Recyclable Single Polymer Floorcovering Article
AssigneeMilliken & Company
InventorsDale R. Williams, Joseph Wallen, Ty Grant Dawson, Nils David Sellman, JR., Daniel Taylor McBride, Joseph R. Royer, John L. Sanchez
Life of this patent
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Abstract
This invention relates to tufted floorcovering articles, including carpet tiles and broadloom carpet. In particular, this invention relates to tufted floorcovering articles made from the family of polymers known as polyester. Specifically, this invention relates to tufted carpet tile products made from polyester. The polyester carpet tiles meet commercial performance specifications and are fully end-of-life recyclable.
Claims20
A polyester floorcovering article comprised of:
- (a) polyester pile yarn;
- (b) a spunbond nonwoven polyester primary backing layer;
- (c) a first layer of polyester hot melt adhesive having a certain viscosity, wherein the hot melt adhesive is comprised of at least 50% recycled material;
- (d) a second layer of polyester hot melt adhesive having a viscosity or molecular weight that is three to five times higher than the viscosity or molecular weight of layer “c;” and
- (e) a polyester needlepunch nonwoven secondary backing layer.
A floorcovering article comprised of:
- (a) a layer of polyester yarn selected from the group consisting of loop pile, cut pile, or a combination of loop and cut pile;
- (b) a layer of polyester primary backing layer selected from the group consisting of spunbond nonwoven, stitchbonded nonwoven, woven tape, and needlepunch nonwoven;
- (c) a layer of polyester adhesive having a certain viscosity;
- (d) a layer of polyester adhesive having viscosity at least two times greater than the viscosity of layer “c;” and
- (e) a layer of polyester secondary backing layer in the weight range of 200 gsm to 850 gsm.
A polyester floorcovering article comprised of:
- (a) 100% polyester yarn with a weight range of 15-60 oz/yd2;
- (b) a polyester woven tape primary backing layer;
- (c) a polyester adhesive layer having viscosity in the range from 2100 cps to 8500 cps;
- and
- (d) a secondary backing layer comprised of polyester.
A floor covering article comprised substantially of 100% polyester material, wherein the article contains an average post-consumer recycle content in the range from 70% to 100% by weight, and wherein the article is fully recyclable at the end-of-life.
Dependencies are inferred from the claim text.