# US 2015/0147564 A1 · Recyclable surface covering and method and system for manufacturing a recyclable surface covering

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- Number: US 2015/0147564 A1
- Document ID: US20150147564A1
- Status: Published application
- Kind: A1
- Application number: 14/613,045
- Filed: 2015-02-03
- Published: 2015-05-28
- Earliest claimed: 2010-02-04
- Assignees: Ecore International Inc.
- Applicants: Ecore International Inc.
- Inventors: Arthur B. DODGE, III; John McFALLS
- Web page: https://patentgrep.com/patent/US20150147564A1

## CPC

- B32B 25/14: comprising {synthetic rubber copolymers (B32B25/18 and B32B25/20 take precedence)}
- B32B 3/26: characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids {(foam layer B32B5/18; layer of synthetic resin characterised by fillers that create voids or cavities B32B27/205); characterised by an apertured layer}
- B32B 3/30: characterised by a layer formed with recesses or projections, e.g. {hollows, grooves, protuberances, ribs (apertured layer B32B3/266; layer with cavities or internal voids B32B3/26)}
- B32B 5/02: characterised by structural features of a {fibrous or filamentary} layer {(layer formed of metallic wires B32B15/02; layer formed of natural mineral fibres B32B19/02; layer formed of wood fibres B32B21/02)}
- B32B 5/022: {Non-woven fabric}
- B32B 5/024: {Woven fabric}
- B32B 5/026: {Knitted fabric}
- B32B 5/028: {Net structure, e.g. spaced apart filaments bonded at the crossing points}
- B32B 5/16: characterised by features of a layer formed of particles, e.g. chips, powder {or granules (layer formed of natural mineral particles B32B19/00; layer being formed of wood fibres, chips or particles B32B21/02)}
- B32B 5/18: characterised by features of a layer {of} foamed material
- B32B 5/24: one layer being a fibrous or filamentary layer
- B32B 5/30: one layer {being formed of particles, e.g. chips,} granules, powder
- B32B 7/12: using interposed adhesives or interposed materials with bonding properties
- B32B 9/02: comprising animal or vegetable substances {, e.g. cork, bamboo, starch}
- B32B 21/00: Layered products comprising {a layer of} wood, e.g. wood board, veneer, wood particle board
- B32B 25/04: comprising rubber as the main or only constituent of a layer, {which is} next to another layer of {the same or of} a {different material (next to a layer of a particular substance B32B9/043; next to a bituminous or tarry layer B32B11/044; next to a water setting substance layer B32B13/042; next to a metal layer B32B15/06; next to a glass layer B32B17/063; next to a layer formed of natural mineral fibres or particles B32B19/043; next to a wood layer B32B21/045; next to a cellulosic plastic layer B32B23/046)}
- B32B 25/047: {of particles}
- B32B 25/10: next to a fibrous or filamentary layer
- B32B 25/16: comprising polydienes {homopolymers} or poly-halodienes {homopolymers (B32B25/12 takes precedence)}
- B32B 27/065: {of foam}
- B32B 27/30: comprising vinyl {(co)polymers; comprising acrylic (co)polymers}
- B32B 27/304: {comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF}
- B32B 27/32: comprising polyolefins {(comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30)}
- B32B 27/34: comprising polyamides
- B32B 37/02: characterised by a sequence of laminating steps, e.g. by adding new layers at consecutive laminating stations
- B32B 37/1207: {Heat-activated adhesive (B32B37/04 takes precedence)}
- B32B 37/182: {one or more of the layers being plastic}
- B32B 38/0036: {Heat treatment (for heating or cooling of layers during lamination B32B37/06, B32B37/08)}
- B32B 39/00: Layout of apparatus or plants, e.g. modular laminating systems
- D06N 7/0071: {characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing}
- D06N 7/0084: {with at least one layer obtained by sintering or bonding granules together}
- E04F 13/18: of organic plastics with or without reinforcements or filling materials (of plastic-bound fibres or chips E04F13/16 ){or with an outer layer of organic plastics with or without reinforcements or filling materials; plastic tiles (E04F13/0864 takes precedence)}
- E04F 15/10: of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite {tiles}, hardboard {, or with a top layer of other materials}
- E04F 15/107: {composed of several layers, e.g. sandwich panels (layered products in general B32B; producing decorative panels or veneers B44C5/04)}
- B32B 37/08: characterised by the cooling method
- B32B 38/1875: {Tensioning}
- B32B 41/00: Arrangements for controlling or monitoring lamination processes; Safety arrangements
- B32B 2037/1238: {in the form of powder}
- B32B 2250/02: 2 layers
- B32B 2250/03: 3 layers
- B32B 2260/025: Particulate layer
- B32B 2260/046: Synthetic resin
- B32B 2262/02: Synthetic macromolecular fibres
- B32B 2262/0261: Polyamide fibres
- B32B 2262/0276: Polyester fibres
- B32B 2262/062: Cellulose fibres, e.g. cotton
- B32B 2262/08: Animal fibres, e.g. hair, wool, silk
- B32B 2264/0207: Particles made of materials belonging to B32B25/00
- B32B 2266/0278: Polyurethane
- B32B 2272/00: Resin or rubber layer comprising scrap, waste or recycling material
- B32B 2305/022: Foam
- B32B 2305/70: Scrap or recycled material
- B32B 2307/102: Insulating
- B32B 2307/30: having particular thermal properties
- B32B 2319/00: Synthetic rubber
- B32B 2471/00: Floor coverings (B32B2419/04 takes precedence)
- B32B 2471/02: Carpets
- B32B 2471/04: Mats
- B32B 2607/00: Walls, panels
- D06N 2205/106: Scrap or recycled particles
- Y02P 70/62: related technologies for production or treatment of textile or flexible materials or products thereof, including footwear
- Y10T 156/10: Methods of surface bonding and/or assembly therefor
- Y10T 156/1052: with cutting, punching, tearing or severing
- Y10T 156/12: Surface bonding means and/or assembly means with cutting, punching, piercing, severing or tearing
- Y10T 156/15: Combined or convertible surface bonding means and/or assembly means
- Y10T 156/1744: Means bringing discrete articles into assembled relationship
- Y10T 156/1751: At least three articles
- Y10T 428/23943: Flock surface
- Y10T 428/24405: Polymer or resin [e.g., natural or synthetic rubber, etc.]
- Y10T 428/24802: Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
- Y10T 428/249921: Web or sheet containing structurally defined element or component
- Y10T 428/249982: With component specified as adhesive or bonding agent
- Y10T 428/249985: Composition of adhesive or bonding component specified
- Y10T 428/249986: Void-containing component contains also a solid fiber or solid particle
- Y10T 428/249991: Synthetic resin or natural rubbers
- Y10T 428/3167: Of cork
- Y10T 428/31725: Of polyamide
- Y10T 428/3183: Next to second layer of natural rubber
- Y10T 428/31855: Of addition polymer from unsaturated monomers
- Y10T 428/31931: Polyene monomer-containing
- Y10T 428/31971: Of carbohydrate
- Y10T 442/10: Scrim [e.g., open net or mesh, gauze, loose or open weave or knit, etc.]
- Y10T 442/3911: Natural or synthetic rubber sheet or film
- Y10T 442/40: Knit fabric [i.e., knit strand or strip material]
- Y10T 442/679: Natural or synthetic rubber sheet or film
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- D06N: WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- E04F: FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS (windows, doors E06B)
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A process and system for making a laminated surface covering and the surface covering itself are described. The covering includes several layers bonded to each other. The system performs the process. One example of the process includes passing a first material across a first conveyor, passing a second material across a second conveyor, passing a bonding material across a third conveyor, contacting the first material and the second material to the bonding material, and heating at least one of the first material and the second material. The process also includes introducing the first material, the second material, and the bonding material into a pressure zone such that the bonding material is introduced between a bottom surface of the first material and a top surface of the second material. The process applies pressure to bond the first material and second material together via the bonding material to produce a laminated material.

## Claims

### Claim 1

A prefabricated vinyl tile, comprising:
a vinyl portion;
an acoustical portion; and
an adhesive layer for fixing the vinyl portion to the acoustical portion;
wherein the acoustical portion is a mixture including a crumb rubber component, a polyurethane foam component, and a resin binder component.

### Claim 2

A prefabricated vinyl tile, comprising:
a vinyl portion;
an acoustical portion comprising a mixture of a crumb rubber component, a polyurethane foam component, and a resin binder component; and
a polyurethane adhesive layer for fixing the vinyl portion to the acoustical portion.

### Claim 3

A method of making a prefabricated vinyl tile, comprising:
providing a vinyl slab portion;
providing an acoustical slab portion comprising a mixture of crumb rubber, Polyurethane foam and resin binder; and
bonding the vinyl slap portion to the acoustical portion.