Surface coverings containing fused recycled material and processes of making the same
AssigneeMannington Mills, Inc.
InventorsPeter Desai, Hao A. Chen, Nicholas Zerebecki
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Abstract
A backing or an intermediate layer for a surface covering is described which comprises a fused recycled material, wherein the material comprises a thermoplastic material, for instance, a vinyl material from a vinyl backed carpet or vinyl backed carpet manufacturing waste or both. Surface coverings containing the backing or intermediate layer of the present invention are also described as well as methods of making the backing or intermediate layer and methods of making the surface coverings containing the backing or intermediate layer of the present invention.
Claims11
A surface covering comprising a backing or intermediate layer comprising a fused recycled material, wherein said recycled material comprises at least one thermoplastic material and wherein said backing layer or intermediate layer or both further comprises face fibers, at least one vinyl resin, at least one plasticizer, at least one inorganic filler, and at least one stabilizer.
A surface covering comprising a backing or intermediate layer comprising a fused recycled material, wherein said recycled material comprises at least one thermoplastic material and wherein the surface covering is a textile substrate, further comprising a primary backing having textile fibers extending upwardly from the primary backing and forming a surface, an adhesive or polymeric pre-coat layer affixed to the back surface of the primary backing, an intermediate backing layer affixed to the adhesive or polymeric pre-coat layer, a reinforcement material layer or stabilizer layer affixed to the intermediate layer, wherein the backing layer is affixed to the bottom surface of the reinforcement material layer or stabilizer layer and wherein the backing layer or intermediate layer or both comprises a fused recycled material comprising a thermoplastic material.
A vinyl floor surface covering comprising a substrate comprising fused recycled thermoplastic material and a wear layer comprising cured thermoplastic material wherein the recycled material comprises recycled particles or granules that substantially maintain their identity as particles or granules on a microscopic level.
Dependencies are inferred from the claim text.