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23g isocyanate
0.5 mL dibutyl tin dilaurate
AA. 16g 100x325 mesh mixed fines (MF) glass
49g coal fly ash (CFA)
16g polyurethane grade castor oil
23g isocyanate
0.5 mL dibutyl tin dilaurate
BB. 65 parts 100x325 mesh mixed fines (MF)
crushed post-consumer glass
23 parts isocyanate
12 parts castor oil
CC. at least 42% by weight coal fly ash (CFA)
unmodified, dry, filtered castor oil
isocyanate
DD. at least 50% by weight coal fly ash (CFA)
castor oil
optional additional polyol
isocyanate
optional catalyst
EE. at least 60% by weight coal fly ash (CFA)
castor oil
isocyanate
optional catalyst
FF. at least 70% by weight coal fly ash (CFA)
castor oil
optional additional polyol
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isocyanate
optional catalyst
GG. coal fly ash (CFA)
castor oil
polyol blend
isocyanate
optional catalyst
HH. coal fly ash (CFA)
castor oil
isocyanate blend
optional catalyst
II. coal fly ash (CFA)
castor oil
prepolymer isocyanate
optional catalyst
JJ. coal fly ash (CFA)
castor oil
prepolymer isocyanate blend
optional catalyst
KK. coal fly ash (CFA)
castor oil
optional polyol blend
prepolymer isocyanate
optional catalyst
LL. 62.5 parts coal fly ash (PV 20A)
parts castor oil
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4.97 parts PPG polyol MW 3,000 f=3
17.57 parts prepolymer isocyanate
optional catalyst
MM. 62.5 parts coal fly ash (PV 20A)
13.52 parts castor oil
6.72 parts PPG polyol MW 3000 f=3
5.26 parts isocyanate
5.29 parts prepolymer isocyanate
dibutyl tin dilaurate catalyst
NN. 62:5 parts coal fly ash (PV 20A)
15.04 parts castor oil
7.47 parts PPG polyol MW 3000 f=3
7.52 parts isocyanate
dibutyl tin dilaurate catalyst
00. 62.5 parts coal fly ash (PV 20A)
13.62 parts castor oil
6.78 parts PPG polyol MW 3000 f=3
4.98 parts isocyanate
5.34 parts prepolymer isocyanate
dibutyl tin dilaurate catalyst
PP. 62.5 parts coal fly ash (PV 20A)
13.52 parts castor oil
13.43 parts PPG polyol MW 4000 f=2
5.26 parts isocyanate
5.29 parts prepolymer isocyanate
dibutyl tin dilaurate catalyst
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QQ. 62.5 parts coal fly ash (PV 20A)
15.04 parts castor oil 1
14.94 parts PPG polyol MW 4000 f=2
7.52 parts isocyanate
dibutyl tin dilaurate catalyst
RR. 62.5 parts coal fly ash (PV 20A)
13.62 parts castor oil
6.78 parts PPG polyol MW 2000 f=2
4.98 parts isocyanate
5.34 parts prepolymer isocyanate
dibutyl tin dilaurate catalyst
SS. 62.5 parts coal fly ash (PV 20A)
13.52 parts castor oil
6.72 parts PPG polyol MW 2000 f=2
5.26 parts isocyanate
5.29 parts prepolymer isocyanate
dibutyl tin dilaurate catalyst
In accordance with another possibly preferred embodiment of the present
invention, the preferred filler is a post-consumer recycled soda lime glass
having
a pH in deionized water of greater than 8.4, more preferably greater than 9.0,
most preferably greater than 10Ø
In accordance with one test in deionized water, the recycled soda lime
glass had a pH of 10.73, in another test the pH was 9.24.
Such a recycled soda lime glass also has the following specifications:
1. PRODUCT INFORMATION
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Product Name: Cullet - Recycled Glass
Chemical Family: Silicon
Synonyms: Soda Lime Glass, Crushed Glass
Formula: Si02 + Metal Oxides (Na20, CaO, A12O3)
CAS Number: None
DOT Shipping Name: None
DOT Shipping ID No.: N/A
DOT Hazard Class: N/A
EPA Hazard Waste Class: None
EPA Hazard Waste ID No.:None
Moisture: 0.1 % max
LOI: 0.1 % max
Tramp Metals: 0.01% max
II. CHEMICAL COMPOSTION
NAME % ACGIH TLV OSHA PEL CAS #
Soda Lime Glass 100 10mg/M3 *15mg/M3 None
* 5mg/M3
(OSHA PEL based on Nuisance Dust)
* Total Dust
** Respirable Dust
III. PHYSICAL PROPERTIES
Boiling Point: N/A Vapor Density (Air-1): N/A
Melting Point: 3100 F or 1704 C Specific Gravity (Water=1):2
Vapor Pressure (mmHg): N/A % Volatile: None
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Solubility in Water: Insoluble
Evaporation Rate: N/A
Appearance & Odor: Solid having variable appearance without odor.
IV. REACTIVITY DATA
Stability: Stable
Incompatibilities: None
'Hazardous Decomposition Products: None
Conditions to Avoid: None
Hazardous Polymerization: Will not occur
Conditions to Avoid: None
V. SIZES
70 to 100 mesh, 100 to 120 mesh, 70 to 325 mesh, 80 to 325 mesh, 100
to 325 mesh
VI. SOURCE
100% post-consumer glass from private and municipal recycling
programs.
In accordance with another example, one can blend recycled post-
industrial waste filler (such as coal fly ash) with recycled post-consumer
waste
filler (such as crushed glass) to produce a hybrid recycled filler.
In accordance with still another example, one can mix recycled post-
industrial filler and recycled post-consumer filler, with renewable or bio-
based
fillers or extenders such as cork, wood, corn, and/or the like.
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The surface coverings of the present invention may be hardback or
cushion back products. For example, the precoat, the tiecoat, and the backing
may each be foam or non-foam layers. In accordance with one example, the
precoat is non-foamed and the backing is foamed. It may be preferred that the
polyurethane composition layer form a precoat, tiecoat, or backing, a combined
precoat and tiecoat, a combined precoat and backing, a combined tiecoat and
backing, or the like. One can increase the cushion or resilience of the
backing
by adding more air, more blowing agent, felt, thickness, or the like. It is
possibly
preferred that a polyurethane hardback or cushion back product such as a
polyurethane hardback or cushion back carpet tile have the structure of one of
FIGS. 2 - 5, 7 - 10, 12 - 15, 17 - 20, and 21 - 26. It may also be preferred
that
a polyurethane backed area rug, roll goods, or floor mat of the present
invention
have the structure of one of FIGS. 2 - 5, 21, and 25.
In accordance with a particular example of an indoor/outdoor
polyurethane backed area rug having a structure like that of FIG. 2, a tufted
face
greige carpet material (no precoat) had a cut pile, Nylon 6,6, jet dyed, 20
oz/yd2
face yarn, 8th gauge, tufted through a 4 oz/yd2 non-woven, polyester primary
backing, was laid over a mechanically frothed, MDI based polyurethane at a 750
gram cup weight and an average add-on of 27 oz/yd2. The uncured
polyurethane composition was poured onto a belt, doctored and then joined to
the carpet greige goods under a marriage roll. The polyurethane was cured
under heat.
In accordance with another example, an indoor/outdoor polyurethane
backed area rug had an overall average height of about 7458.03pm
(micrometers), an average polyurethane backing height of about 1507.64 pm
(micrometers), and a total weight of about 51.79 oz/yd2.
In accordance with at least selected embodiments of the present
invention, a nip, marriage, or gauge roll 62 (FIG. 1), 162, (FIG. 6), 262
(FIG. 11),
362 (FIG. 16) presses the face material 20, 120, 220, 320 into the uncured
polyurethane composition and sets the height of the total product (prior to
any
chemical blowing).
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The surface covering of the present invention may in at least one
embodiment be 6 foot wide roll goods sometimes referred to a 6 foot broadloom.
In accordance with at least selected embodiments, gravitational forces
should dominate the sum of other process induced forces. Examples of these
other forces are tensions or thermal contractions from cooling.
The gravity model on a cantilever beam:
Eqn. 1 qL4
~B 8EI
This can be simplified for carpet tile applications by:
Eqn. 2 - WL4
SB 864Et3
Where:
W = the carpet weight (lbs/yd 2)
L Length of overhang (use 6" as a constant)
E Young's Modulus (Q / s) for the composite
t the bound thickness (in.) - do not include the pile height
8= the maximum deflection of the beam (in.)
One can measure the weight (W), deflection (in.), and thickness (in.) in order
to
calculate the modulus (psi or pounds per square inch).
Assume W is held constant at 8 Ibs/yd2 (or 128 oz/yd2). Further assume t is
held
constant at 0.20 in. One can then see the relationship between 8 and E.
If we now hold the Modulus constant (e.g., E=1,000 psi), one can illustrate
the
relationship between 8 and t.
Finally, one can hold thickness and modulus constant and illustrate the
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relationship of 8 and W.
Note that in each of these examples the equations assume that the angle of
deflection is small such that the trigonometric approximation of sin (Y) = Y.
In
this case, we want large deflections, so these become qualitative rather than
quantitative figures.
In accordance with at least one aspect of the present invention, we want
to increase weight, reduce thickness, and reduce modulus of the composite.
The combination of a thin and heavy backing requires that the backing
materials
are characterized by higher density. This may be achieved by the selection of
dense raw materials such as dense fillers. For example, CaCO3 is a common
filler used in floor covering products. It has a specific gravity (SG) of 2.6.
If a filler
is selected with a SG greater than 5 and the concentration by weight remained
the same (>50%), then a significant shift in the compound density would occur.
If
the choice was Iron (Fe) with a SG of 7.8 and with a concentration of 70%,
then
the density could be nearly tripled resulting in a 2/3 reduction in thickness
at the
same backing weight.
In accordance with at least another aspect of the present invention, we
want to increase weight, reduce thickness, increase flexibility, increase
resilience, and reduce modulus of the composite. The combination of a thin and
heavy backing may require that the backing materials are characterized by
higher density. This may be achieved by the selection of dense raw materials
such as dense fillers. For example, CaCO3 is a common filler used in floor
covering products. It has a specific gravity (SG) of 2.6. If a filler is
selected with a
SG greater than 5 and the concentration by weight remained the same (>50%),
then a significant shift in the compound density would occur. If the choice
was
Iron (Fe) with a SG of 7.8 and with a concentration of 70%, then the density
could be nearly tripled resulting in a 2/3 reduction in thickness at the same
backing weight.
If a ferromagnetic material is selected as the filler, it creates the option
of
selectively creating permanent magnetic properties in the backing. A magnetron
located on or after the production range could be switched on/off to produce
the
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optional magnetic property. If the ferromagnetic material is an oxide, such as
ferrite, then the material will not only be dense and magnetizable, but will
also
starve a fire event from oxygen and self extinguish.
In accordance with at least selected embodiments, an exemplary surface
covering such as a lay flat flooring product or tile has an upper show surface
and
a backing. It is preferred that the show surface such as a carpet or textile
material be bonded to the backing during manufacture of the surface covering.
The backing preferably has a very low bending modulus (very flexible), a high
density, is thin, and is resilient. Flexibility (low modulus) and high density
(heavy) may be the two most important factors that effect tile flatness.
The face or upper show surface is preferably an aesthetically pleasing
carpet or textile material. For example, a graphics tufted, printed, dyed, or
the
like decorative carpet or textile (tufted, woven, bonded, nonwoven, flocked,
needled, knit, or the like) of natural and/or synthetic fibers such as wool,
polyamide (Nylon), polyester, polyolefin, blends, and the like.
Preferably, the face exits the manufacturing process with substantially
zero tension and resists growth or shrinkage during product use.
It is contemplated that the lay flat product may be any desired shape and
may be in the form of roll goods, modular product, 6-foot broadloom, 12-foot
broadloom, carpet, carpet tile, flooring, floor tile, floor covering, floor
mat,
stabilized broadloom, rug, runner, or the like. For example, a 6-foot wide
roll of
lay flat composite may be cut into tiles, rugs, mats, runners, and/or the
like. The
face 12 is not limited to a precoated carpet or greige goods (non-precoated)
face
material although such a face may be preferred. Also, it may be possibly
preferred that the face be range dyed (jet dyed) prior to lamination or
backing to
further reduce any latent stresses or tensions in the face. Further,
lamination or
backing of the face may be carried out at a low enough temperature and the
face
material or materials (for example, primary backing and tufts) may be selected
to
avoid the addition of stresses or instability (such as shrinkage) during
processing, backing, lamination, curing, etc.
In accordance with possibly preferred embodiments, the backing includes
one or more stabilizing layers, backing layers, foam or cushion layers, a
friction
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enhancing coating, magnetic or magnetizable particles, remains flexible at
standard operating temperatures, and/or the like. In accordance with one
example, the backing is a thin (less than about 5mm, preferably less than
about
3mm), very flexible, dense, resilient, polymeric material.
In accordance with one example, the face is a jet dyed, tufted, polyamide
(Nylon) 6 or 6,6 carpet face with a stable primary backing of, for example,
woven
and/or nonwoven polyamide (Nylon), polyester, and/or stabilized polypropylene.
It may be preferred that the carpet face has a tuft lock or precoat of the
same material as backing, for example, a polyurethane precoat and a
polyurethane backing, a combined single polyurethane coating that serves as
both precoat and tiecoat, or precoat and backing, a nonfoam precoat and a foam
backing, a nonfoam precoat and tiecoat and a foam backing, and/or the like.
In accordance with another example, a hardback floor tile has a flexible,
heavy (dense), thin backing with the following preferred properties:
1. backing density - about 180 to 250 Ibs/ft3 (3-4 g/cc)
2. backing thickness - about 0.15 inch
3. tile drape - about 2 to 4 inches of drape on a 6 inch tile overhang
In accordance with at least selected embodiments of other aspects of the
present invention, it may be preferred:
1. To use an adhesive to join a greige tufted substrate to a polyurethane (PU)
cushion structure that provides above average wet and dry tuft bind, and PU
lamination strength greater than the cohesion of the PU cushion.
1.1. Adhesive Physical Properties
1.1.1. High flexibility, low modulus (<3,000 psi)
1.1.2. non-PVC, non-latex
1.1.3. composite cuts easily with standard carpet knife
1.1.4. resin may be an aqueous emulsion, hot melt, or multipart
reaction applied with a coating blade, film lamination, or in-situ
extrusion at speeds greater than 50 fpm (feet per minute).
1.2. The adhesive should provide a moisture barrier in the composite
structure.
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1.3. The adhesive may optionally contain recycled content.
1.3.1. >50% recycled content
1.3.2. preferably post consumer recycled content
1.4. The adhesive may optionally provide enhanced flammability resistance
to meet vertical flammability tests.
1.4.1. IMO certification (cruise ships)
1.5. The adhesive may become an after life cycle "zipper" to separate the
tufted substrate from the PU cushion structure.
1.5.1. zipper may be thermal
1.5.2. zipper may be mechanical
1.5.3. zipper may be chemical
1.6. The adhesive used above should be commercially competitive.
2. The composite using the adhesive can be recycled into item 1.3 or into the
PU cushion.
2.1. Rather than separating components, carpet composite may be
desized and integrated into the filler integral to the adhesive.
3. The PU cushion structure may be substituted with another cushion material
that:
3.1. Provides economic advantage.
3.2. Enables an economically viable recyclable composite.
3.3. Possibly needled felt
3.4. Possibly resized end of life (EOL) carpet with binder
4. The PU cushion structure may be substituted with another material that:
4.1. Creates an optional hardback using the same (or expanded) capital
investments for the adhesive from item 1.
4.2. Utilizes recycled content.
4.3. Provides a clear EOL recycling process.
4.4. Provides an economic advantage over competitive hardback.
4.5. Standard carpet knives easily cut the composite.
5. The aforementioned options may create improved products.
In accordance with at least certain other embodiments of other aspects of
the present invention, it may be preferred:
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1. To use an adhesive to join a greige tufted substrate to a polyurethane
(PU) cushion structure that provides above average wet and dry tuft bind, and
PU lamination strength greater than the cohesion of the PU cushion.
1.1. The adhesive may provide a moisture barrier in the composite
structure.
1.2. The adhesive may optionally contain recycled content.
1.3. The adhesive may optionally provide enhanced flammability
resistance to meet vertical flammability tests.
1.4. The adhesive may become an after life cycle "zipper" to separate
the tufted substrate from the PU cushion structure.
1.5. The adhesive should be commercially competitive.
2. The composite using the adhesive can be recycled into item 1.2.
3. The PU cushion structure may be substituted with another material that:
3.1. Provides economic advantage.
3.2. Enables an economically viable recyclable composite.
4. The PU cushion structure may be substituted with another material that:
4.1. Creates an optional hardback using the same (or expanded) capital
investments for the adhesive from item 1.
4.2. U EV824804738UStilizes recycled content.
4.3. Provides a clear recycling process.
4.4. Provides an economic advantage over competitive hardback.
5. The aforementioned options may create improved products.
6. The aforementioned options should meet customer expectations of fitness
for use including installation.
In accordance with yet another example, a lay flat flooring product has a
backing that is flexible, dense, thin, and resilient,
flexible - product drape greater than about 2 inches of drape on a 6-inch
product overhang or a bending modulus less than about 2000 psi;
dense - backing density of greater than about 20 Ibs/ft3;
thin - backing height (thickness) of less than about 10 mm;
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resilient - product can be rolled or folded at least once and will go back to
a lay flat position.
In accordance with still another example, a lay flat hardback flooring
product has a backing that is flexible, dense, thin, and resilient,
flexible - product drape greater than about 3 inches of drape on a 6-inch
product overhang or a bending modulus less than about 1000 psi;
dense - backing density of greater than about 50 Ibs/ft3;
thin - backing height (thickness) of less than about 5 mm;
resilient - product can be rolled or folded several times and will go back to
a lay flat position.
In accordance with still another example, a lay flat cushion back flooring
product has a backing that is flexible, dense, thin, and resilient,
flexible - product drape greater than about 2 inches of drape on a 6-inch
product overhang or a bending modulus less than about 3000 psi;
dense - backing density of greater than about 15 Ibs/ft3;
thin - backing height (thickness) of less than about 15 mm;
resilient - product can be rolled or folded at least once and will go back to
a lay flat position.
In accordance with a possibly preferred example, a lay flat hardback
flooring product has a backing that is flexible, dense, thin, and resilient,
flexible - product drape greater than about 4 inches of drape on a 6-inch
product overhang or a bending modulus less than about 500 psi;
dense - backing density of greater than about 200 Ibs/ft3;
thin - backing height (thickness) of less than about 3 mm;
resilient - product can be rolled or folded many times and will go back to a
lay flat position.
In accordance with yet another example, a lay flat carpet tile product has
a backing that is flexible, dense, thin, and resilient,
flexible - product drape greater than about 2 inches of drape on a 6-inch
product overhang;
dense - backing density of greater than about 25 Ibs/ft3;
thin - backing height (thickness) of less than about 5 mm;
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resilient - product can be rolled or folded at least once and will go back to
a lay flat position.
In accordance with still another example, a lay flat roll goods product has
a backing that is flexible, dense, thin, and resilient,
flexible - product drape greater than about 4 inches of drape on a 6-inch
product overhang;
dense - backing density of greater than about 100 Ibs/ft3;
thin - backing height (thickness) of less than about 5 mm;
resilient - product can be rolled or folded several times and will go back to
a lay flat position.
In accordance with yet another example, a lay flat floor mat product has a
backing that is flexible, dense, thin, and resilient,
flexible - product drape greater than about 2 inches of drape on a 6-inch
product overhang;
dense - backing density of greater than about 50 Ibs/ft3;
thin - backing height (thickness) of less than about 5 mm;
resilient - product can be rolled or folded at least once and will go back to
a lay flat position.
In accordance with a possibly preferred embodiment, a lay flat flooring
product includes a face material and a backing bonded thereto during product
manufacture.
In accordance with another example, a lay flat flooring product is a
laminated composite of a face, a backing, and an adhesive layer there between.
The adhesive may be the same material as the backing, may be less filled or
unfilled, or may be of a different material. Preferably, the adhesive is
flexible,
resilient, and thin.
In accordance with one object of the present invention, there is provided a
lay flat flooring product comprising an upper show surface disposed in
overlying
relation to a single or multi-layer, flexible, heavy, thin backing, said
backing
having at least one of a bending modulus of less than about 3,000 psi, a
thickness of less than about 15 mm, and a density of greater than about 15
Ibs/ft3.
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In accordance with yet another object of the present invention, there is
provided a method of producing a lay flat flooring product such as a lay flat
tile or
roll goods product with a carpet or textile face and a flexible, heavy, thin,
resilient
backing, comprising the steps of: preparing a backing composition; depositing
the backing composition in a layer; placing a carpet or textile face material
on the
deposited backing layer to form a multi-layer structure; setting or curing the
backing so that the backing composition forms a flexible, heavy, thin,
resilient
backing, and wherein the carpet or textile face material is bonded to the
backing.
In accordance with at least one embodiment, a surface covering such as
a lay flat flooring product comprises an upper show surface disposed in
overlying
relation to a single or multi-layer, flexible, heavy, thin backing.
The surface covering above further comprising a fibrous backing sheet
disposed across an underside portion of the backing.
The surface covering above, wherein the surface covering is a tile or roll
goods.
The surface covering above, wherein the show surface is a decorative
textile or carpet layer.
The surface covering above, wherein the carpet or textile is formed of
polyester, Nylon, polyolefin, and combinations thereof.
The surface covering above, wherein the carpet or textile is knit, woven,
tufted, bonded, nonwoven, needled, and the like.
The surface covering above, wherein the backing is resilient.
The surface covering above, wherein the show surface is disposed in
overlying relation to a multi-layer backing.
The surface covering above, wherein the backing includes at least one
stabilizing layer.
The surface covering above, wherein said stabilizing layer is at least one of
woven or nonwoven glass.
The surface covering above, further comprising a fibrous backing sheet
disposed across an underside portion of the backing.
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In accordance with at least one embodiment, a method of producing a
surface covering such as a lay flat flooring product with a carpet or textile
surface
and a flexible, heavy, thin, resilient backing, comprises the steps of:
preparing a
backing composition; depositing the backing composition in a layer; placing a
carpet or textile surface material on the deposited backing layer to form a
multi-
layer structure; pressing the multi-layer structure while setting the backing
with,
for.example, heat so that the backing composition forms a flexible, heavy,
thin,
resilient backing, and wherein the carpet or textile surface material is
bonded to
the backing.
The method above wherein the carpet or textile surface material is at least
one of graphics tufted, printed or dyed.
The method above wherein one or more additional layers are added in, over
or under the backing composition layer.
In at least one embodiment, there is provided a surface covering such as a
lay flat flooring product having an upper show surface disposed in overlying
relation to a single or multi-layer, flexible, heavy, thin, resilient backing.
A fibrous
backing sheet may be disposed across an underside of the backing. The
surface covering may be a tile or roll goods. The show surface may be a
decorative textile or carpet layer.
In accordance with at least one example, a lay flat flooring product
comprises an upper show surface disposed in overlying relation to a single or
multi-layer, flexible, heavy, thin backing, said backing having at least one
of a
bending modulus of less than about 3,000 psi, a thickness of less than about
15
mm, and a density of greater than about 15 Ibs/ft3.
The product above further comprises a flexible fibrous backing sheet
disposed at a position below an underside of the backing.
The product above, wherein the flooring product is one of a tile and roll
goods.
The product above, wherein the show surface is a decorative textile or
carpet layer.
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The product above, wherein the show surface is formed of a material
selected from polyester, polyamide (Nylon), polyolefin, and combinations
thereof.
The product above, wherein the show surface is one of knit, woven,
tufted, bonded, nonwoven, needled, graphics tufted, printed, dyed, and
combinations thereof.
The product above, wherein the backing is resilient.
The product above, wherein the show surface is disposed in overlying
relation to a multi-layer backing.
The product above, wherein the backing includes at least one stabilizing
layer.
The product above, wherein said stabilizing layer is at least one of woven or
nonwoven glass.
The product above, wherein said backing has a bending modulus of less
than about 3,000 psi, a thickness of less than about 15 mm, and a density of
greater than about 15 Ibs/ft3.
The product above, wherein said backing preferably has a bending modulus
of less than about 2,000 psi, a thickness of less than about 10 mm, and a
density
of greater than about 20 Ibs/ft3.
The product above, wherein said backing has a bending modulus of less
than about 1,000 psi, a thickness of less than about 5 mm, and a density of
greater than about 50 Ibs/ft3.
The product above, wherein said backing has a bending modulus of less
than about 1,000 psi, a thickness of less than about 4 mm, and a density of
greater than about 100 Ibs/ft3.
The product above, wherein said backing has a bending modulus of less
than about 500 psi, a thickness of less than about 3 mm, and a density of
greater
than about 200 Ibs/ft3.
In accordance with at least one embodiment, a method of producing a lay
flat flooring product such as a lay flat tile or roll goods product with a
carpet or
textile face and a flexible, heavy, thin, resilient backing, comprising the
steps of:
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preparing a backing composition; depositing the backing composition in a
layer;
placing a carpet or textile face material on the deposited backing layer to
form a
multi-layer structure; setting or curing the backing so that the backing
composition forms a flexible, heavy, thin, resilient backing, and wherein the
carpet or textile face material is bonded to the backing.
The method above wherein the carpet or textile face material is at least
one of graphics tufted, printed or dyed.
The method above further comprising the step of adding one or more
additional layers in, over or under the backing composition.
In accordance with at least one embodiment, a method of producing a lay
flat flooring product such as a lay flat tile or roll goods product with a
carpet or
textile face, and a flexible, heavy, thin, resilient backing, comprising the
steps of:
preparing a backing composition; inverting a carpet or textile face material;
depositing the backing composition on the inverted face material to form a
multi-
layer structure; setting or curing the backing so that the backing composition
forms a flexible, heavy, thin, resilient backing, and wherein the carpet or
textile
face material is bonded to the backing.
The method above, wherein the carpet or textile face material is at least
one of graphics tufted, printed, and dyed.
The method above further comprising the step of adding one or more
additional layers in, over or under the backing composition layer.
A lay flat flooring product produced by one of the methods above.
In accordance with at least selected examples, the preferred backing is
filled polyurethane (greater than 50% by weight filled). Although less
preferred,
other materials which will provide a relatively heavy, thin, flexible, and
resilient
backing may be used. For example, rubber, latex, extruded polymers, hot melts,
adhesives, films, acrylics, and the like may be used.
In accordance with at least selected examples, the preferred adhesive is
an unfilled or lightly filled polyurethane (less than 20% by weight filled).
Although
polyurethane adhesive is preferred, other known adhesives may be used. For
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example, hot melts, polymers, polyolefins, extruded polymers, acrylics, or the
like.
In accordance with at least selected examples, the preferred fillers are
dense fillers having, for example, a specific gravity (SG) greater than 2.
Exemplary fillers include magnetite, iron oxides, ferrite, iron, steel,
nickel, metals,
recycled metals, barite, sand, foundry sand, used foundry sand, glass,
recycled
glass, recycled soda lime glass, glass particles, glass fibers, gypsum,
recycled
gypsum, coal fly ash, calcium carbonate, blends and combinations thereof.
Fillers are typically added in amounts by weight totaling from 0% to about
95%.
In accordance with at least one embodiment, fillers with a specific gravity
(SG) over 5 are preferred (such as iron oxide).
In accordance with at least one other embodiment, magnetic or
magnetizable filler materials are preferred. Such ferromagnetic fillers may be
added at 5% by weight or greater filler loads, preferably 10% or greater by
weight.
In accordance with at least one example, a method of producing a lay flat
product includes the steps of:
1. Producing a substantially tensionless face;
2. Treating the face to remove stresses;
3. Laminating or backing the face;
4. Selectively magnetizing the composite; and
5. Rolling or cutting the composite to form lay flat products.
In accordance with at least one object of the present invention, there is
provided a floor covering product comprising a textile face structure disposed
in
overlying contacting relation to at least one layer of polyurethane backing
composition filled with at least one filler selected from calcium carbonate,
sand,
used foundry sand, recycled gypsum, recycled glass, glass particles, glass
fibers, cork, coal fly ash, recycled metal, rubber, recycled rubber, and
combinations thereof.
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In accordance with at least one object of the present invention, there is
provided a method of forming combinations of floor covering products selected
from carpet, carpet tiles, area rugs, floor tiles, runners, mats, and floor
mats on a
single processing line, the method comprising the steps of:
(a) delivering a mass of polyurethane forming composition onto an
endless belt;
(b) leveling the polyurethane forming composition to a desired
thickness;
(c) placing a preformed textile face structure into overlying contacting
relation with the leveled polyurethane forming composition;
(d) curing the polyurethane forming composition in place across the
underside of the textile face structure; and
(e) cutting the composite of textile face structure with cured
polyurethane to at least two different sizes.
In accordance with at least one object of the present invention, there is
provided a system of polyurethane backed floor covering products such as
tiles,
mats, roll goods, and the like produced on a single polyurethane range.
The system of floor covering products above wherein each such product
includes at least 10% by weight recycled content.
The system of floor covering products above wherein each such product
includes at least 10% by weight post consumer recycled content.
In accordance with at least one embodiment, a surface covering such as
a floor covering comprises a textile face structure disposed in overlying
contacting relation to a layer of filled polyurethane.
The surface covering above further comprising a backing disposed across
a side of the layer of polyurethane facing away from the textile face
structure.
The surface covering above further comprises a structural support layer
disposed in embedded relation within the layer of polyurethane.
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The surface covering above, further comprises a structural support layer
disposed in embedded relation within the layer of polyurethane and a backing
disposed across a side of the layer of polyurethane facing away from the
textile
face structure.
The surface covering above, wherein the surface covering is a carpet tile,
an area rug, or a floor mat.
In accordance with at least one embodiment, a method of forming
combinations of the group consisting of carpet, carpet tile, area rugs and
floor
mats on a single processing line, the method comprises the steps of:
(a) delivering a mass of polyurethane forming composition onto an
endless belt;
(b) leveling the polyurethane forming composition to a desired
thickness;
(c) placing a preformed textile face structure into overlying contacting
relation with the leveled polyurethane forming composition;
(d) curing the polyurethane forming composition in place across the
underside of the textile face structure; and
(e) cutting the composite of textile face structure with cured
polyurethane to at least two different sizes.
In accordance with at least selected embodiments, there is provided a
surface covering such as a carpet, carpet tile, area rug, floor mat or the
like
incorporating a textile face disposed in contacting overlying relation to at
least a
polyurethane layer. One or more optional intermediate structure layers may be
disposed within, on, over, or under the polyurethane and one or more optional
backing layers may be disposed across the underside of the polyurethane.
In accordance with at least one embodiment, a floor coveririg product
comprises a textile face structure disposed in overlying contacting relation
to at
least one layer of polyurethane backing composition filled with at least one
filler
selected from calcium carbonate, sand, used foundry sand, recycled gypsum,
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recycled glass, glass particles, glass fibers, cork, coal fly ash, recycled
metal,
rubber, recycled rubber, and combinations thereof.
The product above further comprises a backing material disposed at a
position below an underside of the layer of polyurethane and operatively
bonded thereto.
The product above further comprises at least one structural support layer
disposed in, on or over said layer of polyurethane.
The product above further comprises a structural support layer disposed
in embedded relation within the layer of polyurethane and a backing material
disposed across an underside of the layer of polyurethane.
The product above, wherein the floor covering product is a product
selected from carpet, carpet tiles, floor tiles, rugs, mats, floor mats,
modular
product, roll goods, broadloom carpet, 6 foot broadloom, 12 foot broadloom,
runners, and area rugs.
The product above, wherein at least one filler in said layer of
polyurethane is post consumer recycled soda lime glass, said recycled soda
lime glass having a pH in deionized water of greater than 8.4 and an average
particle size of greater than 325 mesh.
The product above, wherein the floor covering product is an outdoor
product.
The product above, wherein the floor covering product is an
indoor/outdoor product.
The product above, wherein an underside of said layer of polyurethane is
at least one of embossed, textured, and treated to enhance at least the
sliding
friction of said floor covering product with a floor or subfloor.
In accordance with at least one embodiment, a method of forming
combinations of floor covering products selected from carpet, carpet tiles,
area
rugs, floor tiles, runners, mats, and floor mats on a single processing line,
the
method comprises the steps of:
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(a) delivering a mass of polyurethane forming composition onto an
endless belt;
(b) leveling the polyurethane forming composition to a desired
thickness;
(c) placing a preformed textile face structure into overlying contacting
relation with the leveled polyurethane forming composition;
(d) curing the polyurethane forming composition in place across the
underside of the textile face structure; and
(e) cutting the composite of textile face structure with cured
polyurethane to at least two different sizes.
The method above further comprising the step of adding a release layer,
material, or film over the belt prior to the delivering step.
At least two different floor covering products produced by the method
above.
A system of polyurethane backed floor covering products as described
above such as tiles, mats, roll goods, and the like produced on a single
polyurethane range.
The system above, wherein each such product includes at least 10% by
weight recycled content.
The system above, wherein.each such product includes at least 10% by
weight post consumer recycled content.
If face material 20 must be dyed or printed, it is preferred that it be dyed
prior to addition of polyurethane 14.
Polyurethane 14 may include a polyol component, an isocyanate
component, a catalyst, and other agents, fillers, additives, and the like. It
has
been discovered that the catalyst may be eliminated, that the polyol may be
replaced with castor oil, or both.
The surface coverings of the present invention may be hardback or
cushion back products. One can increase the cushion or resilience of the
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backing by adding more air, more blowing agent, felt, thickness, or the like.
It is
possibly preferred that a polyurethane hardback or cushion back product such
as
a polyurethane hardback or cushion back carpet tile have the structure of one
of
FIGS. 2 - 5, 7- 10, 12 - 15, 17 - 20, and 21 - 26. It may also be preferred
that
a polyurethane backed area rug, roll goods, or floor mat of the present
invention
have the structure of one of FIGS. 2 - 5, 21, and 25.
In accordance with a particular example of an indoor/outdoor
polyurethane backed area rug having a structure like that of FIG. 2, a tufted
face
greige carpet material (no precoat) had a cut pile, Nylon 6,6, jet dyed, 20
oz/yd2
face yarn, 8th gauge, tufted through a 4 oz/yd2 non-woven, polyester primary
backing, was laid over a mechanically frothed, MDI based polyurethane at a 750
gram cup weight and an average add-on of 27 oz/yd2. The uncured
polyurethane composition was poured onto a belt, doctored and then joined to
the carpet greige goods under a marriage roll. The polyurethane was cured
under heat.
In accordance with another example, an indoor/outdoor polyurethane
backed area rug had an overall average height of about 7458.03Nm
(micrometers), an average polyurethane backing height of about 1507.64 pm
(micrometers), and a total weight of about 51.79 oz/yd2.
In accordance with at least selected embodiments of the present
invention, a nip, marriage, or gauge roll 62 (FIG. 1), 162, (FIG. 6), 262
(FIG. 11),
362 (FIG. 16) presses the face material 20, 120, 220, 320 into the uncured
polyurethane composition and sets the height of the total product (prior to
any
chemical blowing).
The surface covering of the present invention may in at least one
embodiment be 6 foot wide roll goods sometimes referred to a 6 foot broadloom.
It has been discovered that unmodified castor oil which has preferably
been filtered and/or dried (otherwise not chemically modified) serves as an
excellent natural oil polyol (or major polyol), reduces or eliminates the need
for
an additional surfactant, wetting agent, or the like, and facilitates the
addition of
high filler loads.
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In accordance with selected embodiments, polyurethane compositions are
formed of castor oil together with one or more optional additional polyols, an
isocyanate, an optional filler or fillers, an optional catalyst, and other
optional
agents, fillers, extenders, coating agents, lubricants, or the like.
In accordance with at least selected embodiments, a carpet tile has a
textile face structure disposed in overlying contacting relation to at least
one
layer of flexible, polyurethane backing composition consisting essentially of
castor oil as major polyol, isocyanate, filler, and an optional catalyst, and
an
optional minor polyol, wherein the filler is at least 42% by weight of the
composition and is selected from coal fly ash, recycled gypsum, recycled
glass,
and combinations thereof.
The carpet tile above, wherein the layer of flexible, polyurethane backing
composition is at least one of a precoat, tiecoat, and backing.
The carpet tile above, further including at least one structural support
layer disposed in, on, under, or over the layer of flexible, polyurethane
backing
composition.
In accordance with at least certain embodiments, a carpet tile has a textile
face structure disposed in overlying contacting relation to
at least one layer of flexible, polyurethane backing composition,
the polyurethane composition being the reaction product of
(i) a polyol component in which castor oil is the predominant reactive
polyol; and
(ii) an isocyanate component,
and the polyurethane composition further comprising a filler, the filler being
at
least 42% by weight of the polyurethane composition and preferably being
selected from coal fly ash, recycled gypsum, recycled glass, and combinations
thereof.
The carpet tile above, wherein substantially the entire polyol component is
castor oil, wherein the polyurethane composition is substantially free of
surfactant, wherein the polyurethane composition is substantially free of
catalyst,
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wherein said layer of flexible, polyurethane backing composition is at least
one of
a precoat, tiecoat, backing, combined precoat/tiecoat, combined
precoat/backing, combined tiecoat/backing, combined precoat/tiecoat/backing,
and combinations thereof, further including at least one structural support
layer
disposed in, on, under, or over the layer of flexible, polyurethane backing
composition, further comprising at least one backing layer disposed across the
underside of said layer of flexible, polyurethane backing composition, wherein
the filer component is at least 50% by weight of the polyurethane composition,
further comprising a minor polyol component which is not castor oil, wherein
the
minor polyol component is selected from the group consisting of other natural
and/or petrochemical polyols and combinations thereof, wherein the minor
polyol
component is present in an amount of less than about 50% by weight of the
polyol component of the polyurethane composition, wherein the minor polyol
component is present in an amount of less than about 10% by weight of the
polyurethane composition, wherein the minor polyol component is present in an
amount of less than about 7% by weight of the polyurethane composition, and/or
wherein the minor polyol component is present in an amount of less than about
5
% by weight of the polyurethane composition.
In accordance with at least one embodiment, a polyurethane for
application to a tufted, woven, non-woven, bonded, needled, flocked, needle
punched, or knit textile face structure, includes a polyol component, an
isocyanate component, a catalyst and other agents, fillers, additives, and the
like
wherein the catalyst is eliminated, the polyol is replaced with castor oil, or
both.
In at least one embodiment of a cured flexible polyurethane material, the
polyurethane material is the reaction product of
(i) a polyol component in which castor oil is the predominant
reactive polyol; and
(ii) an isocyanate component,
and the polyurethane material further comprising a filler, the filler being at
least
42% by weight of the polyurethane material.
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In accordance with at least one embodiment of a cured flexible
polyurethane material, the polyurethane material is the reaction product of
(i) a polyol component; and
(ii) an isocyanate component,
and the polyurethane material further comprising a filler, the filler being at
least
42% by weight of the polyurethane material and the cured flexible material
being
formed substantially in the absence of catalyst.
In accordance with at least one embodiment of a cured flexible
polyurethane material, the polyurethane material is the reaction product of
(i) a polyol component; and
(ii) an isocyanate component,
and the polyurethane material further comprising a filler, the filler being at
least
42% by weight of the polyurethane material and the cured flexible material
being
formed substantially in the absence of surfactant, wetting agent, or both.
In accordance with at least one embodiment of a cured flexible reactive
elastomer or reactive elastomeric material, the elastomer or elastomeric
material is the reaction product of
(i) a polyol component; and
(ii) an isocyanate component,
and the elastomer or elastomeric material further comprising a filler, the
filler
being at least 42% by weight of the elastomer or elastomeric material and the
cured flexible material being formed substantially in the absence of
surfactant,
wetting agent, or both. The elastomer or elastomeric material may be used as a
precoat, tiecoat and/or backing. The preferred reactive elastomer or
elastomeric
material may be polyurethane.
In accordance with at least selected embodiments, the polyol component
is preferably a polyol component in which castor oil is the predominant
reactive
polyol.
In accordance with at least selected embodiments, a floor covering*
product has a textile face structure disposed in overlying contacting relation
to at
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least one layer of polyurethane backing composition filled with at least one
filler
selected from calcium carbonate, sand, used foundry sand, recycled gypsum,
recycled glass, glass particles, glass fibers, cork, coal fly ash, recycled
metal,
rubber, recycled rubber, and combinations thereof.
The floor covering product above, further comprising a backing material
disposed at a position below an underside of the layer of polyurethane and
operatively bonded thereto, further comprising at least one structural support
layer disposed in, on, under, or over said layer of polyurethane, further
comprising a structural support layer disposed in embedded relation within the
layer of polyurethane and a backing material disposed across an underside of
the layer of polyurethane, wherein the floor covering product is a product
selected from carpet, carpet tiles, floor tiles, rugs, mats, floor mats,
modular
product, roll goods, broadloom carpet, 6 foot broadloom, 12 foot broadloom,
runners, and area rugs, wherein at least one filler in said layer of
polyurethane is
post consumer recycled soda lime glass, said recycled soda lime glass having a
pH in deionized water of greater than 8.4 and an average particle size of
greater
than 325 mesh, wherein the floor covering product is an outdoor product,
wherein the floor covering product is an indoor/outdoor product, and/or
wherein
an underside of said layer of polyurethane is at least one of embossed,
textured,
and treated to enhance at least the sliding friction of said floor covering
product
with a floor or subfloor.
In accordance with at least one embodiment, a method of forming
combinations of floor covering products selected from carpet, carpet tiles,
area
rugs, floor tiles, runners, mats, and floor mats on a single processing line,
includes the steps of:
(a) delivering a mass of polyurethane forming composition onto an
endless belt;
(b) leveling the polyurethane forming composition to a desired
thickness;
(c) placing a preformed textile face structure into overlying contacting
relation with the leveled polyurethane forming composition;
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(d) curing the polyurethane forming composition in place across the
underside of the textile face structure; and
(e) cutting the composite of textile face structure with cured
polyurethane to at least two different sizes.
The method above, further comprising the step of adding a release layer,
material, or film over the belt prior to the delivering step, producing at
least two
different floor covering products, producing a system of polyurethane backed
floor covering products such as tiles, mats, roll goods, and the like produced
on
a single polyurethane range, wherein each such product includes at least 10%
by weight recycled content, and/or wherein each such product includes at least
10% by weight post consumer recycled content.
In at least selected embodiments, a carpet tile includes a textile face
structure disposed in overlying contacting relation to at least one layer of
flexible,
polyurethane backing composition, the polyurethane composition being the
reaction product of
(i) a polyol component in which castor oil is the predominant reactive
polyol (preferably greater than about 50% of the reactive polyol by
weight or by reactivity, more preferably greater than about 60% of
the reactive polyol by weight or by reactivity, and most preferably
greater than about 75% of the reactive polyol by weight or by
reactivity); and
(ii) an isocyanate component,
and the polyurethane composition further comprising a filler, the filler being
at
least about 42% by weight of the polyurethane composition.
The carpet tile above, wherein the filler is selected from coal fly ash,
recycled gypsum, recycled glass, and combinations thereof, wherein
substantially the entire polyol component is unmodified castor oil (preferably
greater than about 85% by weight of the entire polyol component, more
preferably greater than about 95% by weight of the entire polyol component,
and
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most preferably greater than about 99% by weight of the entire polyol
component), wherein the polyurethane composition is substantially free of
surfactant, wetting agent, or both (preferably less than about 3% by weight of
the
polyurethane composition, more preferably less than about 1% by weight of the
polyurethane composition, and most preferably less than about 0.01 % by weight
of the polyurethane composition), wherein the polyurethane composition is
substantially free of catalyst (preferably less than about 3% by weight of the
polyurethane composition, more preferably less than about 1% by weight of the
polyurethane composition, and most preferably less than about 0.01 % by weight
of the polyurethane composition), wherein said at least one layer of flexible,
polyurethane backing composition is at least one of a precoat, tiecoat,
backing,
combined precoat/tiecoat, combined precoat/backing, combined tiecoat/backing,
combined precoat/tiecoat/backing, and combinations thereof, further comprising
at least one structural support layer disposed in, on, under, or over said
layer of
flexible, polyurethane backing composition, at least one backing layer may be
disposed across the underside of said layer of flexible, polyurethane backing
composition, or both, and/or wherein said textile face structure is at least
one of
tufted, bonded, woven, non-woven, needled, flocked, knit, and needle punched.
Although it may be preferred that the backing is a single layer combined
precoat/backing or combined precoat/tiecoat on the back of greige goods, it is
contemplated that in accordance with at least selected embodiments that each
of
the precoat, tiecoat and/or backing layers may be of the same or of different
formulations, may be foam or nonfoam, may be filled or not filled, and/or the
like.
For example, the precoat may be a nonfoam, nonfilled formulation A, while the
tiecoat is a nonfoam, filled formulation B, and the backing is a foam, filled
formulation C. In another example, the combined precoat/tiecoat is a nonfoam,
filled formulation D while the backing is a foam, filled formulation E. In yet
another example, the combined precoat/tiecoat is a nonfoam, filled, castor oil
polyol based polyurethane layer, while the backing is a foam, filled petroleum
polyol based polyurethane layer.
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It is contemplated that in accordance with at least selected embodiments
that the filler for the precoat, tiecoat and/or backing may be recycled
precoat,
tiecoat, backing, face material, flooring product, or the like. It may be
preferred
to recycle the entire flooring product by grinding or densifying it and using
it as
filler in the precoat, tiecoat and/or backing.
While the present invention has been illustrated and described in relation to
certain potentially preferred embodiments and practices, it is to be
understood
that the illustrated and described embodiments and practices are illustrative
only
and that the present invention includes such embodiments but is not limited
thereto. Rather, it is fully contemplated that modifications and variations to
the
present invention will no doubt occur to those of skill in the art upon
reading the
above description and/or through practice of the invention. It is therefore
intended that the present invention shall extend to all such modifications and
variations as may incorporate the broad principles of the present invention
within the full spirit and scope thereof.
