Biobased carpet precoat composition

Abstract

A carpet or carpet tile comprising a bio-based pre-coat is provided. The resulting carpet or carpet tile has advantages in terms of environmental concerns and reduces the demand for fossil fuels. The pre-coat is made by a pre-coat composition comprising a rosin or rosin derivative and a filler.

Description

Technical Field

[0001] This invention relates to the field of textile floor covering materials, and more particularly to carpets and carpet tiles. Background Technology

[0002] Carpets and carpet tiles typically consist of a woven face layer, a pre-coated layer, and a backing layer. The woven face layer is usually produced by tufting, spinning, or needle punching processes. In tufting, carpet yarns are needled into the backing. In spinning, two sets of carpet yarns are interwoven at right angles. In needle punching, carpet fibers are needled together, possibly using a loosely woven fabric for finishing and / or reinforcement. The yarns and fibers can be made of natural and / or synthetic materials.

[0003] The back of the textile surface layer can be pre-coated with a water-based filled or unfilled latex, known as a pre-coated composition. The yarns or fibers are firmly bonded to the pre-coated composition, providing good adhesion. For tufted and needle-punched carpets, adhesion can be expressed as so-called tufting lock-in force, which is the force required to pull a tuft of pile from a cut-pile carpet or a single loop from a loop-pile carpet. An alternative to the water-based pre-coated composition could be, for example, a filled or unfilled hot-melt composition. Another alternative is to melt the yarns or fibers together on the back of the surface layer.

[0004] In this document, a pre-coated topcoat is an intermediate product produced by pre-coating a topcoat or by melting yarns or fibers together on the back of a topcoat. In this document, a pre-coated layer is a layer comprising a pre-coated composition or molten yarns or molten fibers.

[0005] The backing of wall-to-wall carpets typically consists of a second latex coating and a secondary backing, which is usually a textile substrate. The backing of carpet tiles is generally heavy because it is crucial to the product's performance and durability. It enables them to withstand severe abrasion without deterioration. The backing provides flatness, dimensional stability, stiffness, and weight, thereby minimizing or eliminating the need for adhesives. Carpet tile backing typically consists of a filled backing composition, optionally supplemented with fiberglass mat or loosely woven fiberglass mesh for dimensional stability and / or optionally with a nonwoven fabric as a cover mat.

[0006] Commonly used pre-coated compositions for carpet tiles are based on fossil fuels. Although fossil fuels are continuously formed through natural processes, they are generally considered non-renewable resources because they take millions of years to form, and known recoverable reserves are depleted far faster than new reserves are formed. Furthermore, the use of fossil fuels raises potential environmental problems because the combustion of fossil fuels leads to the formation of carbon dioxide, a well-known greenhouse gas. In addition, the emission of volatile organic compounds (VOCs) from carpets is widely considered a potential indoor air quality problem that can affect human health. VOCs originate not only from the carpet and carpet tiles themselves but also from the adhesives used to attach the carpet or carpet tiles to the floor surface. Materials used in carpets should also not contain toxic components that may be harmful during production, installation, use, maintenance, and disposal. Specific toxicity issues with currently used fossil fuel-based pre-coating materials include the presence of toxic polycyclic aromatic hydrocarbons (PAHs), plasticizers, the formation of toxic components in post-incineration flue gas, and monomers.

[0007] US4640953 discloses a pre-coated resin dispersion having a solids content of about 63% to about 69%, comprising: (1) at least one resin having a ring and ball softening point of about 60°C to about 100°C in an aqueous dispersion having a solids content of about 53% to about 58%; (2) at least one water-soluble polymer; (3) at least one cationic resin; and (4) water. This pre-coated resin dispersion can be used in the manufacture of tufted carpets, particularly carpets manufactured with carboxylated latex as a backing coating. The resin of component (1) is selected from C5-C9 hydrocarbon resins, C5 hydrocarbon resins, polyterpene resins, and rosin esters.

[0008] US2006134374A1 discloses a vinyl polymer adhesive containing post-consumer recycled glass powder filler. US2020181440A1 discloses a carpet backing composition.

[0009] One object of this invention is to provide a carpet or carpet block that reduces the demand for fossil fuels and / or reduces greenhouse gas emissions. Additionally or alternatively, carpets or carpet blocks with low VOCs and / or free of toxic components are needed. Additionally or alternatively, more bio-based and / or more environmentally sustainable carpets or carpet blocks are needed, i.e., with a lower environmental impact. Additionally or alternatively, carpets or carpet blocks that can be produced more economically are needed, preferably fully bio-based carpets or carpet blocks.

[0010] US20110008567 discloses a carpet or carpet block wherein an adhesive backing layer comprises at least one non-chlorinated, non-polyvinyl butyral thermoplastic polymer, which may be an ethylene / vinyl acetate copolymer, at least one filler, which may be CaCO3, in an amount up to 90 wt.%, and 0 wt.% to 15 wt.% of a tackifier. The tackifier may be rosin or a rosin derivative. US20110008567 does not disclose a pre-coated composition.

[0011] WO2018 / 009060 A1 discloses a carpet or carpet panel comprising a woven surface layer, a pre-coated layer, and a backing layer. The backing layer comprises a backing composition including: a natural resin, preferably rosin or a rosin derivative; optionally refined or modified natural oils, preferably optionally refined or modified vegetable oils; optionally a thermoplastic elastomer; and fillers. WO2018 / 009060 A1 does not disclose the pre-coated composition.

[0012] Therefore, the specific object of the present invention is to provide carpets or carpet blocks with a pre-coated finish that reduces the need for fossil fuels and / or reduces greenhouse gas emissions, is free of toxic components, is more environmentally sustainable, can be produced more economically, and has good mechanical properties such as tufting retention. Summary of the Invention

[0013] In a first aspect, the present invention relates to a carpet or carpet panel comprising a woven surface layer, a pre-coating layer, and a backing layer, wherein the pre-coating layer comprises a pre-coating composition, wherein the pre-coating composition comprises:

[0014] The resin is preferably rosin or a rosin derivative.

[0015] Optional thermoplastic elastomers; and

[0016] filler.

[0017] Preferably, based on the total weight of the composition, the pre-coating composition taught herein comprises:

[0018] 1 wt.%-98 wt.% of resin, preferably 2 wt.%-95 wt.% of resin, wherein the resin is preferably rosin or a rosin derivative;

[0019] Optionally, 0 wt.%-20 wt.% thermoplastic elastomer; and

[0020] The filler content is 2wt.%-99wt.%, preferably 5wt.%-98wt.%, more preferably 5wt.%-90wt.% or 10wt.%-85wt.%.

[0021] Preferably, the pre-coating composition comprises 5 wt.%-50 wt.%, more preferably 15 wt.%-35 wt.% or 20 wt.%-30 wt.% of rosin or rosin derivatives. Alternatively or additionally, the pre-coating composition may comprise 50 wt.%-95 wt.% or 50 wt.%-85 wt.%, more preferably 65 wt.%-85 wt.% or 70 wt.%-80 wt.% of filler.

[0022] Preferably, the resin is a natural resin, preferably selected from rosin or its derivatives, such as esterified rosin, hydrogenated rosin, phenolic rosin, terpene rosin, etc. Most preferably, the resin is esterified rosin.

[0023] Preferably, the pre-coating composition comprises up to 10 wt.%, 9 wt.%, 8 wt.%, 7 wt.%, 6 wt.%, 5 wt.%, 4 wt.%, 3 wt.%, 2 wt.%, or 1 wt.% of a thermoplastic elastomer. Most preferably, the pre-coating composition does not contain a thermoplastic elastomer.

[0024] Preferably, the thermoplastic elastomer is a copolymer of ethylene and vinyl acetate (EVA or VAE), and more preferably, the ethylene and vinyl acetate copolymer (VAE) has a vinyl acetate monomer content (mol%) higher than the ethylene monomer content (mol%).

[0025] Preferably, the thermoplastic elastomer is a styrene block copolymer, more preferably a block copolymer of polystyrene and polybutadiene (SBS).

[0026] Preferably, the thermoplastic elastomer is a polyolefin.

[0027] Preferably, the thermoplastic elastomer is a polyhydroxyalkanoate.

[0028] Preferably, the thermoplastic elastomer is a water-soluble polymer.

[0029] In a preferred embodiment of this disclosure, the pre-coating and / or pre-coating composition does not include polyolefins, or includes at most 10 wt.%, 5 wt.%, 2 wt.%, or 1 wt.% polyolefins relative to the total weight of the pre-coating and / or pre-coating composition. In this disclosure, the term "polyolefin" refers to a polymer having the general formula (CH2CHR)n, where R is an alkyl group.

[0030] Preferably, the filler is selected from:

[0031] Inorganic fillers, such as calcium carbonate (limestone), silicates, silicon dioxide, silicon oxides, carbonates, sulfates, antimony oxide, alumina trihydrate, carbon black, talc, clay, and kaolin.

[0032] Organic fillers, such as sawdust, wood flour, nut shell powder, plant materials, plant fibers, plant shells and plant residues, and

[0033] Recycle materials, such as recycled rubber, recycled plastics, and recycled fibers.

[0034] More preferably, the filler is limestone, or even more preferably recycled limestone.

[0035] The filler may be at least partially in particulate form, wherein preferably, based on the total volume of the filler, at least 50 vol.% of the filler is in particulate form having an (average) particle size of 10 µm-200 µm, more preferably 10 µm-150 µm, more preferably 10 µm-105 µm, more preferably 20 µm-100 µm, more preferably 30 µm-80 µm, and most preferably 30 µm-60 µm. This can be determined by dynamic light scattering (DLS).

[0036] In a second aspect, the present invention relates to a method for preparing the carpet or carpet panel taught herein, the method comprising the following steps:

[0037] Prepare the pre-coated compositions taught herein;

[0038] A pre-coated composition is applied to a surface layer to prepare a pre-coated surface layer comprising a top surface containing yarns or fibers and a back surface comprising a pre-coated layer; and

[0039] Apply the backing composition to the pre-coating.

[0040] Throughout this application, when a disclosed composition includes components “(from) x to y” or “xy”, the values ​​of x and y are explicitly included in that range unless otherwise specifically stated. Detailed Implementation

[0041] This invention relates to carpets or carpet tiles, comprising a woven surface layer, a pre-coating layer, and a backing layer, wherein the pre-coating layer comprises a pre-coating composition, wherein the pre-coating composition comprises: a resin, preferably rosin or a rosin derivative; optionally a thermoplastic elastomer; and a filler.

[0042] More specifically, the present invention relates to carpets or carpet tiles comprising a woven surface layer, a pre-coating layer, and a backing layer, wherein the pre-coating layer comprises a pre-coated composition, wherein, based on the total weight of the composition, the pre-coated composition comprises: 2 wt.% to 95 wt.% of rosin or rosin derivatives; 0 wt.% to 20 wt.% of thermoplastic elastomer; and 5 wt.% to 98 wt.% of filler.

[0043] Surprisingly, according to the present invention, carpets and carpet tiles with good properties (i.e., at least comparable to those of prior art carpets and carpet tiles) can be obtained without the need for large quantities of thermoplastic elastomers, such as water-soluble polymers, styrene-based block copolymers, polyolefins, polyhydroxyalkanoates, and ethylene-vinyl acetate copolymers, including good tufting retention. The present invention provides carpets and carpet tiles that can be largely bio-based, even up to 100% bio-based.

[0044] In carpets or carpet tiles, the textile surface layer is typically produced through tufting, weaving, or needle punching processes. A pre-coating layer, typically adhesive, can then be applied to the back (non-decorative) of the textile surface layer to secure the yarns or fibers within it. This pre-coating ensures that the yarns or fibers are bonded together within the surface layer. The resulting pre-coated surface layer comprises yarns or fibers on its top side and the pre-coating layer on its back side. A backing layer can then be applied over the pre-coating to improve flatness, provide dimensional stability, stiffness, and weight, and minimize the need for installation adhesives. Other layers, such as fiberglass mat or loosely woven fiberglass mesh and / or non-woven overlay mat, can be added for dimensional stability to form the carpet or carpet tile, but these layers are not necessary in the context of this invention.

[0045] The components in the pre-coated composition, excluding fillers, constitute the "binder." The binder in the carpet or carpet tile pre-coated composition preferably comprises at least 75%, preferably at least 80%, more preferably at least 85%, more preferably at least 90%, and even more preferably at least 95% bio-based material by weight, and preferably entirely bio-based. As used herein, the term "bio-based" means rapidly renewable material (i.e., material with a harvest cycle of ten years or less) and / or material not made from (non-renewable) fossil fuels and / or material not made from prehistoric organisms (or materials derived from them). Bio-based materials are manufactured using renewable biomass resources.

[0046] Suitable resins are typically in solid form at room temperature. Ideally, the resin has a melting point of about 20°C to about 100°C, preferably about 30°C to 90°C, to enable the resin to be treated at room temperature and to allow the mixing and application processes to be carried out at reasonable processing temperatures.

[0047] The resin used in the context of this invention can be a natural or synthetic resin. The resin is preferably a natural (non-fossil) resin (and therefore bio-based), and more preferably rosin, i.e., unmodified rosin or resin derived from modified rosin (i.e., rosin derivatives). Rosin is a resin obtained from pine trees and some other plants (primarily coniferous trees). It is translucent and ranges in color from yellow to black. Rosin may be brittle at room temperature but melts at stovetop temperatures. It is primarily composed of various resin acids. The rosin used in this invention can be modified, for example, esterified rosin, hydrogenated rosin, dimerized rosin, phenolic rosin, terpene rosin, etc. Suitable esterified rosin can be the product of the reaction of rosin with monohydric alcohols, dihydric alcohols, trihydric alcohols, tetrahydric alcohols, polyhydric alcohols, or combinations thereof (including methanol, dipropylene glycol, glycerol, pentaerythritol, and combinations thereof). The rosin and rosin derivatives used in this invention can be derived from any commercially available type of rosin, such as wood rosin, resin rosin, tall oil rosin, and mixtures thereof in crude or refined form. Esterified rosin is preferred. It has been found that esterified rosin not only affects carbon footprint but also recyclability (partly because different layers in a carpet or carpet block contain more similar components and can be processed in the same recycling process).

[0048] The filler can be any well-known filler, such as mineral fillers or organic fillers. Suitable filler types include calcium carbonate (limestone), silicates, silicon dioxide, silicon oxides, carbonates, sulfates, antimony oxide, aluminum hydroxide, carbon black, talc, clay, kaolin, wood flour, and nutshell powder.

[0049] In a particularly preferred embodiment, the filler is selected from calcium carbonate, magnesium oxide, aluminum hydroxide, and silicon hydroxide; and / or the filler (or pre-coating / composition) comprises at least 50 wt.%, 60 wt.%, 70 wt.%, 80 wt.%, 90 wt.%, or 100 wt.% of calcium carbonate, magnesium oxide, aluminum hydroxide, or silicon hydroxide relative to the total weight of the filler or pre-coating / composition.

[0050] Preferably, the filler does not include glass, or includes at most 10 wt.%, 5 wt.%, or 1 wt.% glass relative to the total weight of the filler. Glass typically has a higher Mohs hardness scale value (compared to other fillers). Mohs hardness is based on the ability to scratch softer materials. The hardness value of glass is approximately 5.5, while that of limestone, for example, is approximately 3. This has been found to result in higher wear on equipment during production and installation. Therefore, preferably, the pre-coated / pre-painted composition does not include glass, or includes at most 5 wt.% or 1 wt.% glass relative to the total weight of the pre-coated or pre-painted composition.

[0051] Preferably, the pre-coated composition comprises 50 wt.%-95 wt.% or 50 wt.%-85 wt.%, more preferably 65 wt.%-85 wt.% or 70 wt.%-80 wt.%. Higher amounts of filler provide a more economical composition, and surprisingly, the resulting carpet or carpet block still has a tufting hold-up of over 1.4 or even 1.8 kg.

[0052] The (average) particle size of the filler can be in the range of about 0.01 µm to about 1 mm, preferably about 1 µm to about 1 mm, and can be separated or graded to produce the desired average particle size. In addition to these fillers, fillers of different shapes, bio-based fillers and / or recycled fillers such as wood chips, natural fibers, plant shells, plant residues, synthetic fibers, glass fibers, recycled fibers, recycled rubber, recycled plastics and other recycled materials can be introduced into the compositions taught herein.

[0053] In a preferred embodiment, the filler is limestone, preferably recycled limestone.

[0054] Preferably, the filler is in granular form, wherein preferably, based on the total volume of the filler, at least 50 vol.% of the filler is in granular form with an (average) particle size of 10 µm-200 µm, more preferably 10 µm-150 µm, more preferably 10 µm-105 µm, more preferably 20 µm-100 µm, more preferably 30 µm-80 µm, and most preferably 30 µm-60 µm. This can be determined by dynamic light scattering (DLS). Optionally, based on the total volume of the filler, at least 10 vol.%, 20 vol.%, 30 vol.%, 40 vol.%, 50 vol.%, 60 vol.%, 70 vol.%, 80 vol.%, 90 vol.%, and 100 vol.% of the filler is in the form of particles having an (average) particle size of 10 µm-200 µm, more preferably 10 µm-150 µm, more preferably 10 µm-105 µm, more preferably 20 µm-100 µm, more preferably 30 µm-80 µm, and most preferably 30 µm-60 µm. Specifically, based on the total volume of the packing, at least 10 vol.%, 20 vol.%, 30 vol.%, 40 vol.%, 50 vol.%, 60 vol.%, 70 vol.%, 80 vol.%, 90 vol.%, 100 vol.% (and / or at most 60 vol.%, 70 vol.%, 80 vol.%, 90 vol.%, 100 vol.%), preferably at least 50 vol.%, of the packing material are... Having an average particle size of at least 10µm, 11µm, 12µm, 13µm, 14µm, 15µm, 16µm, 17µm, 18µm, 19µm, 20µm, 21µm, 22µm, 23µm, 24µm, 25µm, 26µm, 27µm, 28µm, 29µm, 30µm, 31µm, 32µm, 33µm, 34µm, 35µm, 36µm, 37µm, 38µm, or 39µm. m and / or up to 40µm, 41µm, 42µm, 43µm, 44µm, 45µm, 46µm, 47µm, 48µm, 49µm, 50µm, 51µm, 52µm, 53µm, 54µ m, 55µm, 56µm, 57µm, 58µm, 59µm, 60µm, 61µm, 62µm, 63µm, 64µm, 65µm, 66µm, 67µm, 68µm, 69µm, 70 µm, 71µm, 72µm, 73µm, 74µm, 75µm, 76µm, 77µm, 78µm, 79µm, 80µm, 81µm, 82µm, 83µm, 84µm, 85µm, 8 Particle forms of 6µm, 87µm, 88µm, 89µm, 90µm, 91µm, 92µm, 93µm, 94µm, 95µm, 96µm, 97µm, 98µm, 99µm, 100µm.This can be determined using dynamic light scattering (DLS). Surprisingly, particle sizes within these ranges exhibit higher tufting-locking values, particularly compared to particles with larger diameters. vol.% can refer to the percentage of bulk density.

[0055] DLS is a technique for determining the particle size distribution in a colloidal solution or suspension by analyzing fluctuations in the intensity of scattered light. Preferably, DLS uses a Malvern Mastersizer 3000. TM (Follow the manufacturer's manual).

[0056] Preferably, the carpet or carpet panel includes a pre-coating layer consisting of a pre-coating composition. The pre-coating composition preferably comprises:

[0057] (1) 2wt.%-87wt.%, preferably 3wt.%-80wt.%, more preferably about 4wt.%-60wt.%, even more preferably 5wt.%-50wt.%, and even more preferably 6wt.%-40wt.%, for example 15wt.%-35wt.% or about 20wt.%-30wt.% of resin, such as rosin or rosin derivatives;

[0058] (2) 0wt.%-20wt.%, such as 0wt.%-10wt.%, 0.2wt.%-10wt.%, 0.3wt.%-8wt.%, 0.4wt.%-6wt.%, 0.5wt.%-4wt.%, or 0.75wt.%-2.5wt.% thermoplastic elastomers; and

[0059] (3) 13wt.%-98wt.%, such as 20wt.%-95wt.%, 40wt.%-94wt.%, 50wt.%-93wt.%, 60wt.%-92wt.%, and about 65wt.%-85wt.% of fillers. The pre-coating composition is usually applied to the pre-coated topcoat.

[0060] The carpets produced can be classified according to EN1307-2014: Textile floor coverings – Classification. This European standard specifies the requirements for classifying all textile floor coverings and carpet tiles (excluding custom carpets and hallway carpets, see ISO 2424) into use categories based on one or more of the following properties: abrasion resistance, appearance retention, additional performance characteristics, and luxury level.

[0061] The present invention also relates to a method for preparing the carpet or carpet patch taught herein, the method comprising the following steps:

[0062] Prepare pre-coated compositions as taught herein;

[0063] A pre-coated composition is applied to a surface layer to prepare a pre-coated surface layer comprising a top surface containing yarns or fibers and a back surface comprising a pre-coated layer; and

[0064] Apply the backing composition to the pre-coating.

[0065] Optionally, other layers may be added before, during, or after the application of the backing composition, including but not limited to fiberglass mat, fiberglass mesh, foam layer, nonwoven cover mat, etc.

[0066] This invention also relates to the pre-coating compositions taught herein. Preferably, the solids content of the pre-coating composition is at least 40 wt.%, 50 wt.%, 60 wt.%, 70 wt.%, 80 wt.%, 90 wt.%, or 95 wt.%. Solids content refers to the proportion of non-volatile materials in the pre-coating composition, which can be determined after evaporation of any volatile solvent. The pre-coating compositions taught herein can be prepared by mixing the individual components of the pre-coating composition in a molten state. This is typically done at elevated temperatures, such as between 120°C and 200°C. The pre-coating composition can then be shaped into a sheet structure using any method known in the art, and then applied to the back of a top layer to form a pre-coating layer. A backing layer can then be applied to the pre-coating layer. Fiberglass mat or sparse fabric can be introduced into the backing layer using any method known in the art to ensure dimensional stability. Two or more backing layers can be applied, for example to allow the addition of another layer, such as a foam layer, fiberglass mat, or fiberglass sparse mesh, between the two or more backing layers. A covering felt, such as polypropylene nonwoven fabric, can be added to the outer surface of the backing layer to prevent it from sticking to or staining the floor.

[0067] The weight percentages disclosed herein are preferably determined based on dry weight (i.e., moisture content of up to 1 wt.%, 2 wt.%, 3 wt.%, 4 wt.%, 5 wt.%, 6 wt.%, 7 wt.%, 8 wt.%, 9 wt.%, 10 wt.%) and / or based on the weight of each product, component and / or (pre-coated) layer after being kept at 70 degrees Celsius for 2 hours. Attached Figure Description

[0068] Figure 1 A graph showing the particle size distribution for each composition listed in Table 2 is provided.

[0069] Figure 2 The tufting locking force value is provided for a given rosin ester / filler ratio.

[0070] Example

[0071] The present invention will be further illustrated by the following embodiments.

[0072] Measurement methods

[0073] Particle size

[0074] The particle size of the limestone filler was measured using a Malvern Mastersizer 3000 via dynamic light scattering (DLS).

[0075] Tufted locking force

[0076] Tufting hold-up is measured according to NEN-EN-ISO 4919 standard by attaching hooks to individual loop piles of the carpet. The force (in kg) required to pull the loop pile out of the carpet is then measured.

[0077] Composition

[0078] The following pre-coating compositions were prepared:

[0079] Table 1. Pre-coating compositions

[0080]

[0081] Mix the components in a propeller mixer at room temperature.

[0082] The pre-coated composition is then molded and applied to the top layer at approximately 160°C. A backing layer is also applied. In this case, a tufted loop pile carpet is used. Fiberglass felt or loosely woven fabric is incorporated into the backing layer to ensure dimensional stability. A cover felt is added to the outer surface of the backing layer to prevent adhesion or staining of the floor. Finally, the carpet is cut into carpet pieces.

[0083] The tufting locking force of carpet tiles produced similarly with each composition was measured, and it was found that the tufting locking force of carpet tiles produced with pre-coated composition B was significantly improved compared with that of carpet tiles produced with pre-coated composition A.

[0084] filler particle size

[0085] The fillers used are classified to obtain different particle size classifications.

[0086] like Figure 1 The filler particle size classification shown is determined by DLS and used to formulate the pre-coated composition according to composition B.

[0087] The particle size of the filler and the measured tufting locking force of each composition B applied to the carpet block as described above are shown in Table 2 below.

[0088] Table 2. Packing Particle Size Classification

[0089]

[0090] Surprisingly, it was found that the particle size of the filler affected the measured tufting locking force, with grades 3 and 5, i.e., when approximately half of the filler had a particle size of about 10µm–200µm or more specifically 20µm–100µm by volume fraction, yielded the best results. Optimal results were obtained when approximately half of the filler had a particle size of 30µm–60µm by volume fraction (grade 3).

[0091] Ratio of rosin ester to filler

[0092] A pre-coating composition was prepared according to composition B, but with a different ratio of rosin ester to filler.

[0093] The rosin ester to filler ratio was studied in the range of approximately 10 wt.% polymer / 86 wt.% filler to 43 wt.% polymer / 54 wt.% filler. The formulated pre-coat was applied to carpet blocks as described above, and the tufting hold-in was measured. Results are shown below. Figure 2 All proportions provided sufficient tufting retention, meaning that a higher proportion of rosin ester resulted in a better tufting retention.

[0094] The use of bio-based materials reduces the impact of carpet pre-coating on global warming. The carbon present in natural resins is insulated from CO2 in the air. When the product is incinerated, it can potentially be converted into energy through waste-to-energy applications, and the absorbed CO2 is then released back into the air without producing additional CO2.

Claims

1. A carpet or carpet panel comprising a woven surface layer, a pre-coating layer, and a backing layer, wherein the pre-coating layer comprises a pre-coating composition, wherein, based on the total weight of the composition, the pre-coating composition comprises: Esterified rosin ranging from 2 wt.% to 95 wt.%; 0wt.%-20wt.% thermoplastic elastomer; as well as 5wt.%-98wt.% of filler, Wherein, based on the total volume of the packing, at least 50 vol.% of the packing is in the form of particles having a particle size of 30 µm-60 µm as determined by dynamic light scattering (DLS).

2. The carpet or carpet block according to claim 1, wherein the pre-coating composition comprises 5 wt.%-50 wt.%, preferably 15 wt.%-35 wt.% of esterified rosin.

3. The carpet or carpet block according to any one of the preceding claims, wherein the pre-coated composition comprises up to 10 wt.%, preferably 0 wt.%, of a thermoplastic elastomer.

4. The carpet or carpet block according to any one of the preceding claims, wherein the thermoplastic elastomer is selected from copolymers of ethylene and vinyl acetate, styrene block copolymers, polyolefins, and polyhydroxyalkanoates.

5. The carpet or carpet block according to any one of the preceding claims, wherein the thermoplastic elastomer is a water-soluble polymer.

6. The carpet or carpet block according to any one of the preceding claims, wherein the pre-coating and / or the pre-coating composition does not contain polyolefin, or comprises at most 10 wt.%, 5 wt.%, 2 wt.%, or 1 wt.% polyolefin relative to the total weight of the pre-coating and / or the pre-coating composition.

7. The carpet or carpet block according to any one of the preceding claims, wherein the pre-coated composition comprises 50 wt.% to 95 wt.%, preferably 65 wt.% to 85 wt.% of filler.

8. The carpet or carpet block according to any one of the preceding claims, wherein the filler is selected from: Inorganic fillers, such as calcium carbonate (limestone), silicates, silicon dioxide, silicon oxides, carbonates, sulfates, antimony oxide, alumina trihydrate, carbon black, talc, clay, and kaolin. Organic fillers, such as sawdust, wood flour, nut shell powder, plant materials, plant fibers, plant shells and plant residues, and Recycle materials, such as recycled rubber, recycled plastics, and recycled fibers.

9. The carpet or carpet block according to any one of the preceding claims, wherein the filler is selected from calcium carbonate, magnesium oxide, aluminum hydroxide, and silicon hydroxide.

10. The carpet or carpet block according to any one of the preceding claims, wherein the filler does not include glass, or comprises up to 10 wt.%, 5 wt.%, or 1 wt.% glass relative to the total weight of the filler.

11. A method for preparing a carpet or carpet block according to any one of claims 1-10, the method comprising the following steps: Prepare a pre-coating composition as defined in any one of claims 1-10; The pre-coating composition is applied to a surface layer to prepare a pre-coated surface layer comprising a top surface containing yarns or fibers and a back surface comprising a pre-coated layer; and The backing composition is applied to the pre-coating.

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