Production of backing component for carpet products

• US 20070020430A1
• Filed: 06/14/2006
• Published: 01/25/2007
• Est. Priority Date: 06/14/2005
• Status: Abandoned Application

• Current Assignee: Interface Incorporated
• Original Assignee: Interface Incorporated
• Inventors: Lees, Donald
• Application Number:
  US11/452,507
• Publication Number:
  US 20070020430A1
• Time in Patent Office: Days
• US Class Current: 428/97
• CPC Class Codes: B32B 2327/06 PVC, i.e. polyvinylchloride
• CPC Class Codes: B32B 2471/02 Carpets
• CPC Class Codes: B32B 27/12 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/20 using fillers, pigments, thixotroping agents
• CPC Class Codes: B32B 27/30 comprising vinyl (co)polymers; comprising acrylic (co)polymers
• CPC Class Codes: B32B 27/304 comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
• CPC Class Codes: B32B 37/15 with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state
• CPC Class Codes: B32B 37/153 at least one layer is extruded and immediately laminated while in semi-molten state
• CPC Class Codes: B32B 5/22 characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed layer formed of natural mineral fibres or particles next to a foam layer B32B19/047, next to a layer made of particles B32B19/048, or next to a fibrous or filamentary layer B32B19/06; paper layer or cardboard layer next to a paper layer or cardboard layer B32B29/005, next to a foam layer B32B29/007, next to a fibrous or filamentary layer B32B29/02, or next to a particulate layer B32B29/04
• CPC Class Codes: B32B 7/12 using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: C08K 2003/265 Calcium, strontium or barium carbonate
• CPC Class Codes: C08K 3/22 of metals
• CPC Class Codes: C08K 3/26 Carbonates; Bicarbonates
• CPC Class Codes: C08K 5/12 of cyclic polycarboxylic acids
• CPC Class Codes: C08L 27/06 Homopolymers or copolymers of vinyl chloride
• CPC Class Codes: D06N 2203/048 Polyvinylchloride (co)polymers
• CPC Class Codes: D06N 2205/026 Plastisol
• CPC Class Codes: D06N 7/0076 the back coating or pre-coat being a thermoplastic material applied by, e.g. extrusion coating, powder coating or laminating a thermoplastic film
• CPC Class Codes: D06N 7/0081 with at least one extra fibrous layer at the backing, e.g. stabilizing fibrous layer, fibrous secondary backing
• CPC Class Codes: Y10T 428/23979 Particular backing structure or composition
• CPC Class Codes: Y10T 428/23993 : Composition of pile or adhesive

Abstract

Disclosed are plastic compositions for a carpet backing having from about 5 to about 25% by weight PVC resin, from about 5 to about 25% by weight plasticizer, and from about 50 to about 90% by weight filler. In a preferred embodiment, the plastic composition is about 15% by weight Geon-138, about 15% by weight di-isononyl phthalate, and about 70% by weight fly ash. Also disclosed are methods for forming backings for floorcoverings using the disclosed plastic compositions. In preferred embodiments, a plastic composition is applied through a slot-die directly to the underside of a carpet or alternatively onto a conveyor belt on top of which the carpet or floorcovering may be subsequently positioned.

Claims

1. A plastic composition for a carpet backing comprising from about 5 to about 25% by weight PVC resin, from about 5 to about 25% by weight plasticizer, and from about 50 to about 90% by weight filler.

2. The plastic composition according to claim 1, wherein the PVC resin is selected from the group consisting of Geon-138, Geon-121, Formolon-40, VC-216 and combinations thereof.

3. The plastic composition according to claim 1, wherein the plasticizer is selected from the group consisting of di-isononyl phthalate, di-isoheptyl phthalate, di-isoundecyl phthalate and combinations thereof.

4. The plastic composition according to claim 1, wherein the filler is selected from the group consisting of fly ash, dirt, calcium carbonate and combinations thereof.

5. The plastic composition according to claim 1, comprising about 15% by weight Geon-138, about 15% by weight di-isononyl phthalate, and about 70% by weight fly ash.

6. The plastic composition according to claim 1, wherein the plastic composition has a viscosity of from about 30,000 to about 50,000 centipoise.

7. A floorcovering backing comprising the plastic composition according to claim 1.

8. The floorcovering backing of claim 7, wherein the plastic composition has a thickness of from about 20 to about 75 mils.

9. The floorcovering backing of claim 8, wherein the plastic composition has a thickness of about 25 mils.

10. A method for forming a floorcovering comprising:

a. preparing a plastic composition by mixing from about 5 to about 25% by weight PVC resin, from about 5 to about 25% by weight plasticizer, and from about 50 to about 90% by weight filler; and

b. forming the plastic composition into a backing layer.

11. The method of claim 10, wherein forming the plastic composition into a backing layer comprises feeding the plastic composition through a slot-die.

12. The method of claim 11, wherein the plastic composition is prepared in a holding tank and pumped from the holding tank to the slot die with a gear pump or an extruder.

13. The method of claim 10, wherein:

a. the PVC resin is selected from the group consisting of Geon-138, Geon-121, Formolon-40, VC-216 and combinations thereof;

b. the plasticizer is selected from the group consisting of di-isononyl phthalate, di-isoheptyl phthalate, di-isoundecyl phthalate and combinations thereof; and

c. the filler is selected from the group consisting of fly ash, dirt, calcium carbonate and combinations thereof.

14. The method of claim 13, wherein the plastic composition comprises about 15% by weight Geon-138, about 15% by weight di-isononyl phthalate, and about 70% by weight fly ash.

15. The method of claim 11, wherein the backing layer exiting the slot-die is positioned directly onto a conveyor belt.

16. The method of claim 15, further comprising positioning a face of the floorcovering above the backing layer.

17. The method of claim 16, further comprising positioning a stabilizing layer between the backing layer and the face.

18. The method of claim 17, wherein the floorcovering comprises carpet.

19. The method of claim 11, wherein the backing layer exiting the slot-die is positioned on the underside of a face of the floorcovering.

20. The method of claim 19, wherein the floorcovering comprises carpet.