Surface coverings including carbon sequestering materials and making methods

Abstract

To provide floor coverings, such as modular panels or tiles, for installation on interior surfaces engineered to reduce, eliminate, and / or preferably render negative the carbon footprint of the product as measured by a Life Cycle Assessment.SOLUTION: There is provided a floor covering comprising an upper wear layer and a backing compound, wherein the backing compound comprises a binder and at least one filler, wherein the at least one filler comprises concentrated carbon.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] This application claims priority to U.S. Provisional Patent Application No. 62 / 790,349, filed on Jan. 9, 2019, and U.S. Provisional Patent Application No. 62 / 791,162, filed on Jan. 11, 2019, the entire contents of each of which are hereby incorporated by reference in their entirety.

[0002] Embodiments of the present invention relate to surface coverings, such as floor coverings, and in particular to carpet tiles and other modular panels or tiles, which are specifically designed to reduce, eliminate, and / or preferably make negative the carbon footprint of a product as measured by life cycle assessment.

Background Art

[0003] Floor coverings typically include at least an exposed upper wear layer and a backing layer beneath the wear layer. Carpet tiles are typically formed by tufting yarns onto a primary substrate and coating the underside of the substrate with an adhesive material (often referred to as a “precoat”) to secure the yarns to the primary substrate, having an upper wear layer. In this application, the term “face cloth” refers to the tufted primary substrate before precoat application (i.e., lacking the precoat), and the term “half cloth” refers to the tufted primary substrate having the precoat (i.e., the yarn / primary substrate / precoat composite). The half cloth is then attached to a stabilizing structure backing composite to form a carpet web. The carpet web is then cut into carpet tiles of the desired shape and size.

[0004] Figures 1 and 2 are cross-sectional views showing examples 10, 11 of traditional carpet tile structures. Carpet tile structures 10, 11 include yarns 17 that are tufted onto a tufting primary 19 (also called a primary backing) to form a face cloth 14. In addition to being tufted, the half cloth of the carpet tile may also be woven, non-woven (e.g., needle punched or needle felted), heat fused, etc. An adhesive or precoat layer 22 is disposed on the lower surface of the face cloth 14 to secure the yarns 17 to the tufting primary 19, thereby forming a half cloth.

[0005] Backing composites 12, 21 are provided under the half cloth. The backing composite imparts flatness, dimensional stability, rigidity, and weight to the modular tile, thereby minimizing or eliminating the need for an adhesive to adhere the tile to the floor. The backing composite of a broadloom carpet typically consists of a latex coating (in addition to any latex precoat layer) and a textile substrate such as a woven fabric. Compared to a broadloom carpet, the backing composite of a modular tile usually has to be heavier in order to ensure the performance and durability of the product, for example, so that it can withstand heavy wear without deterioration. Thus, the backing composite of a carpet tile typically includes a polymeric coating or sheet, optionally containing glass beads or a glass scrim for dimensional stability, and / or a lower substrate (often a cloth such as a non-woven fleece) is optionally installed on the lower surface of the tile.

[0006] Figure 1 shows a carpet tile structure 10 having a backing composite 12 with a polymer sheet 18 (not including an embedded fiberglass layer) and a cloth 24 on the lower surface of the tile structure. Figure 2 shows a carpet tile structure 11 including a backing composite 21 having two polymer sheets 18, 20 and a fiberglass layer 16 sandwiched between the backing sheets 18, 20. Carpet tile structure 11 does not include an underlying cloth, similar to carpet tile structure 10.

[0007] A product's carbon footprint is a measure of all greenhouse gases (GHGs) removed from or emitted to the atmosphere during a product's life cycle (e.g., production, use, and disposal). The carbon footprint, also called the total global warming potential (GWP) emissions, is measured in kilograms of carbon dioxide equivalent (kg CO2eq / m 2 ) per square meter. In the determination of GWP emissions, GHGs other than CO2 are converted to CO2 equivalents based on their radiative forcing effects over a 100-year period. A negative total GWP indicates that more GHGs are removed from the atmosphere than are emitted to the atmosphere during the product's life cycle.

[0008] Total GWP emissions can be measured using life cycle assessment (also called life cycle analysis), as described in the ISO 14000 series of environmental management standards. According to these standards, life cycle assessment (LCA) is a technique for evaluating the environmental impact of a product or service by quantifying all inputs and outputs of material flows and assessing how these material flows affect the environment. An LCA for a product is carried out for the entire life cycle of the product; however, the life cycle of a product can be broken down into multiple stages. The stage from raw materials to production is called "cradle-to-gate," and the post-sale stage, including customer use and end-of-life, is called "gate-to-grave" (or "gate-to-end-of-life"). If a product is recycled, the post-sale stage can be called gate-to-cradle.

[0009] An Environmental Product Declaration (EPD) is a third-party verified (certified) report issued by product manufacturers that provides information on the environmental performance of those products. An EPD essentially reports the results of an LCA performed on the product. Specifically, an EPD for a product will report the GWP for each stage of the product's life cycle and the total GWP for the entire life cycle, as determined by the issued standards and defined methodology. The LCA is carried out in accordance with ISO 14040 - ISO 14049 (Part 2, Edition of July 1, 2006), the entirety of which is incorporated herein by reference. These standards include, but are not limited to, ISO 14044: Environmental management - Life cycle assessment - Requirements and guidelines (Part 1, Edition of July 1, 2006), the entirety of which is incorporated herein by reference. The relevant standard for EPDs is ISO 14025: Environmental labels and declarations - Type III environmental declarations - Principles and procedures (Part 1, Edition of July 1, 2006), the entirety of which is incorporated herein by reference.

[0010] ISO standards do not include a rigorous methodology for performing an LCA and calculating GWP, but there are several recognized characterization factors, including the CML-IA August 2006 Characterization Factor for Global Warming Potential, used in Europe, and the Tool for Reduction and Assessment of Chemicals and Other Environmental Impacts ("TRACI"), developed by the US EPA.

[0011] TRACI provides a standard methodology for characterizing and calculating the contribution of a product to GWP. Different recognized methodologies typically give the same or very similar results, but in this application, all GWPs reported herein are calculated (or estimated) using the methodology TRACI 2.1 Global Warming Potential, including biogenic and land use change (LUC). Negative GWP values indicate a negative carbon footprint.

[0012] Embodiments of the present invention are directed to improving the "cradle-to-gate" carbon footprint of a product (i.e., reducing the carbon footprint based on the production of the product). Thus, in this application, unless otherwise specifically specified, all references to carbon footprint or GWP refer to the cradle-to-gate Global Warming Potential, and "cradle-to-gate" is defined, for example, in the standard NEN-EN 15804:2012 Sustainability of construction works - Environmental Product Declarations - Core rules for the product category of construction products. Further, all references to carbon neutrality and carbon negativity respectively mean that the GWP is zero (carbon neutral) or negative (carbon negative) at the cradle-to-gate stage.

[0013] Cradle-to-gate LCA considers all inputs and outputs of GHGs from all aspects of product production, including extraction of raw materials, conversion of feedstocks to chemicals, transportation of materials to the factory, energy involved in product assembly, packaging, and waste and disposal of the product. Thus, the type of materials used in a product, as well as the quantity and weight of such materials, all contribute to the carbon footprint of the product.

[0014] As an example, for carpet tiles, the yarn type, yarn size, fiber / yarn density, tufting primary material, tufting primary weight, and the formulation and amount of the precoat material all contribute to the carbon footprint of the half-cross. Additionally, the backing composite and each of its components also contribute to the carbon footprint of the carpet tile. In modular floor coverings such as carpet tiles, the backing formulations commonly used to form the backing composite are based on fossil fuels and include, for example, bitumen made from fossil fuels, polyvinyl chloride (PVC), or polyolefins. Although fossil fuels continue to be formed through natural processes, they are generally considered non-renewable resources because they take millions of years to form, and the known sustainable reserves are being depleted much faster than they can be newly produced. The use of fossil fuels also raises potential environmental concerns because they form carbon dioxide, a well-known greenhouse gas, upon combustion.

Summary of the Invention

Problems to be Solved by the Invention

[0015] There is a need for floor coverings that require less fossil fuel and / or have a lower level of greenhouse gas emissions. Additionally, or alternatively, there is a need for floor coverings that utilize more bio-based materials and / or are more environmentally sustainable, i.e., have a smaller environmental impact and / or are more rapidly renewable. Additionally, or alternatively, there is a need for floor coverings that are at least partially or fully bio-based and can be produced economically.

Means for Solving the Problems

[0016] Disclosed herein is a surface coating, such as a floor covering, comprising one or more layers, such as a top wear layer and a backing layer. The backing layer may be a backing composite comprising a backing formulation and one or more substrates. In some embodiments, at least one of the layers in the product is designed to be carbon negative when measured by life cycle assessment. In some embodiments, the product as a whole is carbon negative when measured by life cycle assessment. In some embodiments, carbon negativity is achieved, at least in part, by including a filler comprising concentrated carbon in the product.

[0017] A further understanding of the nature and advantages of various embodiments can be realized by reference to the following drawings. In the accompanying drawings, like components or features may have the same reference designations.

Brief Description of the Drawings

[0018]

Figure 1

[0019]

Figure 2

Modes for Carrying Out the Invention

[0020] Embodiments of the present invention relate to multi-layer surface coatings, including floor coverings, for installation on indoor surfaces, such as, but not limited to, modular panels or tiles. More specifically, embodiments of the present invention relate to the formulation and component changes for various components of a floor covering that result in a product having a reduced, zero, and / or negative carbon footprint, either alone or collectively, when subjected to life cycle assessment.

[0021] In some embodiments, the surface coatings described herein have a reduced carbon footprint through the use of natural, bio-based, or recycled materials instead of conventional man-made materials. As used herein, "bio-based" refers to organic materials that occur naturally, or materials intentionally made from substances derived from existing and / or post-Common Era (CE) organisms, as opposed to non-renewable fossil fuels made from prehistoric organisms.

[0022] The 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 non-uniform formulations with inconsistent characteristics, producing products that do not meet the desired performance specifications. However, in the embodiments described herein, the surface coating comprises one or more components that are formed, in whole or in part, from a substantially uniform mixture of man-made materials with natural, bio-based, and / or recycled materials, such as a precoat or backing formulation. In other examples, one or more other components of the surface coating comprise natural, bio-based, or recycled materials. In still other examples, precise manufacturing can reduce the materials overall and reduce the carbon footprint of the product without degrading performance.

[0023] The embodiments described herein provide a carbon neutral or carbon negative surface coating. It should be noted that it is not necessary for all layers or components in the product to be carbon neutral or carbon negative. Rather, the product is designed such that the product can have a net neutral, and preferably a net negative, carbon footprint overall. To accomplish this, various layers are designed to be carbon negative and can offset other carbon positive layers in the product. For example, a backing layer can be carbon negative and offset a half cross with a positive carbon footprint. Alternatively, the half cross of a carpet tile can be carbon negative and offset a backing layer with a positive carbon footprint. Additionally, each discrete layer of the product can be carbon neutral or carbon negative.

[0024] The embodiments described herein include coating formulations (e.g., precoat formulations and backing formulations) that include a high-purity biochar, referred to herein as concentrated carbon.

[0025] As used herein, “biochar” refers to a solid material produced by the pyrolysis (i.e., direct thermal decomposition) of biomass in the absence of oxygen. The pyrolysis of biomass produces a mixture of a solid (biochar), a liquid (bio-oil), and a gas (biogas). Biomass includes any organic material derived from plants or animals, such as wood and wood processing waste, agricultural crops and waste materials, landscaping waste, and animal waste. Biochar can be produced at a pyrolysis temperature of at least 350° C., optionally at least 400° C., at least 600° C., at least 800° C., from 350° C. to 1000° C. inclusive; from 400° C. to 1000° C. inclusive; from 600° C. to 1000° C. inclusive; from 800° C. to 1000° C. inclusive.

[0026] As used herein, "concentrated carbon" refers to biochar having a carbon content of at least 80 wt% as defined herein. As used herein, "carbon content" refers to the percentage by mass of atomic carbon in biochar.

[0027] In some examples, concentrated carbon is a designed material intentionally produced under specified control conditions that has been proven to reliably produce a substance with certain unique properties from a compositional and manufacturing process perspective. In some examples, concentrated carbon is formed in a process driven by renewable gas energy and syngas generated during heating when ligno-cellulosic waste and / or other rapidly renewable plants and husk materials are exposed to high heat under low oxygen conditions. In this process, a material is produced that is carbon-rich, lightweight, blendable, and traps carbon that would otherwise escape to the atmosphere.

[0028] The concentrated carbon described herein can be formed by pyrolyzing biomass at a very high temperature in an oxygen-limited environment. The weight percent of carbon and the concentration of impurities in the concentrated carbon are affected by several factors, including the type of biomass, the carbon content of the biomass, and the pyrolysis conditions.

[0029] Useful sources of biomass for producing the concentrated carbon described herein include any material that is sustainable, rapidly renewable, and has a minimal heavy metal content. In some examples, useful sources of biomass include grass, seaweed, other microbial masses, leaves, bark materials, beans, pods, mangroves, wood waste, and nut shells. In other examples, useful sources of biomass include agricultural waste 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% (weight / weight). In some examples, the pyrolysis temperature is at least 350 °C, at least 400 °C, at least 600 °C, at least 800 °C, including both ends, 350 °C to 1000 °C; including both ends, 400 °C to 1000 °C; including both ends, 600 °C to 1000 °C; or including both ends, 800 °C to 1000 °C. Generally, at higher pyrolysis temperatures, the amount of volatile impurities in the final product is reduced, providing a purer concentrated carbon. Optionally, in the pyrolysis process, it may be fuel-supplied by the combustion of the syngas generated during the process or by auxiliary renewable energy. In some examples, pyrolysis reforms the chemical bonds of the biomass to produce a graphene complex present in the concentrated carbon.

[0030] The concentrated carbon described herein has an H / C org molar ratio 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 0.45. The concentrated carbon described herein has an O / C org molar ratio of less than 0.4, less than 0.35, less than 0.3, less than 0.35, or less than 0.2. 40%, at least 50%, at least 60%, or at least 70%. Optionally, the concentrated carbon described herein has a pH of from about 6.5 to about 10.5, including both ends; from about 7 to about 10.5, including both ends; from about 8 to about 10, including both ends; or from about 9 to about 10, including both ends.

[0031] The surface coatings described herein may typically (but not always) be floor coverings that include a top wear layer and a backing layer, where the backing layer may be a backing composite that includes a backing formulation and at least one substrate.

[0032] Top wear layer The top wear layer of the floor covering can include any conventional or specialty material used for floor coverings. The material for the top wear layer may be selected such that the resulting floor covering exhibits desired characteristics, such as, but not limited to, a decorative appearance, favorable acoustic attributes, good insulation (e.g., good R-value), water resistance, fire resistance, etc. In some examples, the floor coverings described herein are sheets or tiles, including, but not limited to, performance broadloom carpet or carpet tiles, luxury vinyl sheet or tiles, or rubber sheet or tiles. Embodiments of the present invention will be described with specific reference to carpet tiles (e.g., those having the structures shown in FIGS. 1 and 2), but it should be understood by those skilled in the art that the disclosure described herein can be implemented or adapted in other types of surface coatings and in suitable and appropriate applications.

[0033] Some embodiments of the present invention include selecting or varying the type and / or amount of material used in the top wear layer (e.g., the half cross in a carpet tile) to reduce the carbon footprint of the top wear layer and the carbon footprint of the entire tile. For example, in a carpet tile, the yarn size, the yarn tuft height, and the stitch density (e.g., the number of yarn tufts per square inch) all affect the areal weight of the yarn, which in turn affects the carbon footprint of the half cross. "Areal weight" refers to the weight of the yarn used in the half cross. Each of the yarn size, tuft height, and stitch density can be manipulated to adjust the carbon footprint of the half cross.

[0034] More specifically, it has been found that smaller sized yarns can be used without sacrificing the aesthetics of the tufted product. Rather, the smaller sized yarns can be tufted at a smaller tuft height but with a greater tuft density or stitch density (i.e., more tufts per square inch). According to this, less yarn is used overall and has a smaller surface weight of the yarn without sacrificing aesthetics. Further, by using smaller yarns, more tufts can be placed within a given area and a more delicate and precise tuft pattern can be created. Even though the tuft height becomes smaller as the density of the tufts increases, the visibility of the tufting primary (a problem known as greening) is also prevented.

[0035] Yarn size: Some embodiments of the present invention use yarns having a denier of less than 2000, for example, but not limited to, 800 - 1800 including both ends; 900 - 1600 including both ends; 1000 - 1500 including both ends; 1000 - 1400 including both ends; 1000 - 1200 including both ends, and / or 1200 - 1800 including both ends. In some embodiments, the yarn has a denier of 1200. The yarn may be single ply or multi ply. By way of example only, a 1200 denier end yarn can be formed by a single 1200 denier yarn, by a two ply of 600 denier yarns, or by a three ply of 400 denier yarns, etc.

[0036] Tuft height: Some embodiments of the half cross disclosed herein have a yarn tuft with a tuft height of 1 / 32 inch to 6 / 32 inch (0.794 mm to 4.76 mm) including both ends; 2 / 32 inch to 5 / 32 inch (1.59 mm to 3.97 mm) including both ends; 2 / 32 inch to 4 / 32 inch (1.59 mm to 3.175 mm) including both ends; and / or 2 / 32 inch to 3 / 32 inch (1.59 mm to 2.38 mm) including both ends. The half cross may be tufted using any tufting machine, but 1 / 10 and 1 / 12 gauge machines (e.g., those available from Tuftco Corporation and Card Monroe Corporation, both Chattanooga, Tennessee) may be particularly suitable.

[0037] Tuft density: Some embodiments of the half cross disclosed herein have a yarn tuft with a tuft density of 100 to 400 tufts per square inch (「TPI」) including both ends; 110 to 400 TPI including both ends; 140 to 300 TPI including both ends; 160 to 280 TPI including both ends; 170 to 270 TPI including both ends; 170 to 260 TPI including both ends; 180 to 250 TPI including both ends; and / or 180 to 240 TPI including both ends.

[0038] Areal weight: The areal weight of the yarn in the half cross of traditional carpet tiles is at least 20 ounces per square yard (「osy」). The areal weight of the yarn in some embodiments of the half cross described herein is significantly smaller, for example, in the range of 5 to 20 osy including both ends; 6 to 18 osy including both ends; 8 to 17 osy including both ends; 10 to 15 osy including both ends; 6 to 12 osy including both ends; 12 to 18 osy including both ends; and / or 9 to 12 osy including both ends. In some embodiments, the areal weight of the yarn is approximately 5 osy, 6 osy, 7 osy, 8 osy, 9 osy, 10 osy, 11 osy, 12 osy, 13 osy, 14 osy, 15 osy, 16 osy, 17 osy, 18 osy, 19 osy, or 20 osy.

[0039] Yarn material: The material from which the yarn is made can be selected to contribute to the reduction of the carbon footprint. For example, yarns made from natural, bio-based, or recycled materials will provide a lower contribution to the half-cross GWP than yarns made from non-renewable, fossil fuel-based resources. The yarn can be made from any type of fiber material including, but not limited to, nylon (nylon 6 or nylon 6,6), polyester, polypropylene, PET (polyethylene terephthalate), PTT (polytrimethylene terephthalate), PBT (polybutylene terephthalate), PLA (polylactic acid), hemp, wool, cellulose-based materials, and other fibers. In some examples, the yarn is a post-consumer ("PC") or post-industrial ("PI") recycled material, for example, PC or PI recycled nylon, or PC or PI polyethylene terephthalate. Other suitable yarn materials are disclosed in WO2011 / 066620, which is hereby incorporated by reference in its entirety.

[0040] Tufting primary: The tufting primary can be any woven or non-woven material including, but not limited to, polypropylene, polyester, recycled polyester, polylactic acid, nylon, and jute. Traditional tufting primaries typically have a weight of 3 - 4 osy.

[0041] All of the above factors can be selected and manipulated to reduce, and even make neutral or negative, the carbon footprint of the face cloth. Table 1 compares a conventional face cloth construction with an embodiment of the face cloth of the present invention contemplated herein, based on the materials, by their respective associated carbon footprints.

Table 1

[0042] Furthermore, the reduction in the carbon footprint of the half cross is achieved without sacrificing performance. More specifically, surprisingly, carpet tiles including the half cross embodiments disclosed herein comply with the grading levels described in ASTM D7330-2015: Standard Test Method for Assessment of Surface Appearance Change in Pile Floor Coverings Using Standard Reference Scales (2015 edition), which is hereby incorporated by reference in its entirety, and when subjected to the test method described in ASTM D5252-2015: Standard Practice for the Operation of the Hexapod Tumble Drum Tester (2015 edition), which is hereby incorporated by reference in its entirety, it has been found that a strict wear rating (i.e., a rating of 3.5 or higher) can be achieved.

[0043] In accordance with ASTM D5252, to test for abrasion, cut a section of the finished carpet tile and fit it around the inside of a drum that is attached to a rotating device. Place a pod with six feet of a specified weight inside the drum. As used herein, a pod is a mechanical foot simulator. Rotate the drum by the rotating device for a specified number of revolutions, then remove the section of the carpet tile and inspect and grade the overall appearance of the carpet tile. ASTM D7330 describes a grading scale to indicate how well the carpet “withstood” under the test, and the inspector considers factors such as pile crushing, fuzz balls, and thread breakage in grading the carpet. More specifically, ASTM D7330 includes a Texture Appearance Retention Rating (TARR) to grade changes in the tile appearance. A TARR rating of 5 indicates no change in the appearance of the half-cross after the test, and a TARR rating of 1 indicates a very severe change in the appearance of the half-cross after the test. Some embodiments of the carpet tile having a half-cross disclosed herein achieve a TARR rating in accordance with ASTM D7330 of 2.5 or greater, 3.0 or greater, and / or 3.5 or greater when tested in accordance with ASTM D7330. A TARR rating of 3.5 or greater indicates that the tile is suitable for use under the most severe traffic conditions.

[0044] Carpet tiles incorporating embodiments of the half cross disclosed herein also comply with the Vetterman drum test method described in BS ISO 10361:2015 - Textile floor coverings - Production of changes in appearance by means of Vettermann drum and hexapod tumbler tester (which is hereby incorporated by reference in its entirety), and when the tiles are subjected to performance grading in accordance with BS EN ISO 9405:2017 - Textile Floor coverings - Assessment of Changes in Appearance (which is hereby incorporated by reference in its entirety), they may meet the requirements for classification 33: heavy commercial use classification as defined in BS EN 1307:2014 - Textile Floor Coverings - Classification (which is hereby incorporated by reference in its entirety).

[0045] Precoat layer: In a carpet tile, the precoat layer is used to adhere the yarn to the tufting primary layer. Typically, the precoat is applied as an aqueous emulsion of a precoat adhesive, optionally modified with fillers and various additives. In some examples, the carbon footprint of the precoat layer is manipulated and reduced by the selection of materials used as the precoat adhesive, fillers, and / or various additives.

[0046] Suitable precoat adhesives include, but are not limited to, any thermoplastic polymer, including hot melt, latex, ethylene vinyl acetate (EVA), acrylic, bitumen-based formulations, rubber formulations, or any combination of these materials. In some examples, the precoat adhesive includes thermoplastic materials derived from natural or recycled materials, including, but not limited to, starch or recycled polyvinyl butyral.

[0047] The precoat composition contemplated for the floor covering described herein is at a weight percent of about 15 wt% to about 100 wt% ( "weight / weight"), including both ends; about 20% to about 100% (weight / weight), including both ends; about 30% to about 100% (weight / weight), including both ends; about 40% to about 100% (weight / weight), including both ends; about 50% to about 100% (weight / weight), including both ends; about 15% to about 90% (weight / weight), including both ends; about 20% to about 90% (weight / weight), including both ends; about 30% to about 90% (weight / weight), including both ends; about 40% to about 90% (weight / weight), including both ends; about 50% to about 90% (weight / weight), including both ends; about 90% to about 100% (weight / weight), including both ends; about 90% to about 98% (weight / weight), including both ends; about 15% to about 90% (weight / weight), including both ends; about 20% to about 90% (weight / weight), including both ends; about 30% to about 90% (weight / weight), including both ends; about 40% to about 90% (weight / weight), including both ends; about 50% to about 90%, including both ends; about 15% to about 80% (weight / weight), including both ends; about 20% to about 80% (weight / weight), including both ends; about 30% to about 80% (weight / weight), including both ends; about 40% to about 80% (weight / weight), including both ends; about 50% to about 80% (weight / weight), including both ends; about 15% to about 70% (weight / weight), including both ends; about 20% to about 70% (weight / weight), including both ends; about 30% to about 70% (weight / weight), including both ends; about 40% to about 70% (weight / weight), including both ends; about 50% to about 70% (weight / weight), including both ends; about 15% to about 60% (weight / weight), including both ends; about 20% to about 60% (weight / weight), including both ends; about 30% to about 60% (weight / weight), including both ends; about 40% to about 60% (weight / weight), including both ends; about 50% to about 60% (weight / weight), including both ends; about 15% to about 50% (weight / weight), including both ends; about 20% to about 50% (weight / weight), including both ends; about 30% to about 50% (weight / weight), including both ends; or about 40% to about 50% (weight / weight), including both ends, and includes a precoat adhesive.

[0048] Fillers are often incorporated into precoat adhesives to add stiffness and weight, modify the characteristics of the flow, improve tuft bonding, impart desired characteristics such as flame resistance, and for economic advantages. Suitable fillers for precoats include any known organic or inorganic (e.g., mineral) filling materials. In some examples, the precoat filler can include natural, bio-based, or recycled filling materials that can contribute to reducing the carbon footprint of the precoat and ultimately the floor covering. Additionally, or alternatively, the precoat filler can include conventional filling materials. Useful precoat filling materials include fly ash; calcium oxide; calcium carbonate (e.g., limestone); silicates; silica; oxides of silica; carbonates; sulfates; antimony oxides; aluminum trihydrate; carbon black; talcum; clay; kaolin; wood (e.g., wood chips and wood flour); shells (e.g., shell flour); plant materials (e.g., plant fibers, plant husks, and plant residues); re-mined, post-industrial, or recycled organic or inorganic materials (e.g., calcium carbonate, talc, clay, minerals, rubber, plastics, or fibers), and biochar. In some embodiments, the filler includes high-purity biochar, herein referred to as concentrated carbon.

[0049] The precoat composition contemplated for floor covering described herein contains a filler at a weight percentage of from about 0% to about 85% (weight / weight), including both ends; from about 0% to about 80% (weight / weight), including both ends; from about 0% to about 70% (weight / weight), including both ends; from about 0% to about 60% (weight / weight), including both ends; from about 0% to about 50% (weight / weight), including both ends; from about 10% to about 85% (weight / weight), including both ends; from about 10% to about 80% (weight / weight), including both ends; from about 10% to about 70% (weight / weight), including both ends; from about 10% to about 60% (weight / weight), including both ends; from about 10% to about 50% (weight / weight), including both ends; from about 0% to about 10% (weight / weight), including both ends; from about 2% to about 10% (weight / weight), including both ends; from about 20% to about 85% (weight / weight), including both ends; from about 20% to about 80% (weight / weight), including both ends; from about 20% to about 70% (weight / weight), including both ends; from about 20% to about 60% (weight / weight), including both ends; from about 20% to about 50% (weight / weight), including both ends; from about 30% to about 85% (weight / weight), including both ends; from about 30% to about 80% (weight / weight), including both ends; from about 30% to about 70% (weight / weight), including both ends; from about 30% to about 60% (weight / weight), including both ends; from about 30% to about 50% (weight / weight), including both ends; from about 40% to about 85% (weight / weight), including both ends; from about 40% to about 80% (weight / weight), including both ends; from about 40% to about 70% (weight / weight), including both ends; from about 40% to about 60% (weight / weight), including both ends; from about 40% to about 50% (weight / weight), including both ends; from about 50% to about 85% (weight / weight), including both ends; from about 50% to about 80% (weight / weight), including both ends; from about 50% to about 70% (weight / weight), including both ends; or from about 50% to about 60% (weight / weight), including both ends. In some embodiments, the precoat composition does not contain a filler.

[0050] The precoat formulation can also contain various processing aids and additives, such as, but not limited to, antistatic agents, antibacterial agents, anti-chigger agents, and flame retardants. Suitable bio-based additives include, but are not limited to, lecithin and permethrin.

[0051] Conventional precoats rely on high-quality precoat materials to encapsulate and adhere the yarns. The embodiments described herein use precoat materials with reduced mass to reduce the carbon footprint of the precoat and reduce the contribution of the resulting precoat to the carbon footprint of the floor covering. In some examples, the mass of the precoat is reduced by reducing the amount of filler added to the precoat adhesive. In some embodiments, the precoat adhesive lacks any filler. The reduction or elimination of the filler also results in a more concentrated adhesive, requiring a smaller amount for application. In some examples, by precisely applying the precoat to the tufting primary, the mass of the precoat can be further reduced while maintaining performance. For example, conventional precoats have a weight of about 18 osy to about 32 osy, but in some examples described herein, the amount of precoat used is reduced to about 5 osy to about 20 osy, inclusive; about 7 osy to about 18 osy, inclusive; about 7 osy to about 12 osy, inclusive; or about 12 osy to about 18 osy, inclusive. In some embodiments, the amount of precoat used is reduced to less than 20 osy, 18 osy, 16 osy, 14 osy, 12 osy, 10 osy, and 8 osy.

[0052] Table 2 compares examples of conventional precoat compositions to examples of embodiments of the precoat compositions of the invention contemplated herein ("PC").

Table 2

[0053] A typical half cross of a carpet tile has a weight of approximately 50 osy (20 osy yarn, 4 osy tufting primary, and 26 osy precoat). By some or all of the changes proposed above, the weight of the half cross can be significantly reduced. In some embodiments, the half cross (yarn, tufting primary, and precoat) has a weight of 14 osy to 35 osy including both ends; 14 osy to 30 osy including both ends; 14 osy to 25 osy including both ends; 14 osy to 23 osy including both ends; 14 osy to 21 osy including both ends; 15 osy to 19 osy including both ends; or 16 osy to 18 osy including both ends.

[0054] Table 3 compares a conventional half cross construction with embodiments of the half cross of the present invention contemplated herein.

Table 3

[0055] 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 formulation and one or more optional substrates. Embodiments of the floor coverings described herein have a backing formulation comprising a binder and a filler. Examples of the filler include high-purity biochar, which is referred to herein as concentrated carbon. By including concentrated carbon as a filler in the backing formulation, the carbon footprint of the floor covering is dramatically reduced by sequestering carbon. The effect of using concentrated carbon with respect to the carbon footprint can be even more dramatic for floor coverings having a high filler content. For example, in modular floor coverings such as carpet tiles, the backing composite must be rigid so that the tiles can function as loose-laying floor tiles. Typically, the backing composites for modular floor coverings have a high filler content and contribute to the required dimensional stability.

[0056] In addition to being dimensionally stable, the backing formulations and optionally the backing composites described herein are flexible. This flexibility facilitates the installation of the floor coverings described herein. The flexible backing formulations or backing composites described herein yield and bend easily without breaking. The force required to bend the flexible backing formulations or backing composites described herein is small, and as an example, sufficient force can be applied manually without using machinery, for example, when installing a surface covering.

[0057] Filler: The backing formulations for floor coverings described herein include a filler that includes concentrated carbon, i.e., high-purity biochar having a carbon content of at least 80 wt% as defined above. 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 biochars contain 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 contains less than 60 parts per million (“ppm”) of PAHs and / or less than 25 ppm of heavy metals. For example, any concentrated carbon described herein can contain PAHs at a concentration of less than 60 ppm, less than 50 ppm, less than 40 ppm, or less than 30 ppm. In some examples, the concentrated carbon contains less than 7 ppm, less than 5 ppm, or less than 3 ppm of any individual PAH. As a further example, any concentrated carbon described herein can contain heavy metals at a concentration of less than 25 ppm, less than 20 ppm, less than 15 ppm, less than 10 ppm, or less than 5 ppm. In some examples, the concentrated carbon contains less than 3 ppm, less than 2 ppm, or less than 1 ppm of mercury or cadmium. In some examples, the concentrated carbon contains less than 15 ppm, less than 12 ppm, or less than 10 ppm of lead, chromium, or arsenic.

[0058] Any of the concentrated carbons described herein are suitable for use in the backing formulations described herein. Optionally, the concentrated carbon is produced by pyrolysis of a feedstock biomass having a carbon content of at least 50%, at least 60%, or at least 70% (weight / weight). Optionally, the biochar is produced by a pyrolysis process carried out at a temperature of at least 350°C, at least 400°C, at least 600°C, at least 800°C, including both ends, 350°C to 1000°C; including both ends, 400°C to 1000°C; including both ends, 600°C to 1000°C; or including both ends, 800°C to 1000°C.

[0059] The concentrated carbon in the backing formulation may be in the form of particles having a particle size of from about 0.01 μm to about 3 mm, including both ends; from about 0.01 μm to about 2.5 mm, including both ends; from about 0.01 μm to about 2 mm, including both ends; or from about 0.01 μm to about 1 mm, including both ends. In some embodiments, the average particle size of the concentrated carbon particles may be from about 80 μm to about 120 μm, including both ends. The particles may be separated or sized to produce the desired average size. At the time the concentrated carbon raw material is introduced into the backing formulation, it may have a particle size greater than about 3 mm. Typically, the size of the concentrated carbon particles decreases during the production of the backing formulation.

[0060] The filler content in the backing formulation described herein may be 100% concentrated carbon, but typically includes from about 0.1% to about 100% (weight / weight) concentrated carbon, including both ends. In some examples, the filler content may be at least 2% (weight / weight), at least 10% (weight / weight), at least 15% (weight / weight), at least 20% (weight / weight), at least 25% (weight / weight), at least 30% (weight / weight), at least 35% (weight / weight), at least 40% (weight / weight), at least 45% (weight / weight), at least 50% (weight / weight), at least 55% (weight / weight), at least 60% (weight / weight), at least 65% (weight / weight), at least 70% (weight / weight), at least 75% (weight / weight), at least 80% (weight / weight), at least 90% (weight / weight), at least 95% (weight / weight) concentrated carbon. In some examples, the filler content may be concentrated carbon at any weight percent from about 2% to about 98% (weight / weight), including both ends; from about 10% to about 70% (weight / weight), including both ends; from about 20% to about 55% (weight / weight), including both ends; or from about 30% to about 50% (weight / weight), including both ends. If the filler content is less than 100% concentrated carbon, the filler also includes one or more additional filler materials.

[0061] Any additional filler(s), if present, may be any known organic or inorganic (e.g., mineral) filler. In some examples, the additional filler can independently contribute to reducing the carbon footprint of the backing formulation and floor covering and is a natural, bio-based, or recycled filler. However, in other examples, the additional filler may be a conventional filler. Useful inorganic fillers include fly ash; calcium oxide; calcium carbonate (e.g., limestone); silicate; silica; oxides of silica; carbonate; sulfate; antimony oxides; aluminum trihydrate; carbon black; talcum; clay; kaolin; and reclaimed, post-industrial, or recycled forms thereof. Optionally, the additional filler is recycled limestone. Useful organic fillers include wood (e.g., wood chips and wood flour); shells (e.g., shell powder); plant materials (e.g., plant fibers, plant husks, and plant residues); and reclaimed, post-industrial, or recycled forms thereof. Optionally, the additional filler is a recycled material (e.g., recycled rubber, recycled plastic, or recycled fiber).

[0062] The filler (including concentrated carbon and any additional filler(s)) can have a particle size of from about 0.01 μm to about 1 mm, and the filler particles may be separated or sized to produce a desired average size. In some examples, fillers having these particle sizes can be combined with one or more other differently shaped fillers. Optionally, the inorganic filler can be combined with bio-based fillers and / or recycled fillers such as wood chips, natural fibers, plant husks, plant residues, synthetic fibers, glass fibers, recycled fibers, recycled rubber, recycled plastic, recycled minerals, and other recycled materials. Any combination of additional fillers that would provide the desired characteristics for incorporation into the backing formulations disclosed herein can be combined with the concentrated carbon disclosed herein.

[0063] The backing formulation includes a filler that includes concentrated carbon and any additional filler materials in any desired amount. In some examples, the backing formulations described herein include the filler at about 30% to about 95% (weight / weight), including both ends; about 40% to about 95% (weight / weight), including both ends; about 50% to about 95% (weight / weight), including both ends; about 60% to about 94% (weight / weight), including both ends; about 70% to about 92% (weight / weight), including both ends; about 75% to about 90% (weight / weight), including both ends; about 75% to about 88% (weight / weight), including both ends; or about 77% to about 86% (weight / weight), including both ends; about 40% to about 70% (weight / weight), including both ends; about 45% to about 70% (weight / weight), including both ends; about 45% to about 65% (weight / weight), including both ends; and about 50% to about 65% by weight, including both ends.

[0064] In some embodiments, the backing formulations described herein include concentrated carbon at about 0.1% to about 70% (weight / weight), including both ends; about 0.5% to about 65% (weight / weight), including both ends; about 1% to about 65% (weight / weight), including both ends; about 1% to about 60% (weight / weight), including both ends; about 10% to about 60% (weight / weight), including both ends; about 10% to about 55% (weight / weight), including both ends; about 10% to about 50% (weight / weight), including both ends; about 15% to about 60% (weight / weight), including both ends; about 20% to about 60% (weight / weight), including both ends; about 20% to about 50% (weight / weight), including both ends; about 25% to about 55% (weight / weight), including both ends; about 30% to about 50% (weight / weight), including both ends; about 1% to about 15% (weight / weight), including both ends; about 1% to about 10% (weight / weight), including both ends; about 1% to about 5% (weight / weight), including both ends; about 5% to about 15% (weight / weight), including both ends; about 5% to about 10% (weight / weight), including both ends; about 10% to about 15% (weight / weight), including both ends; about 15% to about 50% (weight / weight), including both ends; about 15% to about 40% (weight / weight), including both ends; about 20% to about 40% (weight / weight), including both ends; about 25% to about 35% (weight / weight), including both ends; or about 30% to 40% by weight, including both ends.

[0065] Binder: In addition to the filler, the backing formulations described herein further include a binder that imparts structure to the backing system. The binder includes at least one of a bio-based ester, a bio-based oil, or a polymer, and may optionally include additives that facilitate the production of the backing formulation or impart desired characteristics to the finished backing formulation. In some embodiments, the binder includes one or more bio-based esters, one or more bio-based oils, and one or more polymers, while in other embodiments, the binder does not include all three components.

[0066] The binder may be present in the backing formulations described herein at a weight percent of from about 5% to about 70% (weight / weight), inclusive; from about 5% to about 60% (weight / weight), inclusive; from about 5% to about 50% (weight / weight), inclusive; from about 6% to about 40% (weight / weight), inclusive; from about 8% to about 30% (weight / weight), inclusive; from about 10% to about 25% (weight / weight), inclusive; from about 12% to about 25% (weight / weight), inclusive; or from about 14% to about 23% (weight / weight), inclusive. In some examples, the binder portion of the backing formulation includes at least about 40% (weight / weight) bio-based and / or recycled materials, 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% (weight / weight) bio-based and / or recycled materials, or the binder content may be 100% bio-based or recycled materials.

[0067] Bio-based esters useful in the backing formulations are typically in solid form at room temperature. They may have a melting point between about 65°C and about 160°C (e.g., between about 80°C and 120°C), such that they can be handled at room temperature while the mixing and coating processes can be carried out at a suitable processing temperature.

[0068] The bio-based ester used in the backing formulation described herein may be rosin or a rosin derivative. Rosin is a natural resin obtained from plants such as pine and conifers. Rosin is translucent and its color varies from yellow to black. Rosin mainly consists of various resin acids. The rosin used in the backing formulation may be unmodified or modified (i.e., a rosin derivative). Modified rosins useful in the backing formulation described herein include esterified rosin, hydrogenated rosin, dimerized rosin, phenolic rosin, and terpene-based rosin, etc. By way of example, a suitable esterified rosin can be a reaction product of rosin with a mono-, di-, tri-, tetra-, or polyfunctional alcohol, including methyl alcohol, dipropylene glycol, glycerol, pentaerythritol, and combinations thereof, or combinations of these. The rosin or rosin derivative used in the present invention may be any of the commercially available types of rosin, for example, wood rosin, gum rosin, tall oil rosin, and mixtures thereof, in crude or purified form, and may be derived therefrom.

[0069] The bio-based ester can be present in the backing formulation described herein at a weight percentage of from about 0% to about 50% (weight / weight), including both ends (e.g., from about 5% to about 50% including both ends; from about 5% to about 40% including both ends; from about 7% to about 35% including both ends; from about 8% to about 32% including both ends; from about 9% to about 30% including both ends; from about 10% to about 40% including both ends; from about 11% to about 25% including both ends; from about 12% to about 20% including both ends; from about 12% to about 20% including both ends; from about 15% to about 40% including both ends; from about 20% to about 40% including both ends; or from about 20% to about 40% including both ends).

[0070] The oil in the backing formulation can act as a plasticizer to soften the backing formulation and make it more flexible. By including oil in the binder, the filler loading of the backing formulation can be increased, and more concentrated carbon can be included in the backing formulation. By including oil in the binder, the need for polymers can also be reduced or eliminated. Combining an increase in the amount of filler and a decrease in the amount of polymer in the binder in this way is very beneficial because most fillers have a relatively small environmental impact while polymers have a relatively large environmental impact. Thus, both an increase in the amount of filler and a decrease in the amount of polymer reduce the environmental impact of the binder.

[0071] Oils useful in the backing formulation can 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 reactive ESO. In some examples, the natural oil need not be limited to vegetable oils and can be a non-petroleum oil, such as an oil derived from plants, animals, or seaweed. In some embodiments, the oil can be a synthetic oil, such as an oil synthesized to provide desired characteristics.

[0072] The backing formulations described herein can contain oil at a weight percent of from about 0% to about 20% (wt / wt), including both ends (e.g., from about 1% to 15% including both ends; from about 2% to 15% including both ends; from about 2% to 10% including both ends; from about 1% to 5% including both ends; from about 5% to 15% including both ends; from about 5% to 10% including both ends; from about 0.1% to about 20% including both ends; from about 0.1% to about 15% including both ends; from about 0.25% to about 11% including both ends; from about 0.5% to about 10% including both ends; from about 0.8% to about 8% including both ends; from about 1% to about 6% including both ends; from about 1.4% to about 5% including both ends; or from about 1.8% to about 4% including both ends).

[0073] Polymers (e.g., thermosetting, thermoplastic, or elastomeric) may also be included in the binder. Suitable polymers can be any polymer or copolymer, including block copolymers, known for use in backing formulations for floor coverings. By way of non-limiting example, polymers useful in the backing formulations described herein include polyolefins; polyesters such as polyhydroxyalkanoates; vinyl polymers such as polyvinyl chloride (PVC); urethanes; and epoxides. Optionally, the polymer can 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 have vinyl acetate at a weight percent of 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 between 10% and 70% (wt / wt).

[0074] Some polymers useful in backing formulations are known as bitumen modifiers. These polymers, including EVA, SBS, and SBR, are typically incorporated into backing formulations by mixing at elevated temperatures (generally above 170 °C) and / or in a high-shear mixer. Two common, commercially available bitumen modifiers are Kraton DSBS™ (an SBS block copolymer available from Kraton) and Polybilt 106™ (an EVA elastomer available from ExxonMobil). Some polymers are known as polyolefin polymer modifiers. Examples of commercially available polyolefin polymer modifiers include Vistamaxx™ granules (a propylene-ethylene copolymer available from Exxon Mobile) and Mirel™ granules (a polyhydroxyalkanoate available from Metabolix).

[0075] In some examples, the backing formulations described herein do not contain polymers. In other examples, the backing formulations contain polymers derived from recycled materials. In some examples, the backing formulations described herein do not contain PVC. In other examples, the backing formulations do not contain virgin PVC but contain recycled PVC or PVC derived from recycled materials such as recycled carpet tiles. In some examples, the backing formulations described herein contain a combination of virgin polymers and recycled polymers such as virgin PVC and recycled PVC.

[0076] When the polymer is included in the backing formulation, preferably, but not necessarily, it is included at a weight percentage of 40% (weight / weight) or less; 35% (weight / weight) or less; 30% (weight / weight) or less; 25% (weight / weight) or less; 20% (weight / weight) or less; 15% (weight / weight) or less; 10% (weight / weight) or less; and 5% (weight / weight) or less. In some embodiments, the polymer is included in the backing formulation at a weight percentage of about 1% to 30% (weight / weight), including both ends; about 2% to 25% (weight / weight), including both ends; about 3% to 20% (weight / weight), including both ends; about 4% to 20% (weight / weight), including both ends; about 4% to 15% (weight / weight), including both ends; about 4% to 10% (weight / weight), including both ends; about 10% to 20% (weight / weight), including both ends; about 15% to 30% (weight / weight), including both ends; about 15% to 25% (weight / weight), including both ends; about 15% to 20% (weight / weight), including both ends; about 20% to 30% (weight / weight), including both ends; and about 22% to 28% (weight / weight), including both ends. The polymer may be present at a weight percentage of about 0% to about 30%, including both ends; about 0.1% to about 25%, including both ends; about 0.1% to about 20%, including both ends; about 0.2% to about 10%, including both ends; about 0.3% to about 8%, including both ends; about 0.4% to about 6%, including both ends; about 0.5% to about 4%, including both ends; or about 0.75% to about 2.5%, including both ends.

[0077] The backing formulation can also include additives that facilitate the production of the backing formulation or impart desired characteristics to the finished backing formulation. By way of non-limiting example, the backing formulation can include antioxidants, hydrocarbon waxes, plasticizers, or stabilizers. The additives can optionally be natural, bio-based, or recycled materials in order to contribute to the reduction of the carbon footprint of the floor covering. The additives may be present in the backing formulation at a weight percentage of 0% to about 5%, including both ends.

[0078] In some examples, the backing formulation further includes a hydrocarbon wax. The hydrocarbon wax may be present at about 0% to about 15% by weight of the backing formulation. However, in other examples, the backing formulation is essentially free of hydrocarbon wax. In some examples, the backing formulation is free of bitumen.

[0079] In certain embodiments, the backing formulation comprises (1) a first filler comprising concentrated carbon in an amount of about 2% to about 25% (weight / weight), such as about 5% to about 20% (weight / weight), more preferably about 7% to about 15% (weight / weight), even more preferably about 9% to about 13% (weight / weight), still more preferably about 10% to about 12% (weight / weight); (2) a second filler (i.e., not concentrated carbon) in an amount of about 35% to about 65% (weight / weight), such as about 40% to about 60% (weight / weight), about 45% to about 55% (weight / weight), about 50% to about 55% (weight / weight); (3) a bio-based ester in an amount of about 2% to about 25% (weight / weight), such as about 5% to about 20% (weight / weight), more preferably about 7% to about 17% (weight / weight), even more preferably about 10% to about 15% (weight / weight), still more preferably about 12% to about 14% (weight / weight); (4) an oil (preferably, but not necessarily, a bio-based oil) in an amount of about 1% to about 10% (weight / weight), such as about 2% to about 7% (weight / weight), about 2% to about 5% (weight / weight), about 2% to about 4% (weight / weight), about 3% to about 4% (weight / weight); and (5) a polymer in an amount of about 2% to about 30% (weight / weight), such as about 5% to about 25% (weight / weight), more preferably about 10% to about 20% (weight / weight), even more preferably about 15% to about 20% (weight / weight). comprises.

[0080] In certain embodiments, the backing formulation comprises (1) A first filler containing about 20% to about 60% (weight / weight), for example about 25% to about 55% (weight / weight), more preferably about 30% to about 55% (weight / weight), even more preferably about 35% to about 50% (weight / weight), still more preferably about 40% to about 55% (weight / weight), yet more preferably about 40% to about 50% (weight / weight) of concentrated carbon; (2) A second filler (i.e., not concentrated carbon) of about 0% to about 10% (weight / weight), for example about 0% to about 5% (weight / weight); (3) A bio-based ester of about 5% to about 35% (weight / weight), for example about 10% to about 30% (weight / weight), more preferably about 15% to about 30% (weight / weight), even more preferably about 10% to about 25% (weight / weight), yet more preferably about 15% to about 23% (weight / weight), still more preferably about 18% to about 22%; (4) An oil of about 1% to about 10% (weight / weight), for example about 2% to about 7% (weight / weight), about 2% to about 5% (weight / weight), about 2% to about 4% (weight / weight), about 3% to about 4% (weight / weight) (preferably, but not necessarily, a bio-based oil); and (5) A polymer of about 5% to about 35% (weight / weight), for example about 10% to about 30% (weight / weight), more preferably about 15% to about 30% (weight / weight), even more preferably about 20% to about 30% (weight / weight) is included.

[0081] In certain embodiments, the backing formulation (1) A first filler containing about 15% to about 50% (weight / weight), for example about 20% to about 45% (weight / weight), more preferably about 25% to about 40% (weight / weight), even more preferably about 30% to about 40% (weight / weight), still more preferably about 32% to about 38% (weight / weight) of concentrated carbon; (2) A second filler (i.e., not concentrated carbon) of about 2% to about 30% (weight / weight), for example about 5% to about 25% (weight / weight), more preferably about 10% to about 20% (weight / weight), even more preferably about 15% to about 20% (weight / weight); (3) From about 15% to about 50% (weight / weight), such as from about 20% to about 45% (weight / weight), more preferably from about 25% to about 40% (weight / weight), even more preferably from about 30% to about 40% (weight / weight), still more preferably from about 35% to about 40% (weight / weight) of a bio-based ester; (4) From about 1% to about 15% (weight / weight), such as from about 2% to about 10% (weight / weight), such as from about 3% to about 9% (weight / weight), from about 4% to about 8% (weight / weight), from about 5% to about 7% (weight / weight), from about 6% to about 7% (weight / weight) of an oil (preferably, but not necessarily, a bio-based oil); and (5) From about 1% to about 15% (weight / weight), such as from about 2% to about 10% (weight / weight), from about 3% to about 8% (weight / weight), from about 4% to about 6% (weight / weight), from about 4% to about 5% (weight / weight) of a polymer comprising.

[0082] In certain embodiments, the backing formulation (1) From about 0% to about 10% (weight / weight), such as from about 0% to about 5% (weight / weight), such as from about 1% to about 3% (weight / weight), such as from about 1% to about 2% (weight / weight) of a first filler comprising concentrated carbon; (2) From about 35% to about 65% (weight / weight), such as from about 40% to about 65% (weight / weight), from about 45% to about 60% (weight / weight), from about 50% to about 60% (weight / weight), from about 55% to about 60% (weight / weight) of a second filler (i.e., not concentrated carbon); (3) From about 2% to about 25% (weight / weight), such as from about 4% to about 20% (weight / weight), more preferably from about 5% to about 15% (weight / weight), even more preferably from about 7% to about 12% (weight / weight), still more preferably from about 9% to about 11% (weight / weight) of an oil (preferably, but not necessarily, a bio-based oil); and (4) From about 10% to about 45% (weight / weight), such as from about 20% to about 35% (weight / weight), more preferably from about 25% to about 35% (weight / weight), even more preferably from about 27% to about 33% (weight / weight) of a blend of recycled PVC and recycled carpet comprising.

[0083] The backing formulation of the present invention (referred to as "BC") having the composition shown in Table 4 was prepared as in the examples. Table 4 also compares the estimated TRACI 2.1 GWPs of the backing formulation of the present invention with those of conventional backing formulations. [Table 4-1] [Table 4-2]

[0084] Backing formulations can be characterized in several ways according to known industry standards. As an example, the softening point and consistency of the material can 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, for example, in accordance with the method described in EN1427:2007 Bitumen and bituminous binders - Determination of the softening point - Ring and Ball method. In a preferred embodiment, the backing formulation has a ring and ball softening point in the range of 60 - 180 °C, 70 - 160 °C, 75 - 140 °C, or 80 - 120 °C, determined in accordance with EN1427:2007.

[0085] The viscosity of the backing formulation under specific temperature, load, and load duration conditions can be determined using any method known in the art, for example, it can be measured according to EN 1426:2007 Bitumen and bituminous binders - Determination of needle penetration. The viscosity, also known as the penetration, is expressed as the distance in 1 / 10 of 1 mm that a standard needle penetrates into the material. In a preferred embodiment, the backing formulation has a penetration within the range of 0.2 - 200 × 0.1 mm, for example, 0.5 - 100 × 0.1 mm, 0.8 - 75 × 0.1 mm, or 1 - 50 × 0.1 mm, determined in accordance with EN 1426:2007 at 25°C.

[0086] As reflected in Table 4, the embodiments of the backing formulations described herein contain significantly less synthetic and fossil fuel - based materials compared to conventional backing. Further, the concentrated carbon present in at least some of the backing formulations can sequester carbon such that, when subjected to life - cycle assessment and measured according to the TRACI 2.1 methodology, the backing formulation, the backing composite, and optionally, the resulting floor covering product have a negative carbon footprint. In some embodiments, the reduction in the carbon footprint of the embodiments of the backing formulations contemplated herein is at least 4 kg CO2 / m 2 , at least 3.5 kg CO2 / m 2 , or at least 3.5 kg CO2 / m 2 is achieved.

[0087] Optionally, the backing layer may include one or more substrates that adhere to the backing formulation or are provided / embedded within the backing formulation to form a backing composite. The substrate may be, for example, glass beads, glass scrim, a foam layer, or a non-woven covering (such as fleece). Optionally, a substrate such as a protective layer (such as fleece) to prevent the backing formulation from sticking to the floor or damaging the floor may be provided on the lower surface of the backing formulation.

[0088] In some embodiments, the floor coverings described herein are subjected to a life cycle assessment and are capable of sequestering carbon such that the resulting product has a negative carbon footprint when measured in accordance with the TRACI 2.1 methodology. The GWPs of some carpet tiles ("CT") that conform to certain embodiments described herein are compared to conventional carpet tiles in Table 5. **Table 5**

[0089] The floor coverings 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 individual tiles. For example, it may be provided in square tiles of 50 cm × 50 cm or 1 m × 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, counter tops, backsplashes, etc.

[0090] The floor coverings described herein can conform to the categories specified by the European classification EN 1307-2014: Textile floor coverings - Classification. This European standard defines the requirements for the classification of all textile floor coverings and carpet tiles, except rugs and runners (see ISO 2424:2007 - Textile floor coverings - Vocabulary), in terms of the following characteristics: wear, appearance retention, use categories related to one or more of the additional performance characteristics, and categories for rug luxury ratings.

[0091] The floor coverings described herein can be prepared by standard methods known in the art. As an example, the floor coverings described herein can be prepared by providing a textile top cloth with a top surface containing yarns or fibers and a bottom surface containing a precoat layer, providing the backing layer described herein, and applying the backing layer to the precoat layer on the bottom surface of the textile top cloth.

[0092] The floor coverings described herein can be installed on any indoor surface. In some embodiments, the floor covering is installed by adhering it to the underlying surface. Optionally, the floor covering may be installed using a pressure-sensitive adhesive, which holds the floor covering in place during use but allows at least a portion of the floor covering, e.g., one or more tiles, to be removed without damaging the removed portion of the floor covering. In other embodiments, the individual tiles of the floor covering are adhered to each other but not to the underlying surface, resulting in a floating installation. For example, as disclosed in U.S. Patent No. 7,464,510, joining tools with adhesives may be used to join the tiles together. Alternatively, a mechanical fastening system may be formed along the edges of the modules (e.g., in the core) such that adjacent modules interlock with each other. An example of such a "click-fix" system is disclosed in U.S. Patent Application Publication No. 2016 / 0208500, which is hereby incorporated by reference in its entirety.

Example

[0093] (Example 1) A floor covering comprising an upper wear layer and a backing formulation, the backing formulation comprising a binder and at least one filler, the at least one filler comprising concentrated carbon.

[0094] (Example 2) The floor covering according to Example 1, wherein the concentrated carbon has a carbon content of at least 85%.

[0095] (Example 3) The floor covering according to Example 1 or Example 2, wherein the concentrated carbon contains less than 40 ppm of total polycyclic aromatic hydrocarbons (PAHs) and less than 15 ppm of total heavy metals.

[0096] (Example 4) The floor covering according to any one of Examples 1 to 3, wherein the concentrated carbon has a particle size of from about 0.01 μm to about 3 mm.

[0097] (Example 5) The floor covering according to any one of Examples 1 to 4, wherein the concentrated carbon is present in the backing formulation in a weight percentage of from about 1 wt% to about 60 wt%.

[0098] (Example 6) The floor covering according to Example 5, wherein the concentrated carbon is present in the backing formulation in a weight percentage of from about 10 wt% to about 50 wt%.

[0099] (Example 7) The floor covering according to Example 6, wherein the concentrated carbon is present in the backing formulation in a weight percentage of from about 20 wt% to about 50 wt%.

[0100] (Example 8) The floor covering according to Example 7, wherein the concentrated carbon is present in the backing formulation in a weight percentage of from about 30 wt% to about 50 wt%.

[0101] (Example 9) At least one filler comprises a first filler containing concentrated carbon and a second filler containing a silicate, silica, an oxide of silica, a carbonate, a sulfate, an oxide of antimony, aluminum trihydrate, calcium oxide, fly ash, carbon black, talcum, clay, kaolin, wood chips, wood flour, shell powder, plant material, or recycled material, the floor covering according to any one of Examples 1 to 8.

[0102] (Example 10) The first filler and the second filler are present in the backing formulation in a combined weight percentage of about 40 wt% to about 70 wt%, the floor covering according to Example 9.

[0103] (Example 11) The first filler and the second filler are present in the backing formulation in a combined weight percentage of about 50 wt% to about 70 wt%, the floor covering according to Example 10.

[0104] (Example 12) The binder contains a bio-based ester, the floor covering according to any one of Examples 1 to 11.

[0105] (Example 13) The bio-based ester contains esterified rosin, hydrogenated rosin, phenolic rosin, or terpene-based rosin, the floor covering according to Example 12.

[0106] (Example 14) The bio-based ester is present in the backing formulation in a weight percentage of about 5 wt% to about 40 wt%, the floor covering according to Example 12 or Example 13.

[0107] (Example 15) The binder contains oil, and the oil contains oil derived from plants, animals, or seaweed, the floor covering according to any one of Examples 1 to 14.

[0108] (Example 16) The floor covering according to Example 15, wherein the oil contains plant-derived oil, and the plant-derived oil includes rapeseed oil, sunflower oil, soybean oil, palm oil, castor oil, coconut oil, or refined versions thereof.

[0109] (Example 17) The floor covering according to Example 15 or 16, wherein the plant-, animal-, or seaweed-derived oil is present in the backing formulation at a weight percentage of about 2 wt% to about 15 wt%.

[0110] (Example) The floor covering according to any one of Examples 1 to 17, wherein the binder contains a polymer.

[0111] (Example 19) The floor covering according to Example 18, wherein the polymer is present in the backing formulation at a weight percentage of 30 wt% or less.

[0112] (Example 20) The floor covering according to Example 18 or 19, wherein the polymer includes recycled polyvinyl chloride (PVC) or ethylene vinyl acetate (EVA).

[0113] (Example 21) The floor covering according to any one of Examples 1 to 20, wherein the binder does not substantially contain virgin PVC.

[0114] (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 includes a half cross that includes yarn tufted to a tufting primary fabric and a precoat provided on the lower surface of the tufting primary fabric.

[0115] (Example 23) The floor covering according to Example 22, wherein the half cross has a yarn surface weight of 18 osy or less.

[0116] (Example 24) The floor covering according to Example 23, wherein the half cross has a yarn surface weight of 12 osy or less.

[0117] (Example 25) The floor covering according to any one of Examples 22 to 24, wherein the yarn contains recycled nylon 6 or nylon 6,6.

[0118] (Example 26) The floor covering according to any one of Examples 22 to 25, wherein the yarn has a denier of 900 to 1800 including both ends.

[0119] (Example 27) The floor covering according to Example 26, wherein the yarn has a denier of 1200 to 1800 including both ends.

[0120] (Example 28) The floor covering according to any one of Examples 22 to 27, wherein the half cloth has a tuft density of 140 to 300 tufts per inch including both ends.

[0121] (Example 29) The floor covering according to any one of Examples 22 to 28, wherein the yarn has a tuft height between 2 / 32 inch and 3 / 32 inch including both ends.

[0122] (Example 30) The floor covering according to any one of Examples 22 to 29, wherein when the carpet tile is subjected to the test method described in ASTM D5252-2015, the carpet tile achieves a rating of 3.5 or higher in accordance with the rating grade described in ASTM D7330-2015.

[0123] (Example 31) The floor covering according to any one of Examples 22 to 30, wherein the precoat contains a filler containing concentrated carbon.

[0124] (Example 32) The floor covering according to any one of Examples 22 to 31, wherein the precoat lacks a filler.

[0125] (Example 33) The floor covering according to any one of Examples 22 to 32, wherein the precoat has a weight of less than about 18 osy.

[0126] (Example 34) The floor covering according to any one of Examples 22 to 33, wherein the half cloth has a weight of about 14 osy to about 35 osy.

[0127] (Example 35) The floor covering according to any one of Examples 1 to 34, wherein the floor covering includes a backing composite including a backing formulation and a substrate, and the backing composite is flexible.

[0128] (Example 36) The floor covering according to any one of Examples 1 to 35, wherein the backing formulation has a negative global warming potential (GWP) calculated using the TRACI 2.1 methodology based on the materials.

[0129] (Example 37) The floor covering according to any one of Examples 1 to 36, wherein the entire floor covering has a negative cradle-to-gate GWP calculated using the TRACI 2.1 methodology.

[0130] (Example 38) A floor covering including an upper wear layer and a backing formulation, wherein at least one of the upper wear layer or the backing formulation has a negative GWP calculated using the TRACI 2.1 methodology based on the materials.

[0131] (Example 39) The floor covering according to Example 38, wherein the backing formulation includes a binder and at least one filler, and the at least one filler includes concentrated carbon present in the backing formulation at a weight percentage of about 1 wt% to about 60 wt%.

[0132] (Example 40) The floor covering according to Example 39, wherein at least one filler comprises a first filler containing concentrated carbon and a second filler containing a silicate, silica, an oxide of silica, a carbonate, a sulfate, an oxide of antimony, aluminum trihydrate, calcium oxide, fly ash, carbon black, talcum, clay, kaolin, wood chips, wood powder, shell powder, plant material, or recycled material.

[0133] (Example 41) The floor covering according to Example 40, wherein the first filler and the second filler are present in the backing formulation in a combined weight percentage of from about 40 wt% to about 70 wt%.

[0134] (Example 42) The floor covering according to any one of Examples 39 to 41, wherein the binder further comprises a bio-based ester present in the backing formulation in a weight percentage of from about 5 wt% to about 40 wt%.

[0135] (Example 43) The floor covering according to any one of Examples 39 to 42, wherein the binder comprises a bio-based oil present in the backing formulation in a weight percentage of from about 2 wt% to about 15 wt%.

[0136] (Example 44) The floor covering according to any one of Examples 39 to 43, wherein the binder comprises a polymer present in the backing formulation in a weight percentage of 30 wt% or less.

[0137] (Example 45) The floor covering according to any one of Examples 39 to 44, wherein the binder essentially does not contain virgin PVC.

[0138] (Example 46) The floor covering according to any one of Examples 38 to 45, wherein the floor covering is a carpet tile and the upper wear layer comprises a half cross including yarn tufted to a tufting primary fabric and a precoat provided on the lower surface of the tufting primary fabric.

[0139] (Example 47) The half cross has a yarn surface weight of 18 osy or less, and the floor covering according to Example 46.

[0140] (Example 48) The yarn contains recycled nylon 6 or nylon 6,6, and the floor covering according to Example 46 or Example 47.

[0141] (Example 49) The yarn has a denier of 1200 to 1800 including both ends, and the floor covering according to any one of Examples 46 to 48.

[0142] (Example 50) The precoat contains a filler containing concentrated carbon, and the floor covering according to any one of Examples 46 to 49.

[0143] (Example 51) The precoat is lacking in filler, and the floor covering according to any one of Examples 46 to 50.

[0144] (Example 52) The precoat has a weight of less than about 18 osy, and the floor covering according to any one of Examples 46 to 51.

[0145] (Example 53) The half cross has a weight of about 14 osy to about 35 osy, and the floor covering according to any one of Examples 46 to 52.

[0146] (Example 54) A flexible backing formulation containing a binder and a filler, wherein the binder contains a bio-based ester, a bio-based oil, and a polymer, and the filler contains concentrated carbon.

[0147] (Example 55) The polymer is ethylene vinyl acetate, and the flexible backing formulation according to Example 54.

[0148] (Example 56) The flexible backing formulation according to Example 54 or Example 55, wherein the binder does not contain polyvinyl chloride.

[0149] (Example 57) The bio-based ester is present in the backing formulation at a weight percentage of about 10 wt% to about 40 wt%, the bio-based oil is present in the backing formulation at a weight percentage of about 2 wt% to about 10 wt%, the polymer is present in the backing formulation at a weight percentage of 30 wt% or less, and the concentrated carbon is present in the backing formulation at a weight percentage of about 10 wt% to about 55 wt%. The flexible backing formulation according to any one of Examples 54 to 56.

[0150] (Example 58) The flexible backing formulation according to any one of Examples 54 to 57, wherein the filler further comprises calcium carbonate.

[0151] (Example 59) The flexible backing formulation according to any one of Examples 54 to 57, wherein the backing formulation has a negative global warming potential (GWP) calculated using the TRACI 2.1 methodology based on the materials.

[0152] The description of the floor covering disclosed herein may refer to one or more "layers", but it will be understood that when the floor covering is processed and ready for installation, the floor covering can be a single integrated structure in which the individual layers or the boundaries between the individual layers are not necessarily easily distinguishable and / or the individual layers do not separate from each other.

[0153] The subject matter of embodiments of the present invention is described herein by way of particularity in order to meet legal requirements, but this description is not necessarily intended to limit the scope of the claims. The subject matter of the claims may be embodied in other ways, may include different elements or steps, and may be used in combination with other existing or future technologies. This description should not be construed as implying any particular order or arrangement among or between various steps or elements, except where the order of individual steps or the arrangement of elements is explicitly described.

[0154] Examples of the invention are described for illustrative purposes and not for purposes of limitation, and alternative examples will be apparent to the reader of this patent. Accordingly, the invention is not limited to the examples described above, and various examples can be made and changes can be made without departing from the scope of the invention.

Claims

1. 1. A floor covering comprising an upper wear layer and a backing composition, the backing composition comprising a binder and at least one filler material, the at least one filler material comprising concentrated coal.

2. 10. The floor covering of claim 1, wherein the enriched charcoal has a carbon content of at least 85%.

3. 3. The floor covering of claim 1 or 2, wherein the enriched charcoal contains less than 40 ppm total polycyclic aromatic hydrocarbons (PAHs) and less than 15 ppm total heavy metals.

4. 4. The floor covering of claim 1, wherein the enriched charcoal has a particle size of about 0.01 μm to about 3 mm.

5. 5. The floor covering of any one of claims 1 to 4, wherein the enriched charcoal is present in the backing formulation in a weight percent of from about 1% to about 60% by weight.

6. 6. The floor covering of claim 5, wherein the enriched charcoal is present in the backing formulation in a weight percent of about 10% to about 50% by weight.

7. 7. The floor covering of claim 6, wherein the enriched charcoal is present in the backing formulation in a weight percent of about 20% to about 50% by weight.

8. 8. The floor covering of claim 7, wherein the enriched charcoal is present in the backing formulation in a weight percent of about 30% to about 50% by weight.

9. 9. The floor covering of any one of claims 1 to 8, wherein the at least one filler comprises a first filler comprising concentrated charcoal and a second filler comprising silicate, silica, oxide of silica, carbonate, sulfate, oxide of antimony, aluminum trihydrate, calcium oxide, fly ash, carbon black, talcum, clay, kaolin, wood chips, wood flour, shell flour, plant material, or recycled material.

10. 10. The floor covering of claim 9, wherein the first filler and the second filler are present in the backing formulation in a combined weight percent of about 40% to about 70% by weight.

11. 11. The floor covering of claim 10, wherein the first filler and the second filler are present in the backing formulation in a combined weight percent of about 50% to about 70% by weight.

12. 12. The floor covering of any one of claims 1 to 11, wherein the binder comprises a bio-based ester.

13. 13. The floor covering of claim 12, wherein the bio-based ester comprises an esterified rosin, a hydrogenated rosin, a phenolic rosin, or a terpene-based rosin.

14. 14. The floor covering of claim 12 or 13, wherein the bio-based ester is present in the backing formulation in a weight percent of from about 5% to about 40% by weight.

15. 15. A floor covering according to any one of claims 1 to 14, wherein the binder comprises an oil, the oil comprising a vegetable, animal or seaweed derived oil.

16. 16. The floor covering of claim 15, wherein the oil comprises a vegetable-derived oil, the vegetable-derived oil comprising rapeseed oil, sunflower oil, soybean oil, palm oil, castor oil, coconut oil, or refined versions thereof.

17. 17. The floor covering of claim 15 or 16, wherein the vegetable, animal, or marine derived oil is present in the backing formulation in a weight percent of about 2% to about 15% by weight.

18. 18. The floor covering of any one of claims 1 to 17, wherein the binder comprises a polymer.

19. 20. The floor covering of claim 18, wherein the polymer is present in the backing formulation in a weight percent of 30% or less by weight.

20. 20. The floor covering of claim 18 or 19, wherein the polymer comprises recycled polyvinyl chloride (PVC) or ethylene vinyl acetate (EVA).

21. 21. The floor covering of any one of claims 1 to 20, wherein the binder is essentially free of virgin PVC.

22. 22. The floor covering of 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 yarn tufted to a tufting primary backing and a precoat provided on the underside of the tufting primary backing.

23. 23. The floor covering of claim 22, wherein the half-cloth has a yarn areal weight of 18 osy or less.

24. 24. The floor covering of claim 23, wherein the half-cloth has a yarn areal weight of 12 osy or less.

25. 25. The floor covering of any one of claims 22 to 24, wherein the yarn comprises recycled nylon 6 or nylon 6,6.

26. 26. A floor covering according to any one of claims 22 to 25, wherein the yarn has a denier of from 900 to 1800 inclusive.

27. 27. The floor covering of claim 26, wherein the yarn has a denier of 1200 to 1800 inclusive.

28. 28. The floor covering of any one of claims 22 to 27, wherein the half-cloth has a tuft density of 140 to 300 tufts per inch, inclusive.

29. 29. The floor covering of any one of claims 22 to 28, wherein the yarn has a tuft height of between 2 / 32 inch and 3 / 32 inch inclusive.

30. 30. The floor covering of any one of claims 22 to 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.

31. 31. The floor covering of any one of claims 22 to 30, wherein the precoat comprises a filler comprising enriched charcoal.

32. 32. The floor covering of any one of claims 22 to 31, wherein the precoat is devoid of filler.

33. 33. The floor covering of any one of claims 22 to 32, wherein the precoat has a weight of less than about 18 osy.

34. 34. The floor covering of any one of claims 22 to 33, wherein the half-cloth has a weight of from about 14 osy to about 35 osy.

35. 35. The floor covering of any one of claims 1 to 34, wherein the floor covering comprises a backing composite comprising the backing formulation and a substrate, the backing composite being flexible.

36. 36. The floor covering of any one of claims 1 to 35, wherein the backing formulation has a negative Global Warming Potential (GWP), based on materials and calculated using TRACI 2.1 methodology.

37. 37. A floor covering according to any one of claims 1 to 36, wherein the entire floor covering has a negative cradle-to-gate GWP, calculated using TRACI 2.1 methodology.

38. 1. A floor covering comprising an upper wear layer and a backing composition, wherein at least one of the upper wear layer or the backing composition has a negative GWP, calculated based on the material and using TRACI 2.1 methodology.

39. 40. The floor covering of claim 38, wherein the backing formulation comprises a binder and at least one filler, the at least one filler comprising concentrated charcoal.

40. 40. The floor covering of claim 39, wherein the at least one filler comprises a first filler comprising concentrated charcoal and a second filler comprising silicate, silica, oxide of silica, carbonate, sulfate, oxide of antimony, aluminum trihydrate, calcium oxide, fly ash, carbon black, talcum, clay, kaolin, wood chips, wood flour, shell flour, plant material, or recycled material.

41. 41. The floor covering of claim 40, wherein the first filler and the second filler are present in the backing formulation in a combined weight percent of about 40% to about 70% by weight.

42. 42. The floor covering of any one of claims 39 to 41, wherein the binder further comprises a bio-based ester present in the backing formulation at a weight percent of from about 5% to about 40% by weight.

43. 43. The floor covering of any one of claims 39 to 42, wherein the binder comprises a bio-based oil present in the backing formulation in a weight percent of from about 2% to about 15% by weight.

44. 44. The floor covering of any one of claims 39 to 43, wherein the binder comprises a polymer present in the backing formulation at a weight percent of 30% or less by weight.

45. 45. The floor covering of any one of claims 39 to 44, wherein the binder is essentially free of virgin PVC.

46. 46. ​​The floor covering of 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 yarn tufted to a tufting primary backing and a precoat provided on the underside of the tufting primary backing.

47. 47. The floor covering of claim 46, wherein the half-cloth has a yarn areal weight of 18 osy or less.

48. 48. The floor covering of claim 46 or 47, wherein the yarn comprises recycled nylon 6 or nylon 6,6.

49. 49. The floor covering of any one of claims 46 to 48, wherein the yarn has a denier of 1200 to 1800 inclusive.

50. 50. The floor covering of any one of claims 46 to 49, wherein the precoat comprises a filler comprising enriched charcoal.

51. 51. The floor covering of any one of claims 46 to 50, wherein the precoat is devoid of filler.

52. 52. The floor covering of any one of claims 46 to 51, wherein the precoat has a weight of less than about 18 osy.

53. 53. The floor covering of any one of claims 46 to 52, wherein the half-cloth has a weight of from about 14 osy to about 35 osy.

54. A flexible backing formulation comprising a binder and a filler, the binder comprising a bio-based ester, a bio-based oil, and a polymer, and the filler comprising enriched charcoal.

55. 55. The flexible backing formulation of claim 54, wherein the polymer is ethylene vinyl acetate.

56. 56. The flexible backing formulation of claim 54 or 55, wherein the binder does not include polyvinyl chloride.

57. 57. The flexible backing formulation of any one of claims 54 to 56, wherein the bio-based ester is present in the backing formulation at a weight percent of about 10% to about 40% by weight, the bio-based oil is present in the backing formulation at a weight percent of about 2% to about 10% by weight, the polymer is present in the backing formulation at a weight percent of 30% or less by weight, and the enriched coal is present in the backing formulation at a weight percent of about 10% to about 55% by weight.

58. 58. The flexible backing formulation of any one of claims 54 to 57, wherein the filler further comprises calcium carbonate.

59. 58. The flexible backing formulation of any one of claims 54 to 57, wherein the backing formulation has a negative Global Warming Potential (GWP), based on materials and calculated using TRACI 2.1 methodology.

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