Recyclable Single Polymer Floorcovering Article

a single-layer, polymer technology, applied in the field of tufted floorcovering articles, can solve the problems of increasing the number and increasing the cost of tufted carpet tiles

Inactive Publication Date: 2014-09-18
MILLIKEN & CO
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0012]The invention provides for a tufted carpet that meets the commercial tile performance requirements. The invention further provides for a carpet made from a single polymer family, in this case polyester. The invention provides for a tufted carpet with an ash content of less than 0.25% and a solution intrinsic viscosity (“IV”) of greater than 0.50 dl / g. The invention provides for a tufted carpet that is completely recyclable without separation steps.

Problems solved by technology

The complexity of the carpet, including multiple incompatible layers comprised of various materials, limits recycling and end-of-life options.
Because landfill space is limited in quantity and expensive to utilize, with costs continuing to rise, the disposal of carpets in landfills is not acceptable.
However, these fillers typically create a serious problem for downstream recycling.
A rating of less than 3 typically represents unacceptable wear performance.
Fibers such as polyester and polypropylene struggle to achieve acceptable results.
Few of these efforts were commercialized and widely practiced due to costs and sub-standard performance issues.
The use of many of these fillers adds to the already difficult task for recyclers to separate fiber types of the complex composites, by including the task of removing additional inorganic particulates from the comingled waste stream.

Method used

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  • Recyclable Single Polymer Floorcovering Article
  • Recyclable Single Polymer Floorcovering Article

Examples

Experimental program
Comparison scheme
Effect test

example 1

[0076]A floorcovering article comprised substantially of 100% polyester material was prepared as follows:

[0077]A base substrate was constructed of 40 oz / yd2 tufted polyester loop carpet containing a combination of semi-dull and bright yarns. The yarns were tufted through a 130 gsm polyester nonwoven primary backing layer from Freudenberg. The semi-dull yarn was 55% of the tufted face weight and the bright yarn was 45% of the tufted face weight. The yarns were arranged in alternating rows. The semi-dull yarn was a 2 ply, 2 ends per tufting needle, available from Pharr. The bright yarn was a 2 ply, 2 ends per tufting needle, available from Pharr. All yarn was in an undyed state. However, it should be noted that solution dyed yarn may optionally be used.

[0078]The tufted primary backing was scatter coated with EMS Griltex D1539 copolyester hot melt adhesive powder (melt viscosity of 100,000 cps at 160° C. measured per ISO 1133) from EMS Chemie of Domat, Switzerland. 5.8 oz / yd2 of adhesi...

example 2

[0079]The tufted primary backing used in Example 1 was scatter coated with EMS Griltex D1539 copolyester hot melt adhesive powder. 10 oz / yd2 of adhesive was applied. The sample was placed under an IR heater to sinter the adhesive. The carpet composite had good tuft bind (greater than 8 lbs). The Velcro roller fuzzing resistance was less than 2.

example 3

[0080]The tufted primary backing of Example 1 was scatter coated with EMS Griltex D1539 copolyester hot melt adhesive powder. 16 oz / yd2 of adhesive was applied. The sample was placed under an IR heater to sinter the adhesive. The carpet composite had good tuft bind (greater than 8 lbs). The Velcro roller fuzzing resistance was 2.

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Abstract

This invention relates to tufted floorcovering articles, including carpet tiles and broadloom carpet. In particular, this invention relates to tufted floorcovering articles made from the family of polymers known as polyester. Specifically, this invention relates to tufted carpet tile products made from polyester. The polyester carpet tiles meet commercial performance specifications and are fully end-of-life recyclable.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS[0001]This application claims priority to U.S. Patent Application Ser. No. 61 / 777,028, entitled “Recyclable Single Polymer Floorcovering Article,” which was filed on Mar. 12, 2013, and which is entirely incorporated by reference herein.TECHNICAL FIELD[0002]This invention relates to tufted floorcovering articles, including carpet tiles and broadloom carpet. In particular, this invention relates to tufted floorcovering articles made from the family of polymers known as polyester. Specifically, this invention relates to tufted carpet tile products made from polyester. The polyester carpet tiles meet commercial performance specifications and are fully end-of-life recyclable.BACKGROUND[0003]The end-of-life option for the majority of tufted floorcovering articles, such as carpet, is landfill disposal. In their 2011 Annual Report, Carpet America Recovery Effort (CARE) reported that 91% of the removed carpet was sent to landfill. The complexity of the ...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): A47G27/02
CPCA47G27/02D06N7/0081D06N2213/02D06N2213/065D06N2203/061D06N7/0065D06N7/0068D06N7/0076Y10T428/23979Y02W30/62C08J11/10B29B9/06B29B9/12B29B17/0036B29K2067/00B29K2105/26C08J11/12C08J2367/02
Inventor WILLIAMS, DALE R.WALLEN, JOSEPHDAWSON, TY GRANTSELLMAN, JR., NILS DAVIDMCBRIDE, DANIEL TAYLORROYER, JOSEPH R.SANCHEZ, JOHN L.
Owner MILLIKEN & CO
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