Polymeric wet-laid nonwoven mat for flooring applications
AssigneeJohns Manville
InventorsZhihua Guo, Rui Ferreira, Souvik Nandi, Philip Christopher Sharpe
Life of this patent
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Abstract
A flooring product may include an upper flooring material and a glassless wet-laid nonwoven mat. The glassless wet-laid nonwoven mat may include a plurality of polymeric fibers and a binder. The plurality of polymeric fibers have a linear mass density of between about 1.0 denier and 4.0 denier. The plurality of polymeric fibers have lengths of between about 6 mm and 25 mm. The binder has a loss on ignition of at least about 20%. The glassless wet-laid nonwoven mat has a hot-wet % of at least about 20%.
Claims20
A flooring product, comprising:
- an upper flooring material;
- a glassless wet-laid nonwoven mat coupled with the upper flooring material, the glassless wet-laid nonwoven mat comprising:
- a plurality of polymeric fibers and a binder, wherein:
- the plurality of polymeric fibers have a linear mass density of between about 1.0 denier and 4.0 denier;
- the plurality of polymeric fibers have lengths of between about 6 mm and 25 mm;
- the binder has a loss on ignition of at least about 20%;
- and
- the glassless wet-laid nonwoven mat has a hot-wet % of at least about 20%.
A carpet tile, comprising:
- a pile fabric layer;
- at least one backing coupled with the pile fabric layer;
- a glassless wet-laid nonwoven mat coupled with the at least one backing, the glassless wet-laid nonwoven mat comprising:
- a plurality of polymeric fibers and a binder, wherein:
- the plurality of polymeric fibers have a linear mass density of between about 1.0 denier and 4.0 denier;
- the plurality of polymeric fibers have lengths of between about 6 mm and 25 mm;
- the binder has a loss on ignition of at least about 20%;
- and
- the glassless wet-laid nonwoven mat has a hot-wet % of at least about 20%.
A method of manufacturing a flooring product, comprising:
- providing an upper flooring material;
- and
- coupling a glassless wet-laid nonwoven mat with a lower surface of the upper flooring material, the glassless wet-laid nonwoven mat comprising:
- a plurality of polymeric fibers and a binder, wherein:
- the plurality of polymeric fibers have a linear mass density of between about 1.0 denier and 4.0 denier;
- the plurality of polymeric fibers have lengths of between about 6 mm and 25 mm;
- the binder has a loss on ignition of at least about 20%;
- and
- the glassless wet-laid nonwoven mat has a hot-wet % of at least about 20%.
Dependencies are inferred from the claim text.