CA2410390C

CA2410390C - Surface coverings containing fused recycled material and processes of making the same

Info

Publication number: CA2410390C
Application number: CA002410390A
Authority: CA
Inventors: Hao A. Chen; Peter Desai; Nicholas Zerebecki
Original assignee: Mannington Mills Inc
Current assignee: Mannington Mills Inc
Priority date: 1998-02-04
Filing date: 1999-02-03
Publication date: 2008-01-15
Anticipated expiration: 2019-02-03
Also published as: CA2410390A1

Abstract

A backing or an intermediate layer for a surface covering is described which comprises a fused recycled material, wherein the material comprises a thermoplastic material, for instance, a vinyl material from a vinyl backed carpet or vinyl backed carpet manufacturing waste or both. Surface coverings containing the backing or intermediate layer of the present invention are also described as well as methods of making the backing or intermediate layer and methods of malting the surface coverings containing the backing or intermediate layer of the present invention.

Description

r , r SURFACE COVERINGS CONTAINING FUSED RECYCLED
MATERIAL AND PROCESSES OF MAKING THE SAME
BACKGROUND OF THE INVENTION

The present invention relates to hackings for surface coverings, and more particularly relates to backings which contain reeycled material as well &% methods of making such products and incorporating them into surface coveri.ngs.

At the present time, most of the pnst-confiumer vinyl backed carpets and carpet manufacturing waste go to landfills or are destroyed by other tneans such as htirning. With the environinent being of a global concern, the disposal of vinyl backed carpets and manufacturing waste which is, currently done is not an 00 acceptable option.

Further, recycling of vinyl hacked carpets has been attempted hut at most, manufacturers have taken recycled materiai and reduced it to liquid platitisol form in order to form a carpet backing with conventional coating and curing processes. Nowever, such a process has limitations in that only very small amounts of recycled material can be incorporated into a plastisol mix, such as about 5%
or less by weight, and because the oil absorption of recycled material is very high, high levels of plasticizers in plastisols are needed which can lead to further problems. With high levels of plasticizers and plastisols, fitrther processing by conventional methods can become difticult, if not impossible.

Thus, there is a desire by manufacturers to develop ways to use recycled material like carpet backing, such that large amounts of recycled matCrial can he incorporated into products.

SUMMARY OF THE PRESENT INVENTION

A feature of the present invention is to provide a material, e.g., a surface covering, that can contain up to 100% recycled material in one or more components or layers.

Another feature of the present invention is to provide a backing for a surface covering containing recycled material.

An additional feature of the present invention is to provide a surface covering containing a backing or intermediate layer which uses up to 100 % recycled material.

-2-A further feature of the present invention is to provide a method of making a hacking from recycled material and incorporating the backing into surface coverings.

Additional features and advantages of the present invention will be set-forth in part in the description which follows, and in part will be apparent from the description, or may be leamed by the practice of the S present invention. The objectives and other advantages of the present invention will be realized and attained by means of the elements and combinations particularly pointed out in the written description and appended claims.

To achieve these and other advantages and in accordance with the purposes of the present invention, as embodied and broadly descrihr.d herein, the present invention relates to a backing or an intermediate layer 4&0 for a surface covering which contains a fused recycled powder. The recycled powder contains at least a thermoplastic material and the backing or intermediate layer can optionally include other materials, including virgin thermoplastic materials.

The present invention further relates to a surface covering which contains the hacking described above.

15 The present invention, in addition, relates to a method of making a backing or internxxliate layer for a surface covering and includes the steps of applying at least recycled powder to a substrate to form a layer, where the recycled powder contains at least one thermoplastic material; and fusing the recycled powder to ~ form a continuous backing or intermediate layer.

It is to be understood that both the foregoing general description and the following detailed 20 description are exemplary and explanatory only and are intended to provide a further explanation of the present invention, as claimed.

The accompanying drawings, which are incorporated in and constitute a part of this application, illustrate embodiments of the present invention and together with the descriptions serve to explain the principles of the present invention.

25 BRi:_EF DESCRIPTION OF THE DRAWINGS

Figure 1 is a flow chart showing one einhodimznt of a method of the present inveetion. _

-3-Figure 2 is a schematic drawing showina the various steps of makina a surface covering which includes a backing containing recycled material.

Figures 3a-e are cross-sectional views of surface coverings according to several embodiments of the present invention.

DETAILED DESCRiPTTON OF THE PRESENT INVENTION

The present invention relates to a backing (also known as a backing layer) and can be a secondary backing or an intermediate backine layer tor a surface covering. In one embodiment, the backing layer or intermediate layer contains at least a fused recycled niaterial. The recycled tnaterial contains at least one thermoplastic material. Various coatings or layers are discussed herein, and unless stated otherwise, are preferably of a substantially uniform thickness and can be applied using tachniques known to those skilled in the art.

For purposes of the present invention, a surface covering can he any surface covering which makes use of a backing and/or interme=-diate layer, such as a floor covering, wall covering, ceiling covering, countertop covering, and the like. Examples of tloor coverings include, but are not limited to, textile substrates, such as carpets, and resilient tlooring, such as vinyl tlnorinÃ or vinyl surface coverings.
Particularly preferred exampies of textile substrates are hard backed and cushion hacked textile substrates.
While the present invention will be described with respect to the preferred embodiment which is floor coverings, and in particular textile suhstratati and resilient tloorini, the present invention can he applied to other types of surface coverings containing hacking and/or intermediate layers in view of the disclosure herein.

Preferably, the textile Eubstrate is a broadloom carpet, inodular tile, or a wide roll carpet (e.g. 6 ft.
wide). Most preferably, the textile substrate is tile or 6 t't. roll goods.

The textile substrate comprises textile fibers defining a fibrous face, a primary backing to which the textile fibers are secured, and a secondary backing secured to the primary backing. For purposes of the present invention, the term "textile substrate" relates to, but is not limited to, a fiber, web, yarn, thread, sliver, woven fabric, knitted fahric, non-woven fabric, upholstery fabric, tufted carpet, and piled carpet formed, from natural and/or synthctic fibers.

-4-The backing or backing layer for purposes of the present invention can be any layer or substrate which has one or more additional layers adhered to a surface of the hacking layer. Thus, the backing can be the layer which is in contact with the sub-surface, such as a sub-floor, or can be an intermediate layer with other layers above and below the intermediate backing layer.

The recycled material, preferably a powder, contains at least one type of thermoplastic material. The recycled powder used in the present invention is preferably a powder obtained from post-consumer products which contain at least one thermopiastic material. Preferably, the post-consumer product is a carpet and/or carpet manufacturing waste, and more preferably is a vinyl hacked carpet and/or vinyl backed carpet manufacturing waste. Preferably, substantially no thermosetting material is part of the recycled material (e.g.

=10 less than 596 by weight), and more preferably no thermosetting material is present with the recycled material.
With regards to the hacking material, for ptirposes of the present invention, the backing is a thermoplastic material. The thermoplastic material can he an aliphatic thermopla.ctic resin such as one derived by polymerization or copolymerization of an ethylenically unsaturated monomer.
The monomer can be a ethylenically unsaturated hydrocarhon such as an olefin or a nitrile (such as an acrylonitrile), vinyl or vinylidene chloride, vinyl acetate, or an acrylate, such as ethylacrylate or methylmethacrylate. More particularly, the thermoplastic material can he a polyethylene, ethylene/vinyl acetate, polyvinyl chloride, polyisobutylene, and the like. Preferably, the thermoplastic material is a vinyl-type material such as a vinyl resin and more particularly a polyvinyl chloride-type material.

Thermoplastic materials are not suhject to chemical change when heated.
Thennoplastic materials are not infusible, consequently they will gel or soften when a solvznt is applied. Suitable polymers for the backing layers of the present invention are derived from at least one monomer selected from the group consisting of acrylic, vinyl, chlorinated vinyl, styrene, hutadiesne, ethylene, butene, and copolymers or blends thereof. A preferred coating composition is a polymer or copolymer of a vinyl compound, e.g., polyvinyl chloride, polyvinylidine chloride, polyethylene chloride, polyvinyl acetate, polyvinyl acetal, and the like, and copolymers and mixtures thereof. A specific example of a resin coating composition is a vinyl chloride, resin-based plastisol, wherein the plasticizer coinponent of the plastisol is a phthalate-based compound, such as an alkyl phthalate substituted one or two times with a linear or branched C5-C12 alkyl group, which is included in an amount by weight equal to between ahout 15 to 60 percent of the weight of the vinyl chloride resin

-5-component. Particular vinyl chlorides incltide Vinycel 124 (Policyd SA DE CV, Mexico), Geon Registered TM 13 oz(Geon Company, Cleveland, Ohio), Pliovic -70 (The GoodyCar Tire and Ruhher Company, Akron, Ohio), and Oxy 67SF (Occidental Chemical Corp., Dallas, Tex.). Partictilar alkyl phthalate plasticizers include Santicizer Registered TM 160 (Monsanto Company, Saint Louis, Mo.), Palatinol Registered TM 711 P

S (BASF Corporation, Parsippany, N.J.), and Jayflex DHP (Exxon Chemical America, Houston, Tex.).

The backing can be a cushion-back or a hard back backing. In more detail, the backing can be a solid thermoplastic backing or a foamed thermoplastic backing. Preferably, the thermoplastic foamed backing is a foamed vinyl hacking, and more preferably a polyvinyl chloride foamed hacking, such as a closed-cell vinyl foamed backinb. Generally, the hackings will contain a sufticient amotint of at least one blowing agent and plasticizer and can include other ingredients conventionally used in hackings.

Chemically expanded thermoplastic t'oamtJ hackings can he used as the secondary hacking and can be prepared by casting a thermoplastic resin plastisol containing a blowing agent onto the back of the primary backing and heating to expand and fuse the plastisol. Alternatively, a rre-hlown foamed secondary hacking can be laminated, such as by heat, to the primary hackinb. The solid thermoplastic secondary backing can be similarly prepared by casting or by lamination.

Conventional blowing agents can he used and include, hut are not limited to azodicarbonamite, oxybissulfonyl hydroxide, substituted thiatriazole, and the like.:uch as the ones described in U.S. Patent No.
3,661,691.

The recycled powder is ohtained from pnst-ccrosumer products by suhjecting the product, such as a vinyl backed product, to a process which reduces the post-consumer product into a number of pieces (e.g., chunks or granules) which can eventually he furthcr rGJuced in size to form a powder. One operation that can be used to reduce, for instance, the vinyl hacked carpet or vinyl hacked nuanttfactttring waste, to a suitable recycled powder is to first subject the carpet or waste to a face shear ctrCration to remove at least a portion, if not most of the face fiber that may be presznt. While this step is an optional step, it is preferred that at least a portion of the face fiber, and evr.n tnore preferahly at least 50% of the face tiher, and even inore preferably at least 75% of the face fiber, he removed to improve the end use purity of the recycled material which eventually will he formed into a surface covering hacking layer. While there are various types of devices which can remove the face fibers, like ptirc nylon tiher, which inay he attached to the vinyl backed carpet,

-6-one preferred device is a shearing machine, such as one commercially available from Sellers, Inc., United Kingdom.

Whether or not any faoe fiber is removed from the vinyl backed carpet or vinyl backed manufacturing waste, the carpet or waste is then fed into a shredder which breaks down the carpet and waste into various pieces, chunks, or granules. The particular size of the pieces is not critical, so long as the carpet or waste is somehow'"cut up" or formed into pieces so that the carpet or waste can eventually and preferably be reduced to powder form. Preferably, these chunks or granules have a diameter of about 4" or less, and more preferably have a diameter of ahout 3"or less, and most preferably have a diameter of about 2" or less.
Preferably, the diameter range of these chunks or aranules is froin about 1"
to ahout 2". One device that can 010 be used to reduce the carpet andkor waste to such chunks or tranuies ix a shredder, such as one commercially available from Nordfab, Inc., Model t11350K.

The chunks or granules are then reduced to a smaller size by stthjecting them to any operation which can accomplish this purpose. For examPle, a granulatar can he used; tor instance, one available from Rapid Granulator, Model 3260 with a screen size of 1/4 inch, which can recluce the chunks or granule.s to a size of about 'fs" or less, more preferably ahout 3/8" or less, and most Preferahly ahout 1/4" or less. Preferably, the chunks or granules are reduced to a size of from about 'fi" to about 1/4", more preferably from about 3/8"
to about 1/4". With the use of a granulator or sintilar device, the size of the resulting chttnks or granules can . be adjusted to any desired size and thus it is certainly within the hounds of the present invention to vary the size of the particles to sizes desired hy the ultitnate use of the recycled tnaterial.

The chunks or granules now reduced to a smaller size, are then optionally suhjacted to an operation which can separate substantially any existing fiber from the chtinks or granules present. This fiber which may be present is generally face fibers and this operation preferahly removes any low density fibers from the granules or chunks which are typically of a high density. One inethod of separating at least a portion of the fibers from the granules or chunks at this stage, is an aspirator using an air stream separation design. One machine capable of doing this separation is a KF-60 extended aspirator available from Kongskilde. In this optional step, it may be desirable to have a portion of the fiber remain with the granules or chunks of the recycled material or it may be desirable to remove almost all of the fiber, if not all of the fiber, depending upon the end use of the haeking which will he fortned from the recycled niaterial.

-7-The granules or chunks, which may have some fibers attached or present, are then preferably reduced in size to form a powder. Any means can he used to reduce the larger sized granules or chunks to a powder.
Preferred ways of doing so is with the use of a grinder or cryogenic grinding process. lf very fine powder is required for the particular end use, then a cryogenic grinding process is preferred which can be accomplished by spraying the granules or chunks of recycled material with liquid nitrogen and then subjecting the sprayed recycled material to a grinding process. The cryogenic process forms finer powder because of the brittleness of the material resulting from the liquid nitrogen treatment and because of the reduced agglomeration of the material during the grinding process. If the powder size is not as important, then an ambient grinding process can he used with any type of grinder such as a Wedco Therm-O-Fine UR-28 00 grinding systetn available from Wedco, Inc.. Any size of recycled material can he used in the backing or intermediate layer, so long as the material can take the form of a hackint or intermediate layer by fusing, which will be described in more detail helow. It is preferred that the recycled powder have a particle size of 3,000 microns or less and more preferahly 1,000 microns or less. A preferred range of powder size would be from about 250 microns to about 1,500 microns, and a more preferred range would be from about 300 microns to about 900 microns. Figure 1 suniinarize.s the preferred steps of making the recycled powder.
The recycled powder upon analysis typically contains at least one thertnopiastic material, such as a vinyl-based material, and can also contain at least one plasticizer, at least one inorganic filler, at least one stabilizer, and generally a small amount of face fibers, such as nylon, polypropylene, polyester, and/or glass fibers. These fibers which may be present can assist as acting like a reinforcement fiber material in the backing layer once the recycled powder is fused.

The recycled material, preferably in powder forin, which is tormed can be used alone to form a backing or intermediate layer or can he mixed with other conventional ingredients, such as virgin thermoplastic material to form the backing or intermediate layer. Any combination of the recycled material with virgin material is possible. For instance, frotn ahout 1% by weight recycled material to about 100%

recycled material can be used along with from about 0% virgin niaterial to about 99% by weight virgin material to form a mixture which can ultiinately he fused into a hacking layer or intermediate layer.
Preferably, when forming the final backing layer, a backing layer containing about 100% recycled material is preferred. When an intermediate backing layer is tormed, it is preferred that at least 10% by weight virgin

-8-thermoplastic material is also present with the recycled material, and more preferably at least about 50% by weight virgin thermoplastic material is present along with the recycled material, and most preferably at least about 90% by weight virgin thermoplastic material is present along with the recycled material.

Besides virgin thermoplastic material, other conventional ingredients can be present along with the recycled material to form a backing or intzrmediate layer, such as inorganic fillers, resins, plasticizers, stabilizers, foaming agents, hlowing agents, and the like. The amount of any one of these ingredients can be the same as conventionally used by those skilled in the art in forming such layers. Since a foaming or blowing agent can be incorporated into the recycled material, a toain layer or cushion-hacked layer can be formed with the recycled material of the present invention.

~0 In forming the backing or intermediate layer, the recycled material, preferably powder, with or without additional ingredients or components, is applied onto a suhstratc in any tnanner in which powders can be applied to eventually form a continuous layer, which is preferably suhstantially uniform in thickness. The substrate can be a release paper, a belt, or preferably, the bottom surface of a priinary backing or other layer in a carpet or other surface covering. Once the recycled powder with or without other ingredients or components is applied, preferably in a uniform or Suhstantial uniform fashion, the recycled material is fused to form a continuous layer. Fusing or ftised, for purposes of the present invention, is understood to mean that the recycled material, preferably a powder, is not completely reduced to a liquid state, like liquid plastisol, = but instead, is the,joining of the individual particles or granules of the recycled material, in any manner, preferably with the application of heat, to form a continuouti layer.
Gerierally, some of the recycled particles or granules, and preferably a majority, and most preferably over 90% of the recycled particles or granules substantially maintain their identity as particles on a macroscopic level, hut are part of the continuous layer.
In one embodiment of the present invention, after the recycled material has been fitsed to form a continuous layer, visually, one can identify niany of the inJividual recycled particles in the backing layer. The fusing of the recycled material is preferably with the application of heat and pressure. More preferably, the fusing of the recycled material is accomplished with the use of' a dotihle-helt press such as one available from Schilling-Knobel of Gerniany.

With a double-belt pre.sr., the recycled material and any other layers of the surface covering travel

-9-between a inoving top belt and a inovin3 hottoin belt where htuit is applied thmugh each belt onto the recycled material. Generally, a heated platen is located above the top belt and below the bottom belt to provide the application of heat onto the belt and then onto the recycled inaterial. This platen can also provide pressure onto the recycled material. Preferably, the heated platen provides up to about 100 psi and more preferably $ about 40 psi or less, and even more preferably about 0.1 psi to about 10 psi onto the recycled material. Most preferably, no pressure is applied onto the recycled material at this point.
Preferably, any pressure that may be applied through the platens is at a consistent pressure. The temperature applied to the recycled material is generally a temperature sufficient to fuse the recycled particles of the recycled material together without causina any substantial melting of the recycled particles. The top belt is preferably maintained at a temperature of from ahout 215 C to ahout 220 C while the hottoin belt which is the furthest away from the recycled material is preferably kept at a teinperature of froin about I 10 C
to ahout 130 C so as to avoid any damage to the other layers which may exist with the recycled material. Once the recycled material with or without other layers present is heated and fused, the material then preferably goes between two sets of nip rolls which apply a pressure of about 75 psi or less onto the material traveling on the belts and then the material 15 goes through a cooling zone whcrein cold water or other cooling mcclium is circulated through additional platens located above the top belt and below the hottom belt which cools the belt and cools the surface covering. Preferably, during the fusing stage, the pressure and teinperature are held constant or substantially = held constant. The material then can he rolled if desired onto a roller or fed into a cutter. Figure 2 depicts a preferred process of making tha surface covering with the use of a douhle belt press.

20 In a more preferred embodiment, a surface covering, in this case, a hard backed carpet can be made as follows. Unbacked carpet is placed on an unwinding station where this unbacked carpet is fed face down on a moving belt preferably the bottom belt of a douhle-helt press. The unhacked carpet can be a primary backing with textile fibers extending upwardly from the backinb and forming a surface. With the carpet face down on the bottom belt of the dciuhle-heit press, an adhesive or polymCric pre-coat is applied, for instance, 25 by applying a dispersion grade or suspension grade therinoplastic resin onto the primary backing or unbacked carpet. This adhesive or polymeric pre-coat layer can he a 100% virgin dry blend or can be a mixture of virgin material along with recycled material. In lieu ot' a dry blend, a liquid crade resin can lie applied as.the adhesive or polymeric pre-coat layer. Preferably, a dry blend is applied. The adhesive or polymeric pre-coat

-10-layer is applied in conventional ainounts, hut preferahly the amount is from about 15 ounces per square yard to about 60 ounces per square yard. Preferably, the adhesive or polymeric pre-coat layer is a dry blend of at least one PVC resin, at least one plasticizer, and at least one stabilizer.

If the adhesive or polymeric pre-coat layer is a dry grade, the material along with the unbacked carpet is vibrated by a plate underneath the bottom belt which aids in the particles in the adhesive or polymerie pre-coat layer to fall between the fiber bundles and improves the dispersion of the particles on the unbacked carpet. The material can then be subjected to a process which will gel the adhesive or polymeric pre-coat layer, such as with the use of infrared heat. Then, a reinforcement material is applied onto the surface of the adhesive or polymeric pre-coat layer. Examples of rzinf'orcement materials include, but are not limited to, 00 a non-woven material or woven inaterial, such as a non-woven fiber glass mat or fleece and the like. This reinforcement material is generally placed on the surface of the adhesive or polymeric pre-coat layer while the layer is still in a liquid or gel state. Prior to or after the reinforceinent material is applied, an intermediate layer can be applied.

The intermediate layer can he forined frotn 100% recycled material or can contain lesser amounts of the recycled material or can contain 100 'Yo virgin material. Preferably, the intermediate layer contains at least 509b virgin material and more preferahly at least 75 4'o virgin inaterial and most preferably at least 909c virgin material with the remaining balance being suhs-antially recycled material.
This intermediate backing layer = is also an optional layer and can he made from the same tnaterial as the secondary hacking iayer. Preferably, the intermediate backing layer is a hard backed and is not a foamed layer. The intermediate layer is preferably a thermoplastic material and more preferably is a polyiner or copolynier of a vinyl compound, such as polyvinyl chloride. The intermediate backing layer is preferably applied in the form of a dry blend but can be applied as a liquid coating. The intermediate hacking layer whether applied as a dry blend or as a liquid coating can be applied in the manners conventionally known to those skilled in the art. Preferably, the amount of intermediate layer applied is an amount of froin ahotit 10 oz/yd' to about 150 oz/yd2.

Once the reinforcement material is applied, the carpet can then he subjected to a suitable pressure to create a good bond between the individual fibers and/or yarns the adhesive or polymeric or pre-coat layer as well as the reinforcement material with the pre-coat layer. An application of pressure of this sort can be applied by a pressure roller or other stiitahle device.

The unbacked carpet can then move to a station where the final hacking is applied which preferably is from a 100% recycled powder. This material can he applied with the use of a scattering machine or other conventional application davice just like the dry adhesive or polymeric pre-coat layer. Preferably, the recycled material powder is applied in an amount of from about 40 to about 150 ounces per square yard, and more preferably from about 70 to about 90 ounces per square yard, and most preferably about 80 ounces per square yard. As described above, the material, once substantially uniformly applied to the unbacked carpet, is then subjected to a fusing process. The carpet can then he suhie;etcsd to a cooling zone also described previously and then rolled or fed to a cutter.

Referring to Fiaure 2, an unwindin- roll (50) contains release paper or the primary hacking of a O carpet or other layer which is ttnwound onto the lower belt (51) of the double belt system (53). A scattering machine (52) scatters powder containing the pre-coat ingredients which can contain recycled powder onto the material being unwound from (50), and the vibrating chute assists in evenly distributing the powder uniformly throughout the layer on the bottom belt. An infrared heater (54) is used to heat pre-coat material to gel or fuse the pre-coat material, and then fihergla::s is applied to form a reinforcenient layer and a crush roll (55) is used IS to crush the fiberglass onto the pre-coat layer. Afterwards, a scattering/cooling machine (56) is used to applied the secondary backing layer tnaterial which contains at Ir,atit the recycled powder. Then, a second infrared unit (57) is used to heat the secondary hacking material. A series of heating platens (58) is located above the upper belt (60) and balow the hottom belt (51) and the heater (59) is used to heat the platens (58).
Nip rolls (61) are used to press the material on the belt. Cooling platens (62) are then used above the upper 20 belt (60) and below the bottom hult (51) to cool the material. Finally, a belt cleaning system (63) is used to remove debris from the belts and a rewinding roll (64) is used to roll the finished product.

Figure 3 a) through e) depict various emhoAimant:; of the preferred surface covering which is a textile product. In each embodiment in the Figttrz, tihtrc (65) are locate,d on top and a secondary backing (70) is located at the very bottom of the covering and a primary hacking layer (66) secures the fibers (65). A

25 reinforcement layer (68) can he located beneath the pre-coat layer (67) and/or beneath an intermediate layer (71). An intermediate layer (69) can also he located beneath the reinforcement layer (68). In each case, each layer is affixed in some manner such as by casting, adhesive, or other means conventional in-the art. -As an alternative to using the priinary hacking as the stihstrata in which all other layers are applied thereto, it is certainly within the hounds of the present invention to make any layer of the surface covering first and then add other desirable layers to the top and/or bottom surface of the first layer made. For instance, the secondary or final backing layer can bz made first and then all layers applied thereto.

$ Besides the above embodiment relating to the ttse of recycled material in one or more layers of a surface covering, another aspect of the present invention is a surface covering wherein the secondary backing layer and preferably the adhesive or polymeric pre-coat layer are made from dry powder blends instead of liquid blends. The advantage with such a system would he that the powder blends are less expensive and are easier to handle in the manufacturinb process. In such a proccsti, the layers can he formecl in the same manner 1o described above with respect to the forination of a layer using recycled material such that the virgin material forming the secondary backing or other layer will forni a contintuuts layer by t'vsing or he suhjected to sufficient heat to melt the powder to form a continueyus layer. The use of the dnuble-belt press described above would he preferred in forniin,g a surface covering containing one or more layers froin a dry powder blend. Preferably, the secondary hacking wotild contain a dry blend of a polymeric resin stich as polyvinyl 15 chloride along with other optional conventional ingredients in a dry blend form, such as at least one plasticizer, at least one filler, at least one stahilizer, and the like. A
foaining agent in the form of a dry blend can also he included. An intCrmediate backing layer and/nr an adhesive or polytneric pre-coat layer can be formed in the same fashion as described earlier. It is within the hounds of the present invention to first form one layer and suhjzct the dry powder blend in the shape of a laycr to appropriate heat to form a continuous 20 layer and then add a second layer in powder torm to the top or hottom tiurface of the tirst formed continuous layer and so on. Alternatively, the layers can all he formed on top of each other in powder form and then subjected at one time to sufficient heat to form a continuotts multi-layered surface covering.

Whether a surface covering contains recycled material or 100% virgin material, the process of curing all at one time is particularly preferred in making resilient vinyl tloaring where all layers are first formed and 25 then the entire surtace covering is suhjcx:ted to sufficient heat to form a multi-layerc:d resilient vinyl flooring which can then have optional strengthening layers, wear layers and/or top coat layers applied afterwards, such as in the manner described in U.S. Patent No. 5,458,953.

In combination with the other emhoQinicnts of the present invention or as a separate alternative, the recycled material of the present invention can he added to the adhesive and/or pre-coat layer. In this embodiment, the adhesive and/or pre-coat layer are preferably applied as a liquid and the recycled material is added to the liquid in any fashion, such as by mixing with the liquid before the liquid is applied as a coat or the recycled material can be applied by introducinb the recycled material on top of the liquid once the liquid is applied as a coat (e.g., applying the recycled material on top of the liquid coat by scattering techniques).
Any amount of recycled material can be applied in this fashion, and preferahly the amount is from about 1%
by weight of the liquid coat to ahout 50% by weight, and more preferably, from ahout 5% to about 15% by weight of the liquid coat. Similarly, any intermecliate layer or even the backing layer, such as the ones 0 described above, can have recycled inaterial introduced and present in the same manner (i.e., recycled material added to liquids which form the layer) as a separate altemative; meaning, the hacking layer need not contain recycled material as long as some other layer(s) contains recycled material.
More than one layer can contain recycled material and preferably, the entire surface covering has frorn ahout I% by weight to about 20% by weight recycled material.

The present invention will he further claritied by the following examples, which are intended to be purely exemplary of the present invention.

EXAMPLES
= Example 1 A surface covering, such as a final hard hacked carpet was made in the following manner. A carpet was made in the same manner as described ahove with respect to the preferred embodiment of using an adhesive or polymeric pre-coat layer having the formula A described below in Table I and the use of a fiberglass fleece (1.0 lb - 2.0 lb/100 ft=, e.g. 1.4 lh/100 ft) obtained from Johns Manville. The unbacked carpet used was a 26 ounce loop obtained froin Mannington Carpets - 1/10 gauge. The final or secondary back coat was applied in powder form as shown in Figure 2 using the preferred amounts and parameters described above in the preferred emhodiment.

The final back coat was formula R. Formula R is recycled powder resulting from vinyl back carpet tile and carpet wastz which was suhjected to a face shear operation to remove suhstantially all.of the fiber with a Sellers Shearing Machine. The sheared carpet tile and carpet waste were then fed into a Nordfab 1350K

shredder to form 2" or less granules or chunks which were then reduced to a smaller size of 1/4" or less with the use of a Rapid Granulator 3260"'', . Low density fiber was separated out of the material with a Kongskilde KF-60T' aspirator and the material was reduced to a powder having a size of from about 330 microns to about 850 microns. Table 2 below, sets forth the various parameters used in making the carpet which was constructed on a double-belt press obtained from Shilling-Knohel of Germany.

-1.5-Formulations Cn-Polvmer Pre-Coat Formulation - A-Pnwder Chemical T e Chemical PHR
PVC Resin VC-113T' 100 Flame Retardant Altimintim Trihydrate 120 Plasticizers Blend S-160 (6036 h wt.) 22.5 DINP (40%) Stabilizer Tile 1.5 Stearic Acid 1.0 Hcimo-Polvnitr PVC Back-Coat - B-Pnder PVC Resin VC-57T"'' 100 Filler CaCO1 180 Plasticizer Blend S-160 (60% by wt.) 60 D1NP (404b) Stabilizer Tile 1.5 Stearic Acid 1.0 Foam Backim;v Dr Blend armulation - F-Powder PVC Resin Geon 438 T'" 100 Flame Retardant Aluniinunt Trihydrate 60 Filler CaCO 60 Plasticizer Blend S-160 (60% hy wt.) 70 D1NP (40%) Stahilizer Tile 2.0 Foaming Agent AZ-120 2.4 Activator Kadox 920 "" 1.0 ~
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1!') xam le 2 A vinyl floor covering was made using the process of the present invention. In particular, on a belt, recycled material having Formula R was applied in an atnount to create a 40 mil thick layer which on top was applied PVC pellets to form a second layer of 40 mils in thickness. Both layers, in powdered form, were then fused to form a continuous multi-layer product. A top coat eontaining an UV
curable urethane-based acrylate thermoset from Lord Corporation was then applied in the manner described in U.S. Patent No. 5,405,674, to form the final product.

xam le 3 A surface covering containing laycrti made from powder hlendti wat inade from using the double-belt press and procedure in Exaniple 1. The process steps of Example I were followed except that in lieu of Formula R as the final backing layer, Fortnt-la B or Formula F were utied to form the final backing layer.
Table 3 below sets forth some results from surface coverings made from Examples 1 and 3.

Tahle 3 Example IA 3A 3B 1B
Radiant Panel (ASTM E-648) .70 - .78 .56 NBS Smoke FL (ASTM E-662) 474 444 515 435 Tuft Bind D(ASTM D- 1335) 7.8 9.9 2.5 6.6 Tuft Bind Wet (ASTM D-1335 6.4 7.4 1.5 5.4 Delamination (ASTM D-3936) No No No -Flatness (ITTL Test-5 means carpet 4 - 2-3 4 totall "hu s" the floer Other embodiments of the nre.cent invention will he apparent to those skilled in the art from consideration of the specification and practice of the present invention disclosed herein. It is intended that the specification and examples hC considered as exemplary only, with a tntC
scope and spirit of the present invention being indicated by the following claims.

Claims

WHAT IS CLAIMED IS:

1. A backing or intermediate layer for a surface covering comprising fused recycled material, wherein said recycled material comprises at least one thermoplastic material.

2. The backing or intermediate layer of claim 1, wherein said fused recycled material is a fused recycled powder.

3. The backing or intermediate layer of claim 1, wherein said surface covering is a carpet.

4. The backing or intermediate layer of claim 1, wherein said surface covering is a floor covering.

5. The backing or intermediate layer of claim 1, wherein said surface covering is a vinyl surface covering.

6. The backing or intermediate layer of claim 1, wherein said surface covering is a hard backed surface covering.

7. The backing or intermediate layer of claim 1, wherein said surface covering is a cushion backed surface covering.

8. The backing or intermediate layer of claim 1, wherein said recycled material has a particle size of from about 50 microns to about 5,000 microns.

9. The backing or intermediate layer of claim 1, wherein said recycled material has a particle size range of from about 50 microns to about 1,000 microns.

10. The backing or intermediate layer of claim 1, wherein said thermoplastic material is vinyl-based or derivatives thereof.

11. The backing or intermediate layer of claim 1, wherein said recycled material is from a vinyl backed carpet or vinyl backed carpet manufacturing waste or both.

12. The backing or intermediate layer of claim 1, wherein said recycled material is pressed.

13. The backing or intermediate layer of claim 1, further comprising face fibers, at least one plasticizer, at least one inorganic filler, at least one stabilizer, or mixtures thereof.

14. The backing or intermediate layer of claim 1, wherein said backing further comprises nylon fibers, polypropylene fibers, polyester fibers, glass fibers, or mixtures thereof.

15. The backing or intermediate layer of claim 1, further comprising virgin thermoplastic material.

16. The backing or intermediate layer of claim 1, wherein said backing is for a resilient vinyl flooring material.

17. The backing or intermediate layer of claim 1, wherein said backing is for a vinyl carpet tile.

18. A method of making a backing or intermediate layer for a surface covering comprising applying recycled material in the form of particles on a substrate to form a layer, wherein said recycled material comprises a thermoplastic material; and fusing said recycled powder to form a continuous backing layer.

19. The method of claim 18, wherein said fusing is achieved with the application of heat.

20. The method of claim 18, wherein said fusing occurs in a double-belt press.

21. The method of claim 20, wherein the double-belt press comprises a bottom belt and a top belt, wherein said bottom belt is kept at a temperature from between about 1100 to about 130°C and said top belt is maintained at a temperature of from about 215° to about 220°C.

22. The method of claim 18, further comprising applying virgin thermoplastic material along with said recycled material to form a layer.

23. A method for preparing a backing or intermediate layer for a surface covering comprising reducing vinyl backed carpet, vinyl backed carpet manufacturing waste, or both into granules and fibers;
separating at least a portion of the fibers from the granules;
reducing said granules to a smaller particle size to form a powder;
applying the powder to a substrate to form a layer and pressing said powder;
fusing said powder for a sufficient time and temperature to form a continuous backing.

24. The method of claim 23, wherein prior to reducing the vinyl backed carpet, vinyl backed carpet manufacturing waste, or both to granules, said process further comprises removing at least a portion of any face fiber from said vinyl backed carpet.

25. The method of claim 23, wherein said granules have a size of from about 1/4" to about 3/16".

26. The method of claim 23, wherein said granules are formed by subjecting the vinyl backed carpet, vinyl backed manufacturing waste, or both to a shredder.

27. The method of claim 26, wherein said shredder reduces the vinyl backed carpet or the vinyl backed manufacturing waste to granules having sizes of from about 1" to about 2" wide.

28. The method of claim 23, wherein at least a portion of said fibers are separated from the granules using an aspirator with air stream separation.

29. The method of claim 23, wherein said granules are reduced to a powder by an ambient grinding process or a cryogenic grinding process.

30. The method of claim 23, wherein said substrate is a bottom surface of a primary backing with textile fibers extending upwardly from the primary backing and forming a surface.

31. The method of claim 23, further comprising feeding a roll of primary backing onto a belt prior to applying the powder; applying dispersion grate or suspension grade thermoplastic resins onto the back of the primary backing to form an adhesive or polymeric pre-coat layer; vibrating the primary backing; reducing the adhesive or polymeric pre-coat layer to a soft gel; placing a reinforcement material on the bottom surface of the adhesive or polymeric pre-coat layer and applying pressure, and wherein the powder is applied onto the bottom surface of the reinforcement material.

32. The method of claim 23, wherein said continuous backing is passed through a cooling zone.

33. The method of claim 23, wherein said fusing occur on a double-belt press.

34. The method of claim 18, wherein said fusing is achieved with the application of heat and pressure.