Surface coverings including carbon sequestration materials and methods of making the same
阅读说明：本技术 包括碳封存材料的表面覆盖物及其制造方法 (Surface coverings including carbon sequestration materials and methods of making the same ) 是由 J·L·韦弗 S·琼斯 A·卡尔佩珀 J·霍布斯 L·阿基利 T·布塔拉 C·D·汉斯勒 于 2020-01-09 设计创作，主要内容包括：用于安装在内部表面上的地面覆盖物,例如组装式(modular)嵌板或组装式拼块,包括上部耐磨层和背衬层,其中背衬层包括填料,该填料包括浓缩碳。地面覆盖物可以封存碳,从而使所得产品在经受生命周期评估时具有负碳足迹。(A floor covering for mounting on an interior surface, such as a modular panel or modular tile, comprises an upper wear layer and a backing layer, wherein the backing layer comprises a filler comprising concentrated carbon. The floor covering may encapsulate carbon, such that the resulting product has a negative carbon footprint when subjected to life cycle assessment.)
1. A floor covering comprising an upper wear layer and a backing composite, wherein the backing composite comprises a binder and at least one filler, wherein the at least one filler comprises concentrated carbon.
2. A floor covering according to claim 1, wherein the concentrated carbon has a carbon content of at least 85%.
3. The floor covering of claim 1 or claim 2, wherein the concentrated carbon comprises less than 40ppm total Polycyclic Aromatic Hydrocarbons (PAHs) and less than 15ppm total weight metals.
4. The floor covering of any one of claims 1 to 3, wherein the concentrated carbon has a particle size of from about 0.01 μm to about 3 mm.
5. The floor covering of any one of claims 1 to 4, wherein the concentrated carbon is present in the backing composite at a weight percentage of about 1% to about 60% by weight.
6. The floor covering of claim 5, wherein the concentrated carbon is present in the backing composite at a weight percentage of about 10% to about 50% by weight.
7. The floor covering of claim 6, wherein a weight percentage of the concentrated carbon is present in the backing composite of about 20% to about 50% by weight.
8. The floor covering of claim 7, wherein the concentrated carbon is present in the backing composite at a weight percentage of about 30% to about 50% by weight.
9. The floor covering according to any one of claims 1 to 8, wherein the at least one filler comprises a first filler comprising the concentrated carbon and a second filler comprising a silicate, silica, an oxide of silica, a carbonate, a sulfate, an oxide of antimony, aluminum trihydrate, calcium oxide, fly ash, carbon black, talc, clay, kaolin, wood chips, wood flour, shell flour, plant material, or recycled material.
10. The floor covering of claim 9, wherein the first filler and the second filler are present in the backing composite at a combined weight percentage of about 40% to about 70% by weight.
11. The floor covering of claim 10, wherein the first filler and the second filler are present in the backing composite at a combined weight percentage of about 50% to about 70% by weight.
12. The floor covering according to any one of claims 1 to 11, wherein the binder comprises a bio-based ester.
13. The floor covering of claim 12, wherein the biobased ester comprises an esterified rosin, a hydrogenated rosin, a phenolic rosin, or a terpene rosin.
14. The floor covering of claim 12 or claim 13, wherein the biobased ester is present in the backing composite at a weight percentage of about 5% to about 40% by weight.
15. The floor covering according to any one of claims 1 to 14, wherein the binder comprises an oil, and wherein the oil comprises an oil of plant, animal or algal origin.
16. The floor covering according to claim 15, wherein the oil comprises a vegetable-derived oil, and wherein the vegetable-derived oil comprises rapeseed oil, sunflower seed oil, soybean oil, palm oil, castor oil, coconut oil, or refined forms thereof.
17. The floor covering of claim 15 or claim 16, wherein the plant, animal, or algae-derived oil is present in the backing composite at a weight percentage of about 2% to about 15% by weight.
18. The floor covering according to any one of claims 1 to 17, wherein the binder comprises a polymer.
19. The floor covering of claim 18, wherein the polymer is present in the backing composite at a weight percentage of no greater than 30% by weight.
20. A floor covering according to claim 18 or claim 19, wherein the polymer comprises recycled polyvinyl chloride (PVC) or Ethylene Vinyl Acetate (EVA).
21. The floor covering according to any one of claims 1 to 20, wherein the binder is substantially free of unused PVC.
22. The floor covering according to any one of claims 1 to 21, wherein the floor covering is a carpet tile and the upper wear layer comprises a half-cloth comprising yarns tufted into a tufting primary cloth and a pre-coat layer disposed on an underside of the tufting primary cloth.
23. The floor covering of claim 22, wherein the half-cloths include a yarn pile weight of no more than 18 osy.
24. The floor covering of claim 23, wherein the half-cloth includes a yarn pile weight of no more than 12 osy.
25. The floor covering of any one of claims 22 to 24, wherein the yarn comprises recycled nylon 6 or nylon 6, 6.
26. The floor covering of any one of claims 22 to 25, wherein the yarns comprise a denier of 900 and 1800, inclusive.
27. The floor covering of claim 26, wherein the yarn comprises a denier of 1200-1800, inclusive.
28. The floor covering of any one of claims 22 to 27, wherein the half-cloth comprises a tuft density of 140 and 300 tufts/inch, inclusive.
29. The floor covering of any one of claims 22 to 28, wherein the yarns comprise a tuft height of 2/32 inches to 3/32 inches, inclusive.
30. The floor covering of any one of claims 22 to 29, wherein when the carpet tile is subjected to the test method set forth in ASTM D5252-2015, the carpet tile achieves a rating equal to or greater than 3.5 according to the rating scale set forth in ASTM D7330-2015.
31. The floor covering according to any one of claims 22 to 30, wherein the pre-coating layer comprises a filler comprising concentrated carbon.
32. The floor covering according to any one of claims 22 to 31, wherein the pre-coat is free of filler.
33. The floor covering of any one of claims 22 to 32, wherein the precoat layer comprises a weight of less than about 18 osy.
34. The floor covering of any one of claims 22 to 33, wherein the half cloth comprises a weight of about 14osy to about 35 osy.
35. The floor covering according to any one of claims 1 to 34, wherein the floor covering comprises a backing composite comprising the backing composite and a substrate, and wherein the backing composite is flexible.
36. The floor covering of any one of claims 1 to 35, wherein the backing composite comprises a negative material-based Global Warming Potential (GWP) calculated using the TRACI 2.1 method.
37. The floor covering according to any one of claims 1 to 36, wherein the overall floor covering includes a negative cradle to gate GWP, calculated using the TRACI 2.1 method.
38. A floor covering comprising an upper wear layer and a backing composite, wherein at least one of the upper wear layer or the backing composite comprises a negative material-based GWP, calculated using the TRACI 2.1 method.
39. The floor covering of claim 38, wherein the backing composite comprises a binder and at least one filler, and wherein the at least one filler comprises concentrated carbon present in the backing composite at a weight percentage of about 1% to about 60% by weight.
40. The floor covering of claim 39, wherein the at least one filler comprises a first filler comprising the carbon concentrate and a second filler comprising silicates, silica, oxides of silica, carbonates, sulfates, oxides of antimony, aluminum trihydrate, calcium oxide, fly ash, carbon black, talc, clays, kaolin, wood flour, shell flour, plant materials, or recycled materials.
41. The floor covering of claim 40, wherein the first filler and the second filler are present in the backing composite at a combined weight percentage of about 40% to about 70% by weight.
42. The floor covering of any one of claims 39 to 41, wherein the binder further comprises a biobased ester present in the backing composite at a weight percentage of about 5% to about 40% by weight.
43. The floor covering of any one of claims 39 to 42, wherein the binder comprises biobased oil present in the backing composite at a weight percentage of about 2% to about 15% by weight.
44. The floor covering of any one of claims 39 to 43, wherein the binder comprises a polymer present in the backing composite at a weight percentage of no greater than 30% by weight.
45. The floor covering of any one of claims 39 to 44, wherein the binder is substantially free of unused PVC.
46. The floor covering according to any one of claims 38 to 45, wherein the floor covering is a carpet tile and the upper wear layer comprises a half-cloth comprising yarns tufted into a tufting primary cloth and a pre-coat layer disposed on an underside of the tufting primary cloth.
47. The floor covering of claim 46, wherein the half-cloths include a yarn pile weight of no more than 18 osy.
48. A floor covering according to claim 46 or claim 47, wherein the yarns comprise recycled nylon 6 or nylon 6, 6.
49. The floor covering of any one of claims 46 to 48, wherein the yarns comprise a denier of 1200 and 1800, inclusive.
50. A floor covering according to any one of claims 46 to 49, wherein the pre-coating includes a filler comprising concentrated carbon.
51. The floor covering according to any one of claims 46 to 50, wherein the pre-coat layer is free of filler.
52. The floor covering of any one of claims 46 to 51, wherein the pre-coat comprises a weight of less than about 18 osy.
53. The floor covering of any one of claims 46 to 52, wherein the half cloth comprises a weight of about 14osy to about 35 osy.
54. A flexible backing composite comprising a binder and a filler, wherein the binder comprises a biobased ester, a biobased oil, and a polymer, and wherein the filler comprises condensed carbon.
55. The flexible backing composite of claim 54, wherein the polymer is ethylene vinyl acetate.
56. The flexible backing composite of claim 54 or claim 55, wherein the adhesive does not comprise polyvinyl chloride.
57. The flexible backing composite of any one of claims 54-56, wherein the biobased ester is present in the backing composite at a weight percentage of about 10% to about 40% by weight, wherein the biobased oil is present in the backing composite at a weight percentage of about 2% to about 10% by weight, wherein the polymer is present in the backing composite at a weight percentage of not greater than 30% by weight, and wherein the concentrated carbon is present in the backing composite at a weight percentage of about 10% to about 55% by weight.
58. The flexible backing composite of any one of claims 54-57, wherein the filler further comprises calcium carbonate.
59. The flexible backing composite of any one of claim 54 to claim 57, wherein the backing composite comprises a negative material-based Global Warming Potential (GWP), calculated using the TRACI 2.1 method.
FIELD
Embodiments of the present invention relate to surface coverings (surface covering), such as floor coverings (floor covering), and in particular to carpet tiles (carpet tiles) and other modular panels or modular tiles (tiles) designed specifically to reduce, eliminate and/or preferably render negative the carbon footprint of a product, as measured by Life Cycle Assessment (Life Cycle Assessment).
Background
The floor covering typically includes at least one exposed upper wear layer and a backing layer below the wear layer. Carpet tiles typically have an upper wear layer formed by: the yarns are tufted into a primary backing fabric and the underside of the backing fabric is coated with an adhesive material (often referred to as a "pre-coat") to lock the yarns into the primary backing fabric. For the purposes of this application, the term "face cloth" refers to the primary backing of the tufts prior to application of the pre-coat (i.e., without the pre-coat), while the term "half cloth" refers to the primary backing of the tufts with the pre-coat (i.e., the yarn/primary backing/pre-coat composite). The half-cloths were then attached to a stable structure backing composite to form a grid carpet (carpet web). The grid carpet is then cut into carpet tiles of the desired shape and size.
Fig. 1 and 2 are cross-sections illustrating examples of conventional carpet tile constructions 10, 11. The carpet tile structures 10, 11 include yarns 17 tufted into a tufted primary 19 (also known as primary backing) to form the face fabric 14. In addition to being tufted, carpet tile halves can also be woven (woven), nonwoven (e.g., needle punched or needle punched felt), melt-bonded (fused-bonded), and the like. An adhesive or pre-coat layer 22 is located on the underside of the face fabric 14 to lock the yarns 17 into the tufted primary backing 19 and thereby form a half-fabric.
The backing composite 12, 21 is disposed under the half-cloth. The backing composite imparts flatness, dimensional stability, stiffness and weight to the assembled tile and thereby minimizes or eliminates the need for adhesives to secure the tile to the floor. The backing composite for broadloom carpet is typically composed of a latex coating (excluding any latex precoat) and a textile substrate (e.g., textile substrate). The backing composite of the modular tile must typically be heavier than broad width carpet to ensure performance and durability of the product, e.g., to achieve heavy wear without degradation failure (determination). Thus, carpet tile backing composites typically include a polymeric coating or sheet, optionally with a glass mat (glass veil) or glass veil (glass script) embedded therein for dimensional stability, and/or optionally with an underlying substrate (typically a fabric, such as a non-woven pile fabric (sweep)) positioned on the underside of the carpet tile.
Fig. 1 shows a carpet tile structure 10 having a backing composite 12, the backing composite 12 having a polymer sheet layer 18 (which does not include an embedded fiberglass layer) and a fabric 24 on the underside of the tile structure. Fig. 2 shows a carpet tile structure 11 having a backing composite 21, the backing composite 21 having two polymer sheet layers 18, 20 and a glass fiber layer 16 between the backing sheet layers 18, 20. The carpet tile structure 11 does not include an underlying fabric as in the example of the carpet tile structure 10.
The carbon footprint of a product measures the total greenhouse gas (GHG) removed from or vented to the atmosphere during the product's life cycle (e.g., production, use, and cleaning). The carbon footprint is also known as net Global Warming Potential (GWP) emissions, as carbon dioxide (CO) per square meter2) Kilogram of equivalents (kg CO)2 eq/m2) To measure. In determining GWP emissions, CO will be excluded2Other GHG's are converted to CO by their radiation forcing effect over a hundred years2And (3) equivalent weight. A negative net GWP indicates that more GHG is removed from the atmosphere than is discharged to the atmosphere during the life of the product.
Net GWP emissions can be measured using the Life Cycle assessment (also known as Life Cycle Analysis) described in the environmental management standards of the ISO 14000 series. According to these standards, Life Cycle Assessment (LCA) is a technique that assesses the environmental impact of a product or service by quantifying all inputs and outputs of material flows and assessing how these material flows impact the environment. The LCA of a product is done for the entire life cycle of the product; however, the life cycle of a product can be divided into multiple phases. The phase from raw materials to manufacturing is known as "cradle-to-gate", while the after-market phase, including consumer use and end of life, is known as "gate-to-grave" (or "gate-to-end-of-life)". If the product is recovered, the after-market stage may be referred to as "gate to cradle".
An Environmental Product Declaration (EPD) is a third party verification (certification) report issued by a Product manufacturer that provides information about the Environmental performance of its Product. The EPD mainly reports the results of performing LCA on the product. In particular, the EPD of the product will report the GWP for each stage of the product's life cycle and the net GWP for the entire life cycle, which can be determined according to published standards and defined methods. LCA was performed according to ISO 14040-ISO 14049 (second edition, version 7/1/2006), the entire contents of which are incorporated herein by reference. These standards include, but are not limited to ISO 14044: environmental management-Life cycle assessment-Requirements and guidelines (first edition, version 7/1 2006), the entire contents of which are incorporated herein by reference. The relevant standards for EPD are ISO 14025: environmental labels and definitions-Type III definitions-Principles and procedures (Environmental tags and statements-class III Environmental statements-Principles and procedures) (first edition, 7.1.2006), the entire contents of which are incorporated herein by reference.
Although the ISO standard does not include the precise method of performing LCA and calculating GWP, there are several well-established characterization factors, including CML-IA used in europe, 8.2006, charateristic Factor for Global Warming Potential (characterizer of Global Warming Potential), and Tool for Reduction and Assessment of Chemicals and Other Environmental impact images, as set forth in USA EPA ("TRACI").
TRACI provides a standard method of characterizing and calculating the contribution of the GWP of a product. Although different approaches are recognized to generally give the same or very similar results, for the purposes of this application any GWP reported herein is calculated (or estimated) using the methods, TRACI 2.1 global warming potential (including biogenic) and Land Utilization Change (LUC). Negative GWP values represent negative carbon footprints.
Embodiments of the present invention relate to improving the carbon footprint of a product from "cradle to gate" (i.e., reducing the carbon footprint based on product production). Thus, for the purposes of this application, unless specifically stated otherwise, all references to carbon footprint or GWP refer to the global warming potential from cradle to gate, where "from cradle to gate" is as defined in the standard NEN-EN 15804:2012Sustainability of construction works-Environmental Product details-Core rules for the Product availability of construction products (NEN-EN 15804:2012 for Sustainability-Environmental Product declaration of construction works-Core rules of Product classes of construction products). Furthermore, all references to carbon neutrality or carbon negativity mean that the GWP at the cradle to gate stage is zero (carbon neutrality) or negative (carbon negativity), respectively.
LCA from cradle to gate considers all GHG inputs and outputs for all aspects of product production, including raw material extraction, raw material to chemical conversion, material to plant transportation, energy involved in manufacturing the product, packaging, and waste generation and disposal. Thus, the type of material used in the product, as well as the amount and weight of such material, can contribute to the carbon footprint of the product.
As an example, for carpet tiles, yarn type, yarn size, fiber/yarn density, tufting substrate material (tufting primary material), tufting substrate weight (tufting primary weight), and pre-coat material formulation and amount all contribute to the carbon footprint of the tile. In addition, the backing composite and each of its components also contribute to the carbon footprint of the carpet tile. Backing compounds (backing compounds) commonly used to form backing composites on modular floor coverings such as carpet tiles are fossil fuel based, for example, they include asphalt made from fossil fuels, polyvinyl chloride (PVC) or polyolefins. Although fossil fuels are continually formed by natural processes, they are generally considered non-renewable resources because they take millions of years to form and the known available reserves are consumed at a much faster rate than the new reserves are manufactured. The use of fossil fuels also raises potential environmental concerns because their combustion can form the notorious greenhouse gas, carbon dioxide.
There is a need for floor coverings that require lower amounts of fossil fuels and/or result in lower levels of greenhouse gas emissions. Additionally or alternatively, there is a need for ground covers that utilize more bio-based materials and/or are more environmentally sustainable, i.e., have lower environmental impact and/or can be regenerated more quickly. Additionally or alternatively, there is a need for partially or fully bio-based floor coverings that can be economically produced.
Summary of The Invention
Disclosed herein are surface coverings, such as floor coverings, that include one or more layers, such as an upper wear layer and a backing layer. The backing layer may be a backing composite comprising a backing composite and one or more substrates. In some embodiments, at least one layer of the product is designed to be carbon negative, as measured by life cycle assessment. In some embodiments, the overall product is carbon negative as measured by life cycle assessment. In some embodiments, carbon negativity is achieved in part by including a filler comprising concentrated carbon in the product.
Brief description of the drawings
A further understanding of the nature and advantages of various embodiments may be realized by reference to the following drawings. In the drawings, similar elements or features may have the same reference numerals.
Fig. 1 is a cross-section of an embodiment of a prior art carpet tile structure that may be suitable for use in embodiments of the present invention.
Fig. 2 is a cross-section of an alternative embodiment of a prior art carpet tile structure that may be suitable for use in embodiments of the present invention.
Detailed Description
Embodiments of the present invention relate to multi-layer surface coverings for installation on interior surfaces, including floor coverings, such as, but not limited to, modular panels or modular tiles. More particularly, embodiments of the present invention relate to the formulation of various components of a floor covering and the modification of various components of a floor covering that, individually or collectively, result in a product having a reduced, zero, and/or negative carbon footprint when subjected to life cycle assessment.
In some examples, the surface coverings described herein have a carbon footprint that is reduced by using natural, bio-based, or recycled materials instead of conventional man-made materials. As used herein, "biobased" refers to naturally occurring organic materials or materials intentionally made from substances derived from currently existing organisms and/or organisms living in a Common Era (Common Era, CE), as opposed to non-renewable fossil fuels made from prehistoric organisms.
Embodiments described herein overcome known compatibility issues when combining man-made materials with natural, bio-based, and/or recycled materials. Such blends often result in heterogeneous formulations with inconsistent properties and products that fail to meet the desired performance specifications. However, in the embodiments described herein, the surface covering includes one or more components formed in whole or in part from a substantially homogeneous mixture of man-made materials and natural, bio-based and/or recycled materials, such as a pre-coat or backing composite. In other examples, the one or more other components of the surface covering include natural, bio-based, or recycled materials. In still other examples, precision manufacturing allows for an overall reduction in materials, which reduces the carbon footprint of the product without degrading performance.
Embodiments described herein provide a carbon neutral or carbon negative surface covering. It should be noted that not every layer or component in the product needs to be carbon neutral or carbon negative. Rather, the product is constructed such that the entire product can have a net neutral carbon footprint and even better a net negative carbon footprint. To achieve this, the layers can be constructed to be carbon negative and to compensate for other layers in the product that are carbon positive. For example, the backing layer may be carbon negative to offset a half cloth with a positive carbon footprint. Alternatively, the carpet tile halves may be carbon negative to offset backing layers with a positive carbon footprint. Each layer of the product can still be carbon neutral or carbon negative in isolation.
Embodiments described herein include coating composites (e.g., pre-coating composites and backing composites) comprising high purity biochar, referred to herein as concentrated carbon.
As used herein, "biochar" refers to a solid material produced by pyrolyzing (i.e., directly thermally decomposing) biomass in the absence of oxygen. Pyrolysis of biomass produces a mixture of solids (biochar), liquids (bio-oil) and gases (biogas). Biomass includes any organic material from plants or animals, such as wood and wood processing waste, crop and waste, yard waste, and animal waste. Biochar can be produced at the following pyrolysis temperatures: at least 350 ℃, optionally at least 400 ℃, at least 600 ℃, at least 800 ℃, 350 ℃ to 1000 ℃, inclusive; 400 ℃ to 1000 ℃, inclusive; 600 ℃ to 1000 ℃, inclusive; 800 ℃ to 1000 ℃, inclusive.
As used herein, "concentrated carbon" refers to biochar as defined herein, having a carbon content of at least 80% by weight. As used herein, "carbon content" refers to the mass percentage of biochar as atomic carbon.
In some examples, carbon concentrates are engineered materials that are intentionally manufactured under defined, controlled conditions that have proven to reliably produce substances with predefined specific characteristics in terms of composition and manufacturing process capability. In some examples, when wood waste and/or other rapidly renewable plant and shell materials are exposed to high heat under low oxygen conditions, concentrated carbon is formed in a process driven by renewable gas energy and syngas generated during heating. This process creates a carbon-rich light blendable material that can lock up carbon that would otherwise escape into the atmosphere.
The concentrated carbon described herein may be formed by pyrolysis of biomass in an oxygen limited environment at very high temperatures. The weight percent of carbon and impurity concentration in the concentrated carbon is affected by several factors, including the type of biomass, the carbon content of the biomass, and the pyrolysis conditions.
Useful biomass sources for producing the concentrated carbon described herein include any sustainable, rapidly renewable material with minimal heavy metal content. In some examples, useful sources of biomass include grasses, algae, other microbial groups, leaves, bark material, legumes, fruit hulls, mangrove, wood waste, and nut shells. In other examples, useful biomass sources include agricultural and municipal waste. In some examples, the feedstock biomass for pyrolysis has a carbon content of at least 50%, at least 60%, or at least 70% (w/w). In some examples, the pyrolysis temperature is at least 350 ℃, at least 400 ℃, at least 600 ℃, at least 800 ℃; 350 ℃ to 1000 ℃ (inclusive); 400 ℃ to 1000 ℃ (inclusive); 600 ℃ to 1000 ℃ (inclusive); or 800 ℃ to 1000 ℃ (inclusive). Generally, higher pyrolysis temperatures will reduce the amount of volatile impurities in the final product, thereby providing a purer concentrated carbon. Optionally, the pyrolysis process may be fueled by combustion of syngas or supplemental renewable energy produced in the process. In some examples, pyrolysis modifies the chemical bonds of the biomass and creates graphene complexes present in the concentrated carbon.
The concentrated carbon described herein has a H/C of less than 0.7, optionally less than 0.65, less than 0.60, less than 0.55, less than 0.50, or less than 0.45orgThe molar ratio. The carbon concentrates described herein have an O/C of less than 0.4, less than 0.35, less than 0.3, less than 0.35, or less than 0.2orgThe molar ratio. 40%, at least 50%, at least 60% or at least 70%. Optionally, the concentrated carbon described herein has a carbon number of about 6.5 to about 10.5 (inclusive); about 7 to about 10.5 (inclusive); about 8 to about 10 (inclusive); a pH of about 9 to about 10, inclusive.
The surface covering described herein may be a floor covering typically (but not always) comprising an upper wear layer and a backing layer, wherein the backing layer may be a backing composite comprising a backing composite and at least one substrate.
Upper wear resistant layer
The upper wear layer of the floor covering may comprise any conventional or special material used for floor coverings. The material used for the upper wear layer may be selected such that the resulting floor covering exhibits desirable properties such as, but not limited to, decorative appearance, favorable acoustic properties, good insulation (e.g., good R-value), water resistance, flame retardancy, and the like. In some examples, the floor coverings described herein are sheets or tiles, including but not limited to high performance broadloom or carpet tile, luxury vinyl sheets or tiles, or rubber sheets or tiles. While embodiments of the present invention have been described with particular reference to carpet tiles (such as, but not limited to, those having the construction shown in fig. 1 and 2), it should be understood that one skilled in the art may implement or adjust the disclosure set forth herein in other types of surface coverings and applications where appropriate and applicable.
Some embodiments of the present invention include selecting or varying the type of material and/or amount of material used for the upper wear layer (e.g., half-cloths in carpet tile) to reduce the carbon footprint of the upper wear layer and the carbon footprint of the entire tile. For example, in carpet tiles, yarn size, yarn tuft height, and stitch density (e.g., number of yarn tufts per square inch) all affect the face weight (face weight) of the yarn, which affects the carbon footprint of the half-shell. "pile weight" refers to the weight of the yarns used in the half-cloth. Each of the yarn size, tuft height, and linear step density can be manipulated to adjust the carbon footprint of the half-cloth.
More specifically, it has been found that smaller size yarns can be used without sacrificing the aesthetics of the tufted product. More specifically, smaller size yarns may be tufted to a lower tuft height, but with a higher tuft density or stitch density (i.e., more tufts per square inch). This results in less yarn being used overall, and thus a lower pile weight of the yarn without sacrificing aesthetics. Furthermore, the use of smaller yarns allows more tufts to be placed in one area, thereby enabling the creation of more complex and precise tufting patterns. Despite the shorter height of the tufts, the higher tuft density prevents the primary tufting fabric from being seen (a problem known as pilling).
Size of yarn: some embodiments of the present invention use yarns having a denier of less than 2000, such as, but not limited to, 800-; 900- > 1600 (inclusive); 1000-; 1000-; 1000-; and/or a denier of 1200- & ltSUP & gt 1800- & ltSUP & gt, inclusive. In some embodiments, the yarn has a denier of 1200. The yarns may be single or multi-ply. By way of example only, a 1200 denier yarn target (end) may be formed by a single ply of 1200 denier yarn, by 2 plies of 600 denier yarn, by 3 plies of 400 denier yarn, and the like.
Tufting height: some embodiments of the semi-fabrics disclosed herein comprise yarn tufts having the following tuft heights: 1/32 inches to 6/32 inches (0.794mm to 4.76mm), inclusive; 2/32 inches to 5/32 inches (1.59mm to 3.97mm), inclusive; 2/32 inches to 4/32 inches (1.59mm to 3.175mm), inclusive; and/or from 2/32 inches to 3/32 inches (1.59mm to 2.38mm), inclusive. Any tufting machine may be used to tuft the blanket, but machines of size No. 10 and 12 (such as those available from Tuftco Corporation and Card Monroe Corporation, of saturnougara, tennessee) may be particularly suitable.
Tufting density: some embodiments of the semi-fabrics disclosed herein comprise yarn tufts having the following tuft densities: 100-; 110-400TPI, including endpoints; 140 — 300TPI, inclusive; 160-280TPI, inclusive; 170-; 170-260TPI, inclusive; 180 TPI, 250TPI, inclusive; and/or 180 TPI, 240TPI, inclusive.
Weight of pile face: the face weight of the yarns in the half-cloths of conventional carpet tiles is at least 20 ounces per square yard ("osy"). In some embodiments of the semi-fabrics described herein, the pile weight of the yarns is significantly lower, for example in the range: 5-20osy, inclusive; 6-18osy, inclusive; 8-17osy, inclusive; 10-15osy, inclusive; 6-12osy, inclusive; 12-18osy, inclusive; and/or 9-12osy, inclusive. In some embodiments, the pile weight of the yarn is about 5osy, 6osy, 7osy, 8osy, 9osy, 10osy, 11osy, 12osy, 13osy, 14osy, 15osy, 16osy, 17osy, 18osy, 19osy, or 20 osy.
Yarn material: the material from which the yarn is made may be selected to help reduce the carbon footprint. For example, yarns made from natural, bio-based, or recycled materials contribute less to the GWP of the fabric than yarns made from non-renewable fossil fuel-based resources. The yarns may be made of any type of fibrous material, including but not limited to nylon (nylon 6 or nylon 6,6), polyester, polypropylenePET (polyethylene terephthalate), PTT (polytrimethylene terephthalate), PBT (polybutylene terephthalate), PLA (polylactic acid), hemp, wool, cellulose plastic and other fibers. In some examples, the yarn is a post-consumer ("PC") or post-industrial ("PI") recycled material, such as PC or PI recycled nylon or PC or PI polyethylene terephthalate. Other suitable yarn materials are disclosed in WO2011/066620, the entire content of which is incorporated herein by reference.
Tufting primary backing: the tufted primary backing may be any woven or nonwoven material including, but not limited to, polypropylene, polyester, recycled polyester, polylactic acid, nylon, and jute. Conventional tufting primary cloths typically weigh 3-4 osy.
All of the above factors can be selected and manipulated to reduce the carbon footprint of the shell fabric, even to make the carbon footprint of the shell fabric neutral or negative. Table 1 compares the structure of conventional and inventive embodiments of the cloths considered herein and the respective associated material-based carbon footprints.
Table 1: structure of cloth
Based solely on the material in the scrim; it is not a cradle to gate life cycle assessment for the cloth (i.e., the estimate does not include the transportation of the material to the plant, the energy involved in manufacturing the product, packaging, and waste generation and disposal).
In addition, a reduction in the half-cloth carbon footprint is achieved without sacrificing performance. More specifically, it has been surprisingly found that according to ASTM D7330-2015: standard Test Method for evaluating the Change in Surface Appearance of a Pile Floor covering Using Standard Reference dimensions (2015 edition), and when subjected to the Test Method set forth in ASTM D5252-2015: Standard Practice for the Operation of the Hexabed Tumber Dry Tester (ASTM D5252-2015: Standard Practice protocol for six-foot Drum Tester Operation) (2015 edition), carpet tiles comprising embodiments of the semi-cloths disclosed herein are capable of achieving a severe wear rating (i.e., a rating equal to or greater than 3.5), ASTM D7330-2015 and ASTM D5252-2015 are incorporated herein by Reference in their entirety.
To test for wear according to ASTM D5252, a finished carpet tile is cut into a size suitable for fitting inside and around a drum mounted on a rotating device. A pod is placed within the drum, with a specified weight of six feet placed on the pod. Here, the pod is a mechanical foot simulator (mechanical foot simulator). The drum is rotated by a designated number of revolutions by a rotating means, and then the carpet tiles are laid, and the overall appearance of the carpet tiles is inspected and rated. ASTM D7330 sets forth a rating standard indicating the degree of "hold up" of a carpet during testing, and inspectors should consider pile compression resistance (pile crush), pilling, broken ends, etc. factors when rating a carpet. More specifically, ASTM D7330 includes Texture Appearance Retention Rating (TARR) for Rating tile Appearance change. A TARR rating of 5 indicates no change in the appearance of the cloth after the test, while a TARR rating of 1 indicates a very severe change in the appearance of the cloth after the test. Some embodiments of carpet tiles having a half-clothe disclosed herein achieve a TARR rating of greater than or equal to 2.5, greater than or equal to 3.0, and/or greater than or equal to 3.5 according to ASTM D7330 when tested according to ASTM D7330. A TARR rating of greater than or equal to 3.5 indicates that the panel is suitable for use in the most severe traffic conditions.
When a carpet tile comprising an embodiment of the semi-cloths disclosed herein receives the Vetterman Dry test method set forth in BS ISO10361: 2015-Textile Floor covering-Production of Changes in Floor area by means of the Vetterman dry and hexagonal tubular tester, the entire contents of which are incorporated herein by reference, and rates its performance according to BS EN ISO 9405: 2017-Textile Floor covering-evaluation of Changes in Appearance by means of the Vetterman roller and six-footed roller tester, the entire contents of which are incorporated herein by reference, it satisfies BS EN1307: 2014-Textile coatings-Classification (BS ISO 9405: 2017-Textile Floor covering-evaluation of Changes in Appearance, the entire contents of which are incorporated herein by reference), and satisfies the BS EN1307: 2014-Textile coatings-Classification (BS 13033: Classification by means of the types of products) using the following Clavic coverage Class 33, the Classification of products by reference) .
Precoat layer: in carpet tiles, a pre-coat layer is used to secure the yarns to the tufted backing layer. Typically, the precoat layer is applied as a water-based emulsion of the precoat binder, which is optionally modified with fillers and various additives. In some examples, the carbon footprint of the precoat layer is controlled and reduced by the selection of materials for use as precoat binders, fillers, and/or various additives.
Suitable pre-coat adhesives include, but are not limited to, any thermoplastic polymer, including hot melt adhesives, latexes, Ethylene Vinyl Acetate (EVA), acrylics, asphalt compounds, rubber compounds, or any combination of these materials. In some examples, the pre-applied adhesive comprises a thermoplastic derived from natural or recycled materials including, but not limited to, starch or recycled polyvinyl butyral.
The precoat composition contemplated for use in the floor coverings described herein includes a weight percent of precoat binder from about 15% to about 100% ("w/w"), inclusive; about 20% to about 100% (w/w), inclusive; about 30% to about 100% (w/w), inclusive; about 40% to about 100% (w/w), inclusive; about 50% to about 100% (w/w), inclusive; about 15% to about 90% (w/w), inclusive; about 20% to about 90% (w/w), inclusive; about 30% to about 90% (w/w), inclusive; about 40% to about 90% (w/w), inclusive; about 50% to about 90% (w/w), inclusive; about 90% to about 100% (w/w), inclusive; about 90% to about 98% (w/w), inclusive; about 15% to about 90% (w/w), inclusive; about 20% to about 90% (w/w), inclusive; about 30% to about 90% (w/w), inclusive; about 40% to about 90% (w/w), inclusive; from about 50% to about 90%, inclusive; about 15% to about 80% (w/w), inclusive; about 20% to about 80% (w/w), inclusive; about 30% to about 80% (w/w), inclusive; about 40% to about 80% (w/w), inclusive; about 50% to about 80% (w/w), inclusive; about 15% to about 70% (w/w), inclusive; about 20% to about 70% (w/w), inclusive; about 30% to about 70% (w/w), inclusive; about 40% to about 70% (w/w), inclusive; about 50% to about 70% (w/w), inclusive; about 15% to about 60% (w/w), inclusive; about 20% to about 60% (w/w), inclusive; about 30% to about 60% (w/w), inclusive; about 40% to about 60% (w/w), inclusive; about 50% to about 60% (w/w), inclusive; about 15% to about 50% (w/w), inclusive; about 20% to about 50% (w/w), inclusive; about 30% to about 50% (w/w), inclusive; or about 40% to about 50% (w/w), inclusive.
Fillers are often incorporated into pre-coat adhesives to increase hardness and weight, modify flow characteristics, improve tuft adhesion, impart desired properties such as flame retardancy, and economic benefits. Suitable fillers for the pre-coat include any known organic or inorganic (e.g., mineral) filler material. In some examples, the precoat filler includes natural, bio-based, or recycled filler materials that may help reduce the carbon footprint of the precoat and the final floor covering. Additionally or alternatively, the pre-coat filler may include conventional filler materials. Useful precoat fillers include fly ash; calcium oxide; calcium carbonate (e.g., limestone); a silicate salt; silicon dioxide; an oxide of silicon dioxide; a carbonate salt; a sulfate salt; an oxide of antimony; aluminum trihydrate; carbon black; talc; clay; kaolin; wood (e.g., wood chips and flour); marine shells (e.g., shell powder); plant material (e.g., plant fibers, plant hulls, and plant residues); re-mined, post-industrialized, or recycled organic or inorganic materials (e.g., calcium carbonate, talc, clay, minerals, rubber, plastics, or fibers) and biochar. In some embodiments, the filler comprises high purity biochar, referred to herein as concentrated carbon.
The pre-coating composition intended for use in the floor coverings described herein includes the filler in a weight percent of from about 0% to about 85% (w/w), inclusive; about 0% to about 80% (w/w), inclusive; about 0% to about 70% (w/w), inclusive; about 0% to about 60% (w/w), inclusive; about 0% to about 50% (w/w), inclusive; about 10% to about 85% (w/w), inclusive; about 10% to about 80% (w/w), inclusive; about 10% to about 70% (w/w), inclusive; about 10% to about 60% (w/w), inclusive; about 10% to about 50% (w/w), inclusive; about 0% to about 10% (w/w), inclusive; about 2% to about 10% (w/w), inclusive; about 20% to about 85% (w/w), inclusive; about 20% to about 80% (w/w), inclusive; about 20% to about 70% (w/w), inclusive; about 20% to about 60% (w/w), inclusive; about 20% to about 50% (w/w), inclusive; about 30% to about 85% (w/w), inclusive; about 30% to about 80% (w/w), inclusive; about 30% to about 70% (w/w), inclusive; about 30% to about 60% (w/w), inclusive; about 30% to about 50% (w/w), inclusive; about 40% to about 85% (w/w), inclusive; about 40% to about 80% (w/w), inclusive; about 40% to about 70% (w/w), inclusive; about 40% to about 60% (w/w), inclusive; about 40% to about 50% (w/w), inclusive; about 50% to about 85% (w/w), inclusive; about 50% to about 80% (w/w), inclusive; about 50% to about 70% (w/w), inclusive; or about 50% to about 60% (w/w), inclusive. In some embodiments, the precoat composition does not include a filler.
The precoat formulation may also include various processing aids and additives such as, but not limited to, antistatic agents, antimicrobial agents, anti-dust mite agents, and flame retardants. Suitable bio-based additives include, but are not limited to, lecithin and permethrin.
Conventional precoats rely on a large amount of precoat material to encapsulate and secure the yarns. Embodiments described herein use reduced mass precoat material to reduce the carbon footprint of the precoat and the contribution of the precoat resulting therefrom to the carbon footprint of the floor covering. In some examples, the quality of the precoat layer is reduced by reducing the amount of filler added to the precoat binder. In some examples, the pre-coat adhesive is free of any filler. Reducing or eliminating filler also results in higher binder concentrations, resulting in less binder being required in the application. In some examples, the precise application of the pre-coat to the tufted primary backing allows for further reduction in pre-coat quality while maintaining performance. For example, conventional precoats have a weight of about 18osy to about 32osy, but in some examples described herein, the amount of precoat used is reduced to about 5osy to about 20osy, inclusive; about 7osy to about 18osy, inclusive; about 7osy to about 12osy, inclusive; or about 12osy to about 18osy, inclusive. In some embodiments, the amount of precoat used is reduced to less than 20osy, 18osy, 16osy, 14osy, 12osy, 10osy, and 8 osy.
Table 2 compares examples of conventional precoat compositions with examples of embodiments of the inventive precoat composition ("PC") contemplated herein.
TABLE 2 precoat composition
Conventional precoat compositions
PC I
PC II
Adhesive agent
19％
49.5％
21.6％
Filler material
80％
49.5％
76％
Additive agent
1.0％
1.0％
2.4％
A typical carpet tile half weighs about 50osy (20osy yarn, 4osy tufted primary backing and 26osy pre-coat). The implementation of some or all of the modifications proposed above can significantly reduce the weight of the half-cloths. In some embodiments, the half-cloths (yarn, tufted primary cloth, and pre-coat) weigh 14osy to 35osy, inclusive; 14osy to 30osy, inclusive; 14osy to 25osy, inclusive; 14osy to 23osy, inclusive; 14osy to 21osy, inclusive; 15osy to 19osy, inclusive; or 16osy to 18osy, inclusive.
Table 3 compares the structure of the conventional half-cloths and the embodiments of the half-cloths of the present invention contemplated herein
TABLE 3 semi-cloth structure
Evaluation is based only on the material in the half-cloth, not on the cradle-to-gate life cycle of the half-cloth (i.e. the estimate does not include the transportation of the material to the plant, the energy involved in manufacturing the product, packaging and waste generation and disposal).
As reflected in table 3, some embodiments of the present half-cloths exhibit at least a 65% weight reduction, at least a 50% weight reduction, at least a 40% weight reduction, at least a 30% weight reduction, at least a 25% weight reduction, or at least a 20% weight reduction relative to conventional half-cloth weight. In some embodiments, the present invention contemplates that, in contrast to the conventional half-cloths described above, the cloth is a cloth that is a semi-clothThe carbon footprint reduction of the semi-cloth embodiment of (a) is at least-1 KG CO2/m2At least-1.2 KG CO2/m2At least-1.4 KG CO2/m2At least-1.6 KG CO2/m2At least-1.8 KG CO2/m2At least-2.0 KG CO2/m2At least-2.2 KG CO2/m2At least-2.4 KG CO2/m2At least-2.6 KG CO2/m2At least-2.8 KG CO2/m2Or at least-3.0 KG CO2/m2。
Backing layer
In addition to the upper wear layer, the floor coverings described herein will typically include a backing layer beneath the upper wear layer. The backing layer is typically a backing composite comprising a backing composite and one or more optional substrates. Embodiments of the floor covering described herein have a backing composite that includes a binder and a filler. The filler comprises high purity biochar, referred to herein as condensed carbon. The inclusion of concentrated carbon as a filler in the backing composite dramatically reduces the carbon footprint of the floor covering by sequestering the carbon. The use of concentrated carbon may have a more dramatic effect on the carbon footprint for floor coverings with higher filler content. For example, in modular flooring (e.g., carpet tile), the backing composite must be rigid so that the tile can be used as a free-lay floor tile. Typically, modular floor backing composites have a high filler content to contribute to the desired dimensional stability.
In addition to being dimensionally stable, the backing composites and optional backing composites described herein are flexible. Flexibility facilitates installation of the floor covering described herein. The flexible backing composites or backing composites described herein are easily bent, but do not break. The force required to bend the flexible backing composite or backing composite described herein is small and, as an example, a human may apply sufficient force without the use of machinery, such as when installing a surface covering.
Filler material: backing for floor coverings as described hereinThe compound comprises a filler which, as defined above, comprises concentrated carbon, i.e. high purity biochar having a carbon content of at least 80% by weight. In some examples, the concentrated carbon has a carbon content of at least 85%, at least 90%, at least 95%, or at least 99%. Some biochar includes polycyclic aromatic hydrocarbons ("PAHs") (e.g., naphthalene) and heavy metals (e.g., mercury, cadmium, lead, chromium, and arsenic) as impurities. In some embodiments, the concentrated carbon described herein comprises less than 60 parts per million ("ppm") PAH and/or less than 25ppm heavy metals. For example, any of the carbon concentrates described herein may include PAH at a concentration of less than 60ppm, less than 50ppm, less than 40ppm, or less than 30 ppm. In some examples, the carbon concentrate includes less than 7ppm, less than 5ppm, or less than 3ppm of any individual PAH. As a further example, any of the concentrated carbons described herein can include heavy metals at a concentration of less than 25ppm, less than 20ppm, less than 15ppm, less than 10ppm, or less than 5 ppm. In some examples, the concentrated carbon includes less than 3ppm, less than 2ppm, or less than 1ppm mercury or cadmium. In some examples, the concentrated carbon includes less than 15ppm, less than 12ppm, or less than 10ppm lead, chromium, or arsenic.
Any of the concentrated carbons described herein are suitable for use in the backing composites described herein. Optionally, the concentrated carbon is produced by pyrolyzing a feedstock biomass having a carbon content of at least 50%, at least 60%, or at least 70% (w/w). Optionally, the concentrated carbon is produced by a pyrolysis process carried out at a temperature of at least 350 ℃, at least 400 ℃, at least 600 ℃, at least 800 ℃; 350 ℃ to 1000 ℃, inclusive; 400 ℃ to 1000 ℃, inclusive; 600 ℃ to 1000 ℃, inclusive; or 800 ℃ to 1000 ℃, inclusive.
The concentrated carbon in the backing composite may be in the form of particles having a particle size of about 0.01 μm to about 3mm, inclusive; about 0.01 μm to about 2.5mm, inclusive; about 0.01 μm to about 2mm, inclusive; about 0.01 μm to about 1mm, inclusive. In some embodiments, the mean particle size of the concentrated carbon particles may be from about 80 μm to about 120 μm, inclusive. The particles may be separated or sorted to produce a desired average size. When incorporated into a backing composite, the concentrated carbon feedstock may have a particle size greater than about 3 mm. Typically, the size of the concentrated carbon particles is reduced during the production of the backing composite.
The filler content in the backing composites described herein can be 100% carbon concentrate, but typically includes from about 0.1% to about 100% (w/w), inclusive, of carbon concentrate. In some examples, the filler content comprises at least 2% (w/w), at least 10% (w/w), at least 15% (w/w), at least 20% (w/w), at least 25% (w/w), at least 30% (w/w), at least 35% (w/w), at least 40% (w/w), at least 45% (w/w), at least 50% (w/w), at least 55% (w/w), at least 60% (w/w), at least 65% (w/w), at least 70% (w/w), at least 75% (w/w), at least 80% (w/w), at least 95% (w/w), at least 90% (w/w), at least 95% (w/w) of the concentrated carbon. In some examples, the filler content includes concentrated carbon in any weight percent of: about 2% to about 98% (w/w), inclusive; about 10% to about 70% (w/w), inclusive; about 20% to about 55% (w/w), inclusive; or about 30% to about 50% (w/w), inclusive. If the carbon concentration of the filler content is less than 100%, the filler may also include one or more other filler materials.
The other filler material, when present, may be any known organic or inorganic (e.g. mineral) filler material. In some examples, the other filler material is a natural, bio-based, or recycled filler material that can independently contribute to reducing the carbon footprint of the backing composite and the floor covering. However, in other examples, the other filler material may be a conventional filler material. Useful inorganic fillers include fly ash; calcium oxide; calcium carbonate (e.g., limestone); a silicate salt; silicon dioxide; an oxide of silicon dioxide; a carbonate salt; a sulfate salt; an oxide of antimony; aluminum trihydrate; carbon black; talc; clay; kaolin; and its re-mined, post-industrial or recovered form. Optionally, the other filler is reclaimed limestone. Useful organic filler materials include wood (e.g., wood chips and flour); marine shells (e.g., shell powder); plant material (e.g., plant fibers, plant hulls, and plant residues); and its re-mined, post-industrial or recovered form. Optionally, the other filler is a recycled material (e.g., recycled rubber, recycled plastic, or recycled fiber).
Fillers (including condensed carbon and any other filler material) may have a particle size of about 0.01 μm to about 1mm, and the filler particles may be separated or classified to produce a desired average size. In some examples, fillers having these particle sizes may be combined with one or more other differently shaped fillers. Optionally, the inorganic filler may be combined with: bio-based fillers and/or recycled fillers such as wood chips, natural fibers, plant hulls, plant residues, synthetic fibers, glass fibers, recycled rubber, recycled plastics, recycled minerals, and other recycled materials. Any combination of other fillers that provide the desired properties can be combined with the concentrated carbons disclosed herein for incorporation into the backing composites disclosed herein.
The backing composite includes any desired amount of filler including concentrated carbon and any other filler material. In some examples, the backing composite described herein comprises a weight percentage of filler from about 30% to about 95% (w/w), inclusive; about 40% to about 95% (w/w), inclusive; about 50% to about 95% (w/w), inclusive; about 60% to about 94% (w/w), inclusive; about 70% to about 92% (w/w), inclusive; about 75% to about 90% (w/w), inclusive; about 75% to about 88% (w/w), inclusive; or about 77% to about 86% (w/w), inclusive; about 40% to about 70% (w/w), inclusive; about 45% to about 70% (w/w), inclusive; about 45% to about 65% (w/w), inclusive; and about 50% to about 65%, inclusive.
In some examples, the backing composite described herein comprises a weight percentage of concentrated carbon of about 0.1% to about 70% (w/w), inclusive; about 0.5% to about 65% (w/w), inclusive; about 1% to about 65% (w/w), inclusive; about 1% to about 60% (w/w), inclusive; about 10% to about 60% (w/w), inclusive; about 10% to about 55% (w/w), inclusive; about 10% to about 50% (w/w), inclusive; about 15% to about 60% (w/w), inclusive; about 20% to about 60% (w/w), inclusive; about 20% to about 50% (w/w), inclusive; about 25% to about 55% (w/w), inclusive; about 30% to about 50% (w/w), inclusive; about 1% to about 15% (w/w), inclusive; about 1% to about 10% (w/w), inclusive; about 1% to about 5% (w/w), inclusive; about 5% to about 15% (w/w), inclusive; about 5% to about 10% (w/w), inclusive; about 10% to about 15% (w/w), inclusive; about 15% to about 50% (w/w), inclusive; about 15% to about 40% (w/w), inclusive; about 20% to about 40% (w/w), inclusive; about 25% to about 35% (w/w), inclusive; or about 30% to 40% (w/w), inclusive.
Adhesive agent: in addition to fillers, the backing composites described herein also include binders that provide structure to the backing system. The binder includes at least one of a bio-based ester, bio-based oil, or polymer, and may optionally include additives that facilitate the creation of the backing composite or impart desired properties to the finished backing composite. In some embodiments, the binder includes one or more biobased esters, one or more biobased oils, and one or more polymers, but in other embodiments, the binder does not include all three components.
The binder may be present in the backing composites described herein in the following weight percentages: about 5% to about 70% (w/w), inclusive; about 5% to about 60% (w/w), inclusive; about 5% to about 50% (w/w), inclusive; about 6% to about 40% (w/w), inclusive; about 8% to about 30% (w/w), inclusive; about 10% to about 25% (w/w), inclusive; about 12% to about 25% (w/w), inclusive; or about 14% to about 23% (w/w), inclusive. In some examples, the adhesive portion of the backing composite comprises at least about 40% (w/w) bio-based material and/or recycled material. For example, the binder content may include at least about 50%, at least about 60%, at least about 70%, at least about 80%, at least about 85%, at least about 90%, or at least about 95% (w/w) of the bio-based material and/or recycled material, or the binder content may be 100% of the bio-based material or recycled material.
The biobased esters used in the backing composites are typically in solid form at room temperature. Their melting point can be about 65 ℃ to about 160 ℃ (e.g., about 80 ℃ to 120 ℃) to allow them to be handled at room temperature while allowing the mixing and application process to be performed at reasonable handling temperatures.
The biobased ester used in the backing composites described herein may be rosin or rosin derivatives. Rosin is a natural resin extracted from pine trees and other plants (e.g., conifers). Rosin is translucent and changes color from yellow to black. Rosin is mainly composed of various resin acids. The rosin used in the backing composite may be unmodified or modified (i.e., rosin derivatives). Modified rosins useful in the backing composites described herein include esterified rosins, hydrogenated rosins, dimerized rosins, phenolic rosins, terpene rosins, and the like. For example, a suitable esterified rosin can be the reaction product of rosin with monofunctional, difunctional, trifunctional, tetrafunctional, or multifunctional alcohols (including methanol, dipropylene glycol, glycerol, pentaerythritol, and combinations thereof), or combinations thereof. The rosin or rosin derivative used in the present invention may be or may be derived from any commercially available type of rosin in a crude or refined state, such as wood rosin, gum rosin, tall oil rosin and mixtures thereof.
The biobased ester may be present in the backing composite described herein in the following weight percentages: from about 0% to about 50% (w/w), inclusive (e.g., from about 5% to about 50%, inclusive; from about 5% to about 40%, inclusive; from about 7% to about 35%, inclusive; from about 8% to about 32%, inclusive; from about 9% to about 30%, inclusive; from about 10% to about 40%, inclusive; from about 11% to about 25%, inclusive; from about 12% to about 20%, inclusive; from about 15% to about 40%, inclusive; from about 20% to about 40%, inclusive; or from about 20% to about 40%, inclusive).
The oil in the backing composite may act as a plasticizer to soften and make the backing composite more pliable. By including oil in the binder, the filler loading of the backing composite can be increased, allowing more concentrated carbon to be included in the backing composite. The inclusion of oil in the binder may also reduce or eliminate the need for polymers. This combination of increasing the amount of filler and decreasing the amount of polymer in the binder is very beneficial because most fillers have a relatively low environmental impact, while polymers have a relatively high environmental impact. Thus, increasing the amount of filler and decreasing the amount of polymer both reduce the environmental impact of the adhesive.
The oils used in the backing composites may be natural or synthetic. In some examples, the oil is a natural oil, such as a vegetable oil. In some examples, the oil is a vegetable oil, soybean oil, rapeseed oil, refined rapeseed oil, sunflower oil, refined sunflower oil, high oleic sunflower oil, palm oil, castor oil, and/or coconut oil. Optionally, the oil is refined or modified, such as a hydrogenated or partially hydrogenated vegetable oil. In other examples, the oil is epoxidized soybean oil ("ESO") or a reacted ESO. In some examples, the natural oil need not be limited to vegetable oils, and may be a non-mineral oil (non-fossil oil), such as an oil of plant, animal, or algal origin. In some embodiments, the oil may be a synthetic oil, such as an oil that has been synthesized to provide desired characteristics.
The backing composites described herein can include an oil in a weight percent of about 0% to about 20% (w/w), inclusive (e.g., about 1% to 15%, inclusive, about 2% to 10%, inclusive, about 1% to 5%, inclusive, about 5% to 15%, inclusive, about 5% to 10%, inclusive, about 0.1% to about 20%, inclusive, about 0.1% to about 15%, inclusive, about 0.25% to about 11%, inclusive, about 0.5% to about 10%, inclusive, about 0.8% to about 8%, inclusive, about 1% to about 6%, inclusive, about 1.4% to about 5%, inclusive, or about 1.8% to about 4%, inclusive).
The binder may also include a polymer (e.g., thermoset, thermoplastic, or elastomer). Suitable polymers may be any polymer or copolymer known for use in backing composites for floor coverings, including block copolymers. As non-limiting examples, polymers useful in the backing composites described herein include polyolefins; polyesters, such as polyhydroxyalkanoates; vinyl polymers such as polyvinyl chloride (PVC); a polyurethane; and an epoxy resin. Optionally, the polymer may be a copolymer, such as poly (ethylene-propylene), ethylene-vinyl acetate (EVA), styrene-butadiene rubber (SBR), or poly (styrene-butadiene-styrene) (SBS). Useful EVA copolymers include those having a weight percentage of vinyl acetate from about 1% to about 50%, for example from about 10% to about 40%, with the balance being ethylene. Useful SBS polymers have a styrene content of 10% to 70% (w/w).
Some of the polymers that can be used in the backing composite are known as asphalt modifiers. These polymers, including EVA, SBS and SBR, are typically incorporated into the backing composite by mixing at elevated temperatures (typically above 170 ℃) and/or in a high shear mixer. Two common commercially available asphalt modifiers are Kraton DSBSTM(SBS block copolymer available from Kraton) and Polybilt 106TM(EVA Elastomers available from ExxonMobil). Some polymers are referred to as polyolefin polymer modifiers. Examples of commercially available polyolefin polymer modifiers include VistamaxxTMPellets (propylene-ethylene copolymer, available from Exxon Mobile), MirelTMGranules (polyhydroxyalkanoates, available from Metabolix).
In some examples, the backing composites described herein do not include a polymer. In other examples, the backing composite includes a polymer derived from recycled material. In some examples, the backing composites described herein do not include PVC. In other examples, the backing composite does not include virgin PVC, but includes recycled PVC or PVC derived from recycled materials such as recycled carpet tile. In some examples, the backing composites described herein include a combination of virgin polymer and recycled polymer, such as virgin PV and recycled PVC.
When a polymer is included in the backing composite, the weight percentage of the included polymer is preferably (but not necessarily) not more than 40% (w/w), not more than 35% (w/w), not more than 30% (w/w), not more than 25% (w/w), not more than 20% (w/w); not more than 15% (w/w), not more than 10% (w/w), and not more than 5% (w/w). In some embodiments, the weight percentage of the polymer included in the backing composite is between about 1% and 30% (w/w), inclusive; about 2% to 25% (w/w), inclusive; about 3% to 20% (w/w), inclusive; about 4% to 20% (w/w), inclusive; about 4% to 15% (w/w), inclusive; about 4% to 10% (w/w), inclusive; about 10% to 20% (w/w), inclusive; about 15% to 30% (w/w), inclusive; about 15% to 25% (w/w), inclusive; about 15% to 20% (w/w), inclusive; about 20% to 30% (w/w), inclusive; and about 22% to 28% (w/w), inclusive. The polymer may be present in the following weight percentages: from about 0% to about 30%, inclusive; from about 0.1% to about 25%, inclusive; from about 0.1% to about 20%, inclusive; from about 0.2% to about 10%, inclusive; from about 0.3% to about 8%, inclusive; from about 0.4% to about 6%, inclusive; from about 0.5% to about 4%, inclusive; about 0.75% to about 2.5%, inclusive.
The backing composite may also include additives that facilitate the production of the backing composite or impart desired properties to the finished backing composite. By way of non-limiting example, the backing composite may include an antioxidant, a hydrocarbon wax, a plasticizer, or a stabilizer. The additive may optionally be a natural, bio-based or recycled material that helps to reduce the carbon footprint of the floor covering. The additives may be present in the backing composite in a weight percent of 0% to about 5%, inclusive.
In some examples, the backing composite further includes a hydrocarbon wax. The wax may be present in a weight percentage of the backing composite of about 0% to about 15%. However, in other examples, the backing composite is substantially free of hydrocarbon wax. In some examples, the backing composite is free of pitch.
In embodiments, the backing composite comprises:
(1) about 2% to about 25% (w/w), such as about 5% to about 20% (w/w), more preferably about 7% to about 15% (w/w), even more preferably about 9% to about 13% (w/w), still more preferably about 10% to about 12% (w/w) of a first filler comprising concentrated carbon;
(2) about 35% to about 65% (w/w), such as about 40% to about 60% (w/w), about 45% to about 55% (w/w), about 50% to about 55% (w/w) of a second filler (i.e., non-condensed carbon);
(3) from about 2% to about 25% (w/w), such as from about 5% to about 20% (w/w), more preferably from about 7% to about 17% (w/w), even more preferably from about 10% to about 15% (w/w), still more preferably from about 12% to about 14% (w/w) of a bio-based ester;
(4) about 1% to about 10% (w/w), such as about 2% to about 7% (w/w), about 2% to about 5% (w/w), about 2% to about 4% (w/w), about 3% to about 4% (w/w) of an oil (preferably, but not necessarily, a biobased oil); and
(5) from about 2% to about 30% (w/w), such as from about 5% to about 25% (w/w), more preferably from about 10% to about 20% (w/w), even more preferably from about 15% to about 20% (w/w) of the polymer.
In embodiments, the backing composite comprises:
(1) about 20% to about 60% (w/w), such as about 25% to about 55% (w/w), more preferably about 30% to about 55% (w/w), even more preferably about 35% to about 50% (w/w), still more preferably about 40% to about 55% (w/w), still more preferably about 40% to about 50% (w/w) of a first filler comprising concentrated carbon;
(2) about 0% to about 10% (w/w), such as about 0% to about 5% (w/w), of a second filler (i.e., non-condensed carbon);
(3) about 5% to about 35% (w/w), such as about 10% to about 30% (w/w), more preferably about 15% to about 30% (w/w), even more preferably about 10% to about 25% (w/w), still more preferably about 15% to about 23% (w/w), even still more preferably about 18% to about 22% (w/w) of a bio-based ester;
(4) about 1% to about 10% (w/w), such as about 2% to about 7% (w/w), about 2% to about 5% (w/w), about 2% to about 4% (w/w), about 3% to about 4% (w/w) of an oil (preferably, but not necessarily, a biobased oil); and
(5) from about 5% to about 35% (w/w), such as from about 10% to about 30% (w/w), more preferably from about 15% to about 30% (w/w), even more preferably from about 20% to about 30% (w/w) of the polymer.
In embodiments, the backing composite comprises:
(1) about 15% to about 50% (w/w), such as about 20% to about 45% (w/w), more preferably about 25% to about 40% (w/w), even more preferably about 30% to about 40% (w/w), still more preferably about 32% to about 38% (w/w) of a first filler comprising concentrated carbon;
(2) a second filler (i.e., non-condensed carbon) in an amount of about 2% to about 30% (w/w), such as about 5% to about 25% (w/w), more preferably about 10% to about 20% (w/w), even more preferably about 15% to about 20% (w/w);
(3) from about 15% to about 50% (w/w), such as from about 20% to about 45% (w/w), more preferably from about 25% to about 40% (w/w), even more preferably from about 30% to about 40% (w/w), still more preferably from about 35% to about 40% (w/w) of a bio-based ester;
(4) about 1% to about 15% (w/w), such as about 2% to about 10% (w/w), such as about 3% to about 9% (w/w), about 4% to about 8% (w/w), about 5% to about 7% (w/w), about 6% to about 7% (w/w) of an oil (preferably but not necessarily bio-based oil); and
(5) about 1% to about 15% (w/w), such as about 2% to about 10% (w/w), about 3% to about 8% (w/w), about 4% to about 6% (w/w), about 4% to about 5% (w/w) of the polymer.
In embodiments, the backing composite comprises:
(1) about 0% to about 10% (w/w), such as about 0% to about 5% (w/w), such as about 1% to about 3% (w/w), such as about 1% to about 2%, of a first filler comprising concentrated carbon;
(2) about 35% to about 65% (w/w), such as about 40% to about 65% (w/w), about 45% to about 60% (w/w), about 50% to about 60% (w/w), about 55% to about 60% (w/w) of a second filler (i.e., non-condensed carbon);
(3) from about 2% to about 25% (w/w), such as from about 4% to about 20% (w/w), more preferably from about 5% to about 15% (w/w), even more preferably from about 7% to about 12% (w/w), still more preferably from about 9% to about 11% (w/w) of an oil (preferably, but not necessarily, a biobased oil); and
(4) a blend of recycled PVC and recycled carpet from about 10% to about 45% (w/w), such as from about 20% to about 35% (w/w), more preferably from about 25% to about 35% (w/w), even more preferably from about 27% to about 33% (w/w).
Backing composites ("BC") of the present invention having the compositions shown in table 4 were prepared as examples. Table 4 also compares the TRACI 2.1GWP estimates for the inventive backing composites with conventional backing composites:
table 4: backing composites
Based only on the materials in the backing composite, rather than evaluating the life cycle of the backing composite from cradle to gate (i.e., the estimate does not include the transportation of the materials to the plant, the energy involved in manufacturing the product, packaging and waste generation, and disposal).
Table 4 (continuation)
Based solely on the material in the backing composite; rather than evaluating the life cycle of the backing composite from cradle to door (i.e., the estimate does not include the transport of the material to the plant, the energy involved in manufacturing the product, packaging, and waste generation and disposal). The size of each backing is 2.00kg/m2。
The backing composite can be characterized in a variety of ways according to known industry standards. As an example, the softening point and consistency of the material may be determined. The softening point is a measure of the effect of temperature on the consistency of the material. The softening point can be determined using any method known in the art and can be determined, for example, by the method described in EN1427: 2007-Bitumen and bitterinous binders-Determination of the softening point-Ring and Ball methods (EN1427: 2007-asphalt and asphalt binders-Determination of softening point-Ring and Ball methods). In suitable embodiments, the backing composite has a ring and ball softening point, as determined according to EN1427:2007, in the range of 60-180 ℃, 70-160 ℃, 75-140 ℃, or 80-120 ℃.
The consistency of the backing material under conditions of a particular temperature, load and load duration can be determined using any method known in the art, for example, can be measured according to EN1426: 2007-Bitumen and Bitumen binders-Determination of needle penetration (EN 1426: 2007-asphalt and asphalt binder-penetration Determination). Consistency, also known as needle penetration (needle penetration), is expressed as the distance in tenths of a millimeter that a standard needle penetrates into a material. In suitable embodiments, the backing composite has a penetration at 25 ℃ of 0.2 to 200x 0.1mm, e.g., 0.5 to 100x 0.1mm, 0.8 to 75x 0.1mm, or 1 to 50x 0.1mm, as determined by EN1426: 2007.
As reflected in table 4, embodiments of the backing composites described herein include significantly less synthetic and fossil fuel-based materials than conventional backings. Further, the concentrated carbon present in at least some of the backing composites may sequester the carbon such that the backing composites, and optionally the resulting floor covering product have a negative carbon footprint when subjected to life cycle assessment and measured according to the TRACI 2.1 method. In some embodiments, embodiments of the backing composites contemplated herein have a carbon footprint reduction of at least 4kg CO compared to conventional backing composites2/m2At least 3.5kg CO2/m2Or at least 3.5kg CO2/m2。
Optionally, the backing layer may include one or more substrates adhered to or provided/embedded within the backing composite to form the backing composite. The substrate may be, for example, a glass mat (glass veil), a glass veil (glass scrim), a foam layer or a non-woven covering (e.g. wool). Optionally, the substrate may be located on the bottom side of the backing composite, for example as a protective layer (e.g., a fleece) to prevent the backing composite from adhering to or damaging the floor.
In some embodiments, the floor coverings described herein can sequester carbon such that the resulting product has a negative carbon footprint when subjected to life cycle assessment and measured according to the TRACI 2.1 method. Table 5 compares the GWP of several carpet tiles ("CT") that conform to the specific embodiments described herein with the GWP of conventional carpet tiles.
Table 5: square carpet
Not included in GWP, but the same for conventional carpet tiles and inventive carpet tiles
Based only on the material in the backing composite.
Including estimates of the contributions to the transportation of materials to the plant, the energy involved in manufacturing the products, packaging, and waste generation and disposal
The floor covering described above may be provided in any size or shape and may be used in a variety of different applications. In some embodiments, the floor covering is provided in the form of discrete tiles. For example, it may be provided in square tiles of 50cm x 50cm or 1m x 1 m. The tiles may be used in a variety of different indoor applications including, but not limited to, floor covering applications, wall covering applications, countertops, tailgates, and the like.
The floor coverings described herein may conform to the class specified in the European Classification EN1307-2014 Textile floor coverings-Classification (EN1307-2014 Textile floor covering-Classification). This european standard specifies the requirement to classify the use of all Textile floor coverings and carpet tiles (excluding tiles and carpet tiles) (see ISO 2424:2007-Textile floor covering-vocarbulariy (ISO 2424:2007-Textile floor covering-Vocabulary)) for one or more of the following characteristics: wear, appearance durability, other performance characteristics, and luxury rating categories.
The floor coverings described herein may be prepared by standard methods known in the art. As one example, the floor covering described herein may be prepared by: providing a textile top fabric (textile top fabric) having a top side comprising yarns or fibers and a bottom side comprising a precoat layer, providing a backing layer as described herein, and applying the backing layer to the precoat layer on the bottom side of the textile top fabric.
The floor covering described herein may be mounted on any interior surface. In some embodiments, the floor covering is installed by adhering to an underlying surface. Optionally, the floor covering may be mounted using a pressure sensitive adhesive that holds the floor covering in place during use, but allows removal of at least a portion of the floor covering, such as one or more tiles, without damaging the removed portion of the floor covering. In other embodiments, individual tiles of the floor covering are attached to each other but not to the underlying surface to form a floating installation. For example, adhesive-bearing connectors (adhesive bearing connectors) such as those disclosed in U.S. patent No. 7,464,510 may be used to hold the tiles together. Alternatively, a mechanical locking system may be formed along the edges of the building blocks (e.g. in the central portion) such that adjacent building blocks interlock with each other. One example of such a "click-lock" system is disclosed in U.S. patent application No. 2016/0208500, which is incorporated herein by reference in its entirety.
Examples of the invention
Example 1. a floor covering comprising an upper wear layer and a backing composite, wherein the backing composite comprises a binder and at least one filler, wherein the at least one filler comprises concentrated carbon.
Example 2. the floor covering of example 1, wherein the concentrated carbon has a carbon content of at least 85%.
Example 3. the floor covering of example 1 or example 2, wherein the concentrated carbon comprises less than 40ppm total Polycyclic Aromatic Hydrocarbons (PAHs) and less than 15ppm total weight metals.
Example 4. the floor covering according to any one of examples 1 to 3, wherein the concentrated carbon has a particle size of about 0.01 μ ι η to about 3 mm.
Example 5. the floor covering according to any one of examples 1-4, wherein the concentrated carbon is present in the backing composite at a weight percentage of about 1% to about 60% by weight.
Example 6. the floor covering of example 5, wherein the concentrated carbon is present in the backing composite at a weight percentage of about 10% to about 50% by weight.
Example 7. the floor covering of example 6, wherein the concentrated carbon is present in the backing composite at a weight percentage of about 20% to about 50% by weight.
Example 8. the floor covering of example 7, wherein the concentrated carbon is present in the backing composite at a weight percentage of about 30% to about 50% by weight.
Example 9. the floor covering of any of examples 1-8, wherein the at least one filler comprises a first filler comprising the carbon concentrate and a second filler comprising a silicate, silica, an oxide of silica, a carbonate, a sulfate, an oxide of antimony, aluminum trihydrate, calcium oxide, fly ash, carbon black, talc, clay, kaolin, wood chips, wood flour, shell flour, a plant material, or a recycled material.
Example 10 the floor covering of example 9, wherein the first filler and the second filler are present in the backing composite at a combined weight percent of about 40% to about 70% by weight.
Example 11. the floor covering of example 10, wherein the first filler and the second filler are present in the backing composite at a combined weight percent of about 50% to about 70% by weight.
Example 12. the floor covering according to any one of examples 1-11, wherein the binder comprises a bio-based ester.
Example 13. the floor covering of example 12, wherein the biobased ester comprises an esterified rosin, a hydrogenated rosin, a phenolic rosin, or a terpene rosin.
Example 14. the floor covering of example 12 or example 13, wherein the biobased ester is present in the backing composite at a weight percentage of about 5% to about 40% by weight.
Example 15. the floor covering of any one of examples 1-14, wherein the binder comprises an oil, and wherein the oil comprises an oil of plant, animal, or algal origin.
Example 16. the floor covering of example 15, wherein the oil comprises a plant-derived oil, and wherein the plant-derived oil comprises canola oil, sunflower oil, soybean oil, palm oil, castor oil, coconut oil, or refined forms thereof.
Example 17. the floor covering of example 15 or example 16, wherein the plant, animal, or algae-derived oil is present in the backing composite at a weight percentage of about 2% to about 15% by weight.
Example 18. the floor covering of any one of examples 1-17, wherein the binder comprises a polymer.
Example 19. the floor covering of example 18, wherein the polymer is present in the backing composite at a weight percentage of no greater than 30% by weight.
Example 20. the floor covering of example 18 or example 19, wherein the polymer comprises recycled polyvinyl chloride (PVC) or Ethylene Vinyl Acetate (EVA).
Example 21. the floor covering of any one of examples 1-20, wherein the binder is substantially free of unused PVC.
Example 22. the floor covering according to any one of examples 1 to 21, wherein the floor covering is a carpet tile and the upper wear layer comprises a half-cloth comprising yarns tufted into a tufting primary cloth and a pre-coat layer disposed on an underside of the tufting primary cloth.
Example 23. the floor covering of example 22, wherein the half cloth comprises a pile weight of no more than 18osy of yarns.
Example 24. the floor covering of example 23, wherein the half cloth comprises a pile weight of no more than 12osy of yarns.
Example 25 the floor covering of any one of examples 22 to 24, wherein the yarn comprises recycled nylon 6 or nylon 6, 6.
Example 26 the floor covering of any one of examples 22-25, wherein the yarn comprises a denier of 900-1800, inclusive.
Example 27. the floor covering of example 26, wherein the yarn comprises a denier of 1200-1800, inclusive.
Example 28. the floor covering of any one of examples 22-27, wherein the half-cloth comprises a tuft density of 140 and 300 tufts/inch (inclusive).
Example 29 the floor covering of any one of examples 22-28, wherein the yarn comprises a tuft height of 2/32 inches to 3/32 inches (inclusive).
Example 30. the floor covering of any one of examples 22-29, wherein the carpet tile achieves a rating of 3.5 or greater according to the rating scale set forth in ASTM D7330-2015 when the carpet tile is subjected to the test method set forth in ASTM D5252-2015.
Example 31. the floor covering of any one of examples 22 to 30, wherein the precoat layer includes a filler comprising concentrated carbon.
Example 32. the floor covering of any one of examples 22 to 31, wherein the pre-coat layer is free of filler.
Example 33. the floor covering of any one of examples 22 to 32, wherein the precoat layer comprises a weight of less than about 18 osy.
Example 34. the floor covering of any one of examples 22-33, wherein the half cloth comprises a weight of about 14osy to about 35 osy.
Example 35 the floor covering of any one of examples 1-34, wherein the floor covering comprises a backing composite comprising the backing composite and a substrate, and wherein the backing composite is flexible.
Example 36. the floor covering of any one of examples 1-35, wherein the backing composite comprises a negative material-based Global Warming Potential (GWP) calculated using the TRACI 2.1 method.
Example 37. the floor covering according to any one of examples 1 to 36, wherein the entire floor covering comprises a negative cradle to gate GWP calculated using the TRACI 2.1 method.
Example 38 a floor covering comprising an upper wear layer and a backing composite, wherein at least one of the upper wear layer or the backing composite comprises a negative material-based GWP, calculated using the TRACI 2.1 method.
Example 39. the floor covering of example 38, wherein the backing composite comprises a binder and at least one filler, and wherein the at least one filler comprises concentrated carbon present in the backing composite at a weight percentage of about 1% to about 60% by weight.
Example 40 the floor covering of example 39, wherein the at least one filler comprises a first filler comprising carbon concentrate and a second filler comprising silicates, silica, oxides of silica, carbonates, sulfates, oxides of antimony, aluminum trihydrate, calcium oxide, fly ash, carbon black, talc, clay, kaolin, wood flour, shell flour, plant materials, or recycled materials.
Example 41 the floor covering of example 40, wherein the first filler and the second filler are present in the backing composite at a combined weight percent of about 40% to about 70% by weight.
Example 42 the floor covering of any of examples 39-41, wherein the binder further comprises a biobased ester present in the backing composite at a weight percentage of about 5% to about 40% by weight.
Example 43 the floor covering of any one of examples 39-42, wherein the binder comprises bio-based oil present in the backing composite at a weight percentage of about 2% to about 15% by weight.
The floor covering of any of examples 39-43, wherein the binder comprises a polymer present in the backing composite at a weight percentage of no greater than 30% by weight.
Example 45. the floor covering of any one of examples 39-44, wherein the binder is substantially free of unused PVC.
Example 46. the floor covering according to any one of examples 38-45, wherein the floor covering is a carpet tile and the upper wear layer comprises a half-cloth comprising yarns tufted into a tufting primary cloth and a pre-coat layer disposed on an underside of the tufting primary cloth.
Example 47. the floor covering of example 46, wherein the half cloth comprises a pile weight of no more than 18osy of yarns.
Example 48. the floor covering of examples 46 or 47, wherein the yarn comprises recycled nylon 6 or nylon 6, 6.
Example 49 the floor covering of any one of examples 46-48, wherein the yarn comprises a denier of 1200 and 1800, inclusive.
Example 50. the floor covering according to any one of examples 46 to 49, wherein the precoat layer includes a filler comprising concentrated carbon.
Example 51. the floor covering according to any one of examples 46 to 50, wherein the pre-coat layer is free of filler.
Example 52. the floor covering of any one of examples 46-51, wherein the precoat layer comprises a weight of less than about 18 osy.
Example 53. the floor covering of any one of examples 46-52, wherein the half cloth comprises a weight of about 14osy to about 35 osy.
Example 54 a flexible backing composite comprising a binder and a filler, wherein the binder comprises a biobased ester, a biobased oil, and a polymer, and wherein the filler comprises condensed carbon.
Example 55. the flexible backing composite of example 54, wherein the polymer is ethylene vinyl acetate.
Example 56. the flexible backing composite of example 54 or example 55, wherein the adhesive does not comprise polyvinyl chloride.
Example 57 the flexible backing composite of any one of examples 54-56, wherein the biobased ester is present in the backing composite at a weight percent of about 10% to about 40% by weight, wherein the biobased oil is present in the backing composite at a weight percent of about 2% to about 10% by weight, wherein the polymer is present in the backing composite at a weight percent of not greater than 30% by weight, and wherein the concentrated carbon is present in the backing composite at a weight percent of about 10% to about 55% by weight.
Example 58. the flexible backing composite of any one of examples 54 to 57, wherein the filler further comprises calcium carbonate.
Example 59. the flexible backing composite of any one of examples 54 to 57, wherein the backing composite comprises a negative material-based Global Warming Potential (GWP) calculated using the TRACI 2.1 method.
It should be understood that although the description of the floor covering disclosed herein may refer to one or more "layers," once the floor covering is manufactured and ready for installation, the floor covering may be a cohesive, unified, unitary structure in which the individual layers or boundaries between the individual layers are not necessarily readily discernible and/or in which the individual layers are not separable from one another.
The subject matter of embodiments of the present invention is described with specificity herein to meet statutory requirements, but such description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be embodied in other ways, may include different elements or steps, and may be used in conjunction with other prior art or future technologies. The description should not be construed as implying any particular order or arrangement among or between various steps or elements unless and except when the order of individual steps or elements is explicitly described.
Examples of the present invention have been described for illustrative, but not limiting, purposes, and alternative examples will become apparent to the reader of this patent. Therefore, the present invention is not limited to the above examples, and various examples and modifications may be made without departing from the scope of the present invention.