Surface coatings containing carbon sequestration materials and methods of making them

Abstract

A floor covering, such as a modular panel or tile for installation on an indoor surface, includes an upper wear layer and a backing layer, the backing layer including a filler material including enriched carbon. The floor covering is capable of sequestering carbon such that the resulting product has a negative carbon footprint when subjected to a life cycle assessment.

Description

[Technical Field]

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

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

[0003] Floor coverings typically include at least an exposed upper wear layer and a backing layer underlying the wear layer. Carpet tiles typically have an upper wear layer formed by tufting yarns into a primary backing and coating the underside of the backing with an adhesive material (often called a "precoat") to secure the yarns to the primary backing. In this application, the term "face cloth" refers to the tufted primary backing prior to application of the precoat (i.e., lacking the precoat), and the term "half cloth" refers to the tufted primary backing with the precoat (i.e., the yarn / primary backing / precoat composite). The half cloth is then attached to a stabilized structural backing composite to form a carpet web. The carpet web is then cut into carpet tiles of the desired shape and size.

[0004] 1 and 2 are cross-sectional views illustrating examples of traditional carpet tile constructions 10, 11. The carpet tile constructions 10, 11 include yarns 17 that are tufted into tufting primaries 19 (also called primary backings) to form face cloths 14. In addition to being tufted, the carpet tile half cloths may also be woven, nonwoven (e.g., needlepunched or needlefelted), fused, etc. An adhesive or precoat layer 22 is disposed on the underside of the face cloth 14 to secure the yarns 17 to the tufting primaries 19, thereby forming the half cloths.

[0005] A backing composite 12, 21 is provided under the half cloth. The backing composite provides flatness, dimensional stability, rigidity, and weight to the modular tile, thereby minimizing or eliminating the need for adhesives to secure the tile to the floor. Broadloom carpet backing composites typically consist of a latex coating (in addition to an optional latex precoat layer) and a textile substrate, such as a woven fabric substrate. Compared to broadloom carpet, modular tile backing composites typically must be heavier to ensure product performance and durability, e.g., to withstand heavy wear without degradation. Therefore, carpet tile backing composites typically include a polymeric coating or sheet, optionally embedded with a glass veil or glass scrim for dimensional stability, and / or a bottom substrate (often a fabric such as a nonwoven fleece) is optionally applied to the underside of the tile.

[0006] Figure 1 illustrates a carpet tile construction 10 having a backing composite 12 with a polymer sheet 18 (which does not include an embedded fiberglass layer) and a fabric 24 on the underside of the tile construction. Figure 2 illustrates a carpet tile construction 11 including a backing composite 21 with two polymer sheets 18, 20 and a fiberglass layer 16 sandwiched between the backing sheets 18, 20. Carpet tile construction 11 does not include an underlying fabric like carpet tile construction 10.

[0007] The carbon footprint of a product is a measure of all greenhouse gases (GHGs) removed from or emitted into the atmosphere during the product's life cycle (e.g., creation, use, and disposal). Carbon footprint, also known as total Global Warming Potential (GWP) emissions, is measured in kilograms of carbon dioxide (CO2) equivalents per square meter (kg CO2eq / m 2 ) In determining GWP emissions, non-CO2 GHGs are converted to CO2 equivalents based on their radiative forcing effect over a 100-year period. A negative total GWP indicates that more GHGs are removed from the atmosphere during the product's life cycle than are emitted to the atmosphere.

[0008] Total GWP emissions can be measured using life cycle assessment (also known as 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 assessing the environmental impact of a product or service by quantifying all input and output material flows and evaluating how these material flows affect the environment. An LCA for a product is performed on the entire product life cycle; however, the product life cycle can be broken down into multiple stages. The raw materials to manufacturing stage 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 the product is recycled, the post-sale stage can also be called gate-to-cradle.

[0009] An Environmental Product Declaration (EPD) is a third-party verification (certification) report issued by product manufacturers that provides information about the environmental performance of their products. An EPD essentially reports the results of an LCA performed on a 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 published standards and defined methodologies. The LCA is conducted in accordance with ISO 14040-ISO 14049 (Part 2, July 1, 2006 edition), which are incorporated herein by reference in their entirety. These standards include, but are not limited to, ISO 14044: Environmental management - Life cycle assessment - Requirements and guidelines (Part 1, July 1, 2006 edition), which is incorporated herein by reference in its entirety. The relevant standard for EPDs is ISO 14025: Environmental labels and declarations - Type III environmental declarations - Principles and procedures (Part 1, July 1, 2006 edition), which is incorporated herein by reference in its entirety.

[0010] Although the ISO standard does not include a rigorous methodology for performing an LCA and calculating GWP, several accepted characterization factors exist, 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 a product's contribution to GWP. While different recognized methodologies typically give the same or very similar results, in this application, all GWPs reported herein are calculated (or estimated) using the TRACI 2.1 Global Warming Potential methodology, including biogenic and land use change (LUC). A negative GWP value indicates a negative carbon footprint.

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

[0013] A Cradle to Gate LCA considers all GHG inputs and outputs from all aspects of product production, including the extraction of raw materials, the conversion of feedstocks into chemicals, the transportation of materials to factories, the energy involved in assembling the product, packaging, and the waste and disposal of the product. Thus, the types of materials used in a product, as well as the quantity and weight of such materials, all contribute to the product's carbon footprint.

[0014] As an example, for carpet tiles, the yarn type, yarn size, fiber / yarn density, tufting primary material, tufting primary weight, and precoat material formulation and amount all contribute to the carbon footprint of the half cloth. Additionally, the backing composite and its components also contribute to the carpet tile's carbon footprint. In modular floor coverings such as carpet tiles, backing compounds commonly used to form the backing composite are fossil fuel-based and include, for example, bitumen, polyvinyl chloride (PVC), or polyolefins derived from fossil fuels. Fossil fuels continue to form through natural processes, but because they take millions of years to form, they are generally considered a non-renewable resource, and known viable reserves are being depleted much faster than new ones are being created. The use of fossil fuels also raises potential environmental concerns because their combustion results in the formation of carbon dioxide, a well-known greenhouse gas. Summary of the Invention [Problem to be solved by the invention]

[0015] There is a need for floor coverings that require fewer fossil fuels and / or have lower levels 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 partially or completely bio-based floor coverings that can be economically produced. [Means for solving the problem]

[0016] Disclosed herein are surface coverings, such as floor coverings, that include one or more layers, e.g., an upper wear layer and a backing layer. The backing layer may be a backing composite that includes 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 as measured by life cycle assessment. In some embodiments, the product as a whole is carbon negative as measured by life cycle assessment. In some embodiments, carbon negativity is achieved in part by including a filler material in the product that includes concentrated carbon. Although overlapping with other descriptions, various aspects of the present invention are described below, however, the present invention is not limited to the following. [1] A floor covering comprising an upper wear layer and a backing composition, wherein the backing composition comprises a binder and at least one filler, the at least one filler comprising a solid material having a carbon content of at least 80% by weight, the solid material being produced by pyrolysis of biomass in the absence of oxygen; and the solid material is present in the backing composition in a weight percent of about 1% to about 60% by weight. [2] [1] The floor covering according to [1], wherein the solid material has a carbon content of at least 85%. [3] 10. The floor covering of claim 1, wherein the solid material contains less than 40 ppm of total polycyclic aromatic hydrocarbons (PAHs) and less than 15 ppm of total heavy metals. [4] The floor covering according to any one of [1] to [3], wherein the solid material has a particle size of about 0.01 μm to about 3 mm. [5] [1] The floor covering according to [1], wherein the solid material is present in the backing composition in a weight percentage of about 10% to about 50% by weight. [6] [5] The floor covering according to [5], wherein the solid material is present in the backing composition in a weight percentage of about 20% to about 50% by weight. [7] [6] The floor covering according to [6], wherein the solid material is present in the backing composition in a weight percentage of about 30% to about 50% by weight. [8] [7] The floor covering according to any one of [1] to [7], wherein the at least one filler comprises a first filler comprising a solid material 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. [9] [8] The floor covering of [8], wherein the first filler and the second filler are present in the backing formulation in a combined weight percentage of about 40% to about 70% by weight.

[10] [9] The floor covering of [9], wherein the first filler and the second filler are present in the backing formulation in a combined weight percentage of about 50% to about 70% by weight.

[11]

[10] The floor covering according to any one of [1] to

[10] , wherein the binder comprises a bio-based ester.

[12]

[11] The floor covering according to

[11] , wherein the bio-based ester comprises an esterified rosin, a hydrogenated rosin, a phenolic rosin, or a terpene rosin.

[13]

[11] or

[12] , wherein the bio-based ester is present in the backing formulation in a weight percentage of about 5% to about 40% by weight.

[14]

[14] The floor covering according to any one of [1] to

[13] , wherein the binder comprises oil, and the oil comprises a plant-, animal-, or seaweed-derived oil.

[15]

[14] The floor covering according to

[14] , wherein the oil comprises a plant-derived oil, and the plant-derived oil comprises rapeseed oil, sunflower oil, soybean oil, palm oil, castor oil, coconut oil, or refined versions thereof.

[16]

[14] or

[15] , wherein the plant-, animal-, or seaweed-derived oil is present in the backing formulation in a weight percentage of about 2% to about 15% by weight.

[17]

[16] The floor covering according to any one of [1] to

[16] , wherein the binder comprises a polymer.

[18]

[17] The floor covering according to

[17] , wherein the polymer is present in the backing formulation in a weight percent of 30% or less.

[19] 17. The floor covering according to claim 16, wherein the polymer comprises recycled polyvinyl chloride (PVC) or ethylene vinyl acetate (EVA).

[20] 19. A floor covering according to any one of [1] to

[19] , wherein the binder is essentially free of virgin PVC.

[21] [1] to

[20] . The floor covering according to any one of [1] to

[20] , wherein the floor covering is a carpet tile and the upper wear layer comprises yarn tufted onto a tufting primary backing and a precoat provided on the underside of the tufting primary backing.

[22] 21. The floor covering according to claim 20, wherein the upper wear layer has a yarn surface weight of 18 osy or less.

[23] 22. The floor covering according to claim 21, wherein the upper wear layer has a yarn areal weight of 12 osy or less.

[24]

[21] The floor covering according to any one of

[21] to

[23] , wherein the yarn comprises recycled nylon 6 or nylon 6,6.

[25]

[21] A floor covering according to any one of

[21] to

[24] , wherein the yarn has a denier of 900 to 1800, including both ends.

[26]

[25] The floor covering according to

[25] , wherein the yarn has a denier of 1200 to 1800 including both ends.

[27]

[21] A floor covering according to any one of

[21] to

[26] , wherein the upper wear layer has a tuft density of 140 to 300 tufts per inch, including both ends.

[28]

[21] A floor covering according to any one of

[21] to

[27] , wherein the yarn has a tuft height of between 2 / 32 inch and 3 / 32 inch, including both ends.

[29] A floor covering according to any of

[21] to

[28] , wherein the carpet tile achieves an abrasion rating of 3.5 or greater in accordance with the rating scale set forth in ASTM D7330-2015 when subjected to the test method set forth in ASTM D5252-2015.

[30]

[21] -

[29] . The floor covering according to any one of

[21] to

[29] , wherein the precoat comprises a filler containing a solid material having a carbon content of at least 80% by weight, the solid material being produced by pyrolysis of biomass in the absence of oxygen; and the solid material is present in the precoat at a weight percent of about 0% to about 85% by weight.

[31] 10. A floor covering according to any one of

[21] to

[29] , wherein the precoat is devoid of filler.

[32]

[21] -

[31] The floor covering according to any one of

[21] to

[31] , wherein the precoat has a weight of less than about 18 osy.

[33]

[21] -

[32] The floor covering according to any one of

[21] to

[32] , wherein the upper wear layer has a weight of about 14 osy to about 35 osy.

[34]

[0023] The floor covering according to any one of [1] to

[33] , wherein the floor covering comprises a backing composite comprising a backing compound and a substrate, and the backing composite is flexible.

[35] 10. The floor covering according to any of [1] to

[34] , wherein the backing formulation has a negative Global Warming Potential (GWP), based on materials and calculated using the TRACI 2.1 methodology.

[36] 1. A floor covering according to any of [1] to

[35] , wherein the entire floor covering has a negative cradle-to-gate GWP, calculated using the TRACI 2.1 methodology.

[37] 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.

[38]

[37] The floor covering according to

[37] , wherein the backing composition comprises a binder and at least one filler, the at least one filler comprising a solid material having a carbon content of at least 80% by weight, the solid material being produced by pyrolysis of biomass in the absence of oxygen; and the solid material being present in the backing composition in a weight percent of about 1% to about 60% by weight.

[39]

[38] The floor covering according to

[39] , wherein the at least one filler comprises a first filler comprising a solid material 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.

[40]

[39] The floor covering of

[39] , wherein the first filler and the second filler are present in the backing formulation in a combined weight percentage of about 40% to about 70% by weight.

[41]

[38] The floor covering according to any one of

[38] to

[40] , wherein the binder further comprises a bio-based ester present in the backing formulation in a weight percentage of about 5% to about 40% by weight.

[42]

[41] The floor covering according to any one of

[38] to

[41] , wherein the binder comprises a bio-based oil present in the backing formulation in a weight percentage of about 2% to about 15% by weight.

[43]

[42] The floor covering according to any one of

[38] to

[42] , wherein the binder comprises a polymer present in the backing formulation in a weight percent of 30% or less.

[44] 10. A floor covering according to any of

[38] to

[43] , wherein the binder is essentially free of virgin PVC.

[45]

[37] A floor covering according to any one of

[37] to

[44] , wherein the floor covering is a carpet tile and the upper wear layer comprises yarn tufted onto a tufting primary backing and a precoat provided on the underside of the tufting primary backing.

[46] 45. The floor covering according to claim 45, wherein the upper wear layer has a yarn surface weight of 18 osy or less.

[47] 4. The floor covering according to claim 45 or 46, wherein the yarn comprises recycled nylon 6 or nylon 6,6.

[48] A floor covering according to any one of

[45] to

[47] , wherein the yarn has a denier of 1200 to 1800, including both ends.

[49]

[45] A floor covering according to any one of

[45] to

[48] , wherein the precoat comprises a filler containing a solid material having a carbon content of at least 80% by weight, the solid material being produced by pyrolysis of biomass in the absence of oxygen; and the solid material is present in the precoat at a weight percent of about 0% to about 85% by weight.

[50] 10. A floor covering according to any one of

[45] to

[48] , wherein the precoat is devoid of filler.

[51]

[45] -

[50] The floor covering according to any one of

[45] to

[50] , wherein the precoat has a weight of less than about 18 osy.

[52]

[45] -

[51] The floor covering according to any one of

[45] to

[51] , wherein the upper wear layer has a weight of about 14 osy to about 35 osy.

[53] 1. A flexible backing composition comprising a binder and a filler, wherein the binder comprises a bio-based ester, a bio-based oil, and a polymer, and the filler comprises a solid material having a carbon content of at least 80% by weight, the solid material being produced by pyrolysis of biomass in the absence of oxygen; and wherein the solid material is present in the backing composition at a weight percent of about 1% to about 60% by weight.

[54]

[53] The flexible backing formulation according to

[53] , wherein the polymer is ethylene vinyl acetate.

[55] 5. The flexible backing formulation according to claim 53 or 54, wherein the binder does not contain polyvinyl chloride.

[56]

[53] to

[55] . The flexible backing formulation according to any one of

[53] to

[55] , 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 solid material is present in the backing formulation at a weight percent of about 10% to about 55% by weight.

[57]

[53] The flexible backing formulation according to any one of

[56] to

[57] , wherein the filler further comprises calcium carbonate.

[58] 57. The flexible backing formulation according to any of

[53] to

[57] , wherein the backing formulation has a negative Global Warming Potential (GWP), based on the material and calculated using the TRACI 2.1 methodology.

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

[0018] [Figure 1] 1 is a cross-sectional view of an embodiment of a prior art carpet tile construction that may be suitable for use with embodiments of the present invention.

[0019] [Figure 2] 1 is a cross-sectional view of an alternative embodiment of a prior art carpet tile construction that may be suitable for use with embodiments of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0020] Embodiments of the present invention relate to multi-layer surface coverings, including floor coverings, such as, but not limited to, modular panels or tiles, for installation on indoor surfaces. More specifically, embodiments of the present invention relate to formulations of and modifications to various components of floor coverings that, individually or collectively, result in products with reduced, zero, and / or negative carbon footprints when subjected to a 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 traditional man-made materials. As used herein, "bio-based" refers to materials intentionally made from naturally occurring organic materials or substances derived from living organisms and / or organisms that lived in the Common Era (CE), 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 inhomogeneous formulations with inconsistent characteristics, resulting in products that do not meet desired performance specifications. However, in the embodiments described herein, the surface covering includes one or more components, such as a precoat or backing compound, that are formed, in whole or in part, from a substantially uniform mixture of man-made materials and natural, bio-based, and / or recycled materials. In other examples, one or more other components of the surface covering include natural, bio-based, or recycled materials. In still other examples, precision manufacturing can reduce materials overall, thereby reducing the carbon footprint of the product without compromising performance.

[0023] The embodiments described herein provide a carbon-neutral or carbon-negative surface covering. It should be noted that not every layer or component in a product is required to be carbon-neutral or carbon-negative. Rather, the product is designed so that the product as a whole can have a net-neutral, or better, net-negative, carbon footprint. To accomplish this, various layers can be designed to be carbon-negative to offset other carbon-positive layers in the product. For example, a backing layer can be carbon-negative to offset a half-cloth that has a positive carbon footprint. Alternatively, the half-cloth of a carpet tile can be carbon-negative to offset a backing layer that has a positive carbon footprint. Furthermore, each discrete layer of a product can be carbon-neutral or carbon-negative.

[0024] Embodiments described herein include coating formulations (e.g., precoat formulations and backing formulations) that include high-purity biochar, referred to herein as enriched charcoal.

[0025] As used herein, "biochar" refers to a solid material produced by pyrolysis of biomass in the absence of oxygen (i.e., direct pyrolysis). Pyrolysis of biomass produces a mixture of solids (biochar), liquids (bio-oil), and gases (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 by pyrolysis temperatures of at least 350°C, optionally at least 400°C, at least 600°C, at least 800°C, 350°C to 1000°C, inclusive; 400°C to 1000°C, inclusive; 600°C to 1000°C, inclusive; and 800°C to 1000°C, inclusive.

[0026] As used herein, "enriched charcoal" refers to biochar, as defined herein, having a carbon content of at least 80% by weight. As used herein, "carbon content" refers to the percentage of the biochar's mass that is atomic carbon.

[0027] In some instances, enriched charcoal is an engineered material purposefully created under specified, controlled conditions proven to reliably produce a substance with predetermined, unique properties in terms of composition and manufacturability. In some instances, enriched charcoal is formed when wood waste and / or other rapidly renewable plant and husk materials are exposed to high heat under low-oxygen conditions in a process powered by renewable gas energy and syngas generated during heating. This process creates a carbon-rich, lightweight, blendable material that traps carbon that would otherwise escape into the atmosphere.

[0028] The enriched coals described herein can be formed by pyrolyzing biomass at very high temperatures in an oxygen-limited environment. The weight percent of carbon and the concentration of impurities in the enriched coals 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 enriched charcoal described herein include any material that is sustainable, rapidly renewable, and has minimal heavy metal content. In some examples, useful sources of biomass include grasses, seaweed, other microbial mass, leaves, bark material, beans, seed 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% (wt / wt). In some examples, the pyrolysis temperature is at least 350°C, at least 400°C, at least 600°C, at least 800°C, 350°C to 1000°C, inclusive; 400°C to 1000°C, inclusive; 600°C to 1000°C, inclusive; or 800°C to 1000°C, inclusive. Higher pyrolysis temperatures typically reduce the amount of volatile impurities in the final product, providing a purer enriched charcoal. Optionally, the pyrolysis process may be fueled by combustion of syngas generated during the process or by supplemental renewable energy. In some examples, pyrolysis modifies the chemical bonds of the biomass to create graphene composites present in the enriched char.

[0030] The enriched coals described herein have an H / C 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. org The enriched coals described herein have an O / C molar ratio of less than 0.4, less than 0.35, less than 0.3, less than 0.35, or less than 0.2. org Optionally, the enriched carbon described herein has a pH of from about 6.5 to about 10.5, inclusive; from about 7 to about 10.5, inclusive; from about 8 to about 10, inclusive; or from about 9 to about 10, inclusive.

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

[0032] Upper wear layer The upper wear layer of a floor covering can include any conventional or specialty material used in floor coverings. Materials for the upper wear layer may be selected so that the resulting floor covering exhibits desired characteristics, such as, but not limited to, a decorative appearance, favorable acoustical attributes, good insulation (e.g., good R-value), water resistance, flame 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 sheets or tiles, or rubber sheets or tiles. While embodiments of the present invention are described with specific reference to carpet tiles (e.g., but not limited to, those having the construction shown in Figures 1 and 2), it should be understood that one skilled in the art can implement or adapt the disclosure described herein to other types of surface coverings and in appropriate and suitable applications.

[0033] Some embodiments of the present invention involve selecting or modifying the type and / or amount of material used in the top wear layer (e.g., half cloth 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, yarn tuft height, and stitch density (e.g., the number of yarn tufts per square inch) all affect the yarn areal weight, which in turn affects the carbon footprint of the half cloth. "Area weight" refers to the weight of the yarn used in the half cloth. Yarn size, tuft height, and stitch density can each be manipulated to adjust the carbon footprint of the half cloth.

[0034] More specifically, it has been discovered that smaller sized yarns can be used without sacrificing the aesthetics of the tufted product. Rather, smaller sized yarns can be tufted to a smaller tuft height but a higher tuft or stitch density (i.e., more tufts per square inch). This results in less yarn usage overall and a lower yarn areal weight, without sacrificing aesthetics. Furthermore, the use of smaller yarns allows for more tufts to be placed in a given area, creating a finer, more precise tuft pattern. The increased tuft density also prevents visible tufting primaries (a problem known as grinning), despite the smaller tuft height.

[0035] Yarn Size: Some embodiments of the present invention use yarns having a denier less than 2000, for example, but not limited to, 800-1800 inclusive; 900-1600 inclusive; 1000-1500 inclusive; 1000-1400 inclusive; 1000-1200 inclusive, and / or 1200-1800 inclusive. 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 final yarn may be formed from a single 1200 denier yarn, from a two-ply yarn of 600 denier yarn, or from a three-ply yarn of 400 denier yarn, etc.

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

[0037] Tuft Density: Some embodiments of the half crosses disclosed herein comprise yarn tufts having a tuft density of 100 to 400 tufts per square inch ("TPI"), inclusive; 110 to 400 TPI, inclusive; 140 to 300 TPI, inclusive; 160 to 280 TPI, inclusive; 170 to 270 TPI, inclusive; 170 to 260 TPI, inclusive; 180 to 250 TPI, inclusive; and / or 180 to 240 TPI, inclusive.

[0038] Face Weight: The face weight of the yarn in a traditional carpet tile half cloth is at least 20 ounces per square yard ("osy"). The face weight of the yarn in some embodiments of the half cloths described herein is significantly lower, for example, in the range of 5 to 20 osy, inclusive; 6 to 18 osy, inclusive; 8 to 17 osy, inclusive; 10 to 15 osy, inclusive; 6 to 12 osy, inclusive; 12 to 18 osy, inclusive; and / or 9 to 12 osy, inclusive. In some embodiments, the face 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 a reduced carbon footprint. For example, yarns made from natural, bio-based, or recycled materials will provide a lower half-cross GWP contribution than yarns made from non-renewable, fossil fuel-based resources. The yarns may 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 (polytrimethyl terephthalate), PBT (polybutyl terephthalate), PLA (polylactic acid), hemp, wool, cellulosic materials, and other fibers. In some examples, the yarns are post-consumer ("PC") or post-industrial ("PI") recycled materials, such as PC or PI recycled nylon, or PC or PI polyethylene terephthalate. Other suitable yarn materials are disclosed in WO 2011 / 066620, the entire contents of which are incorporated herein by reference.

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

[0041] All of the above factors may be selected and manipulated to reduce, or even neutralize or negative, the carbon footprint of a facecloth. Table 1 compares conventional facecloth constructions with the inventive facecloth embodiments contemplated herein by their associated carbon footprints, based on material. [Table 1]

[0042] Furthermore, the reduction in the carbon footprint of the half cloth is achieved without sacrificing performance.More specifically, it has been surprisingly discovered that carpet tiles comprising the half cloth embodiments disclosed herein can achieve a severe wear rating (i.e., a rating of 3.5 or higher) 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 incorporated herein by reference in its entirety, in accordance with the rating scale 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 incorporated herein by reference in its entirety.

[0043] To test for abrasion in accordance with ASTM D5252, a section of finished carpet tile is cut and fitted around the circumference of a drum attached to a rotator. A six-foot pod of a specified weight is placed inside the drum. Herein, a pod is a mechanical foot simulator. The rotator rotates the drum for a specified number of revolutions, after which the carpet tile section is removed and the carpet tile's overall appearance is inspected and rated. ASTM D7330 describes a rating scale to indicate how well the carpet "held up" under the test, and inspectors consider factors such as pile crush, pilling, and thread breakage in grading the carpet. More specifically, ASTM D7330 includes a Texture Appearance Retention Rating (TARR) to rate changes in tile appearance. A TARR rating of 5 represents no change in the appearance of the half cloth after testing, and a TARR rating of 1 indicates a very drastic change in the appearance of the half cloth after testing. Some embodiments of carpet tiles with half cloths disclosed herein achieve a TARR rating according to ASTM D7330 of 2.5 or greater, 3.0 or greater, and / or 3.5 or greater when tested according to ASTM D7330. A TARR rating of 3.5 or greater indicates that the tile is suitable for use under the most intense traffic conditions.

[0044] Carpet tiles, including half-cloth embodiments disclosed herein, may also meet the requirements for a Division 33: Heavy Commercial Use classification as set out in BS EN 1307:2014 - Textile Floor Coverings - Classification (incorporated herein by reference in its entirety), when the tiles are subjected to a performance rating in accordance with the Vetterman drum test method set out in BS ISO 10361:2015 - Textile floor coverings - Production of changes in appearance by means of Vettermann drum and hexapod tumbler tester (incorporated herein by reference in its entirety), and BS EN ISO 9405:2017 - Textile Floor coverings - Assessment of Changes in Appearance (incorporated herein by reference in its entirety).

[0045] Precoat Layer: In carpet tiles, the precoat layer is used to bond the yarn to the tufting primary layer. Typically, the precoat is applied as a water-based emulsion of precoat adhesive, optionally modified with fillers and various additives. In some instances, 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 any thermoplastic polymer, including, but not limited to, 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 comprises a thermoplastic material derived from natural or recycled materials, including, but not limited to, starch or recycled polyvinyl butyral.

[0047] Precoat compositions contemplated for floor coverings described herein may be from about 15% to about 100% by weight ("wt / wt"), inclusive; from about 20% to about 100% (wt / wt), inclusive; from about 30% to about 100% (wt / wt), inclusive; from about 40% to about 100% (wt / wt), inclusive; from about 50% to about 100% (wt / wt), inclusive; from about 15% to about 90% (wt / wt), inclusive; from about 20% to about 90% (wt / wt), inclusive; from about 30% to about 90% (wt / wt), inclusive. weight); Approximately 40% to approximately 90% (weight / weight), including both ends; Approximately 50% to approximately 90% (weight / weight), including both ends; Approximately 90% to approximately 100% (weight / weight), including both ends; Approximately 90% to approximately 98% (weight / weight), including both ends; Approximately 15% to approximately 90% (weight / weight), including both ends; Approximately 20% to approximately 90% (weight / weight), including both ends; Approximately 30% to approximately 90% (weight / weight), including both ends; Approximately 40% to approximately 90% (weight / weight), including both ends; Approximately 50% to approximately 90% (weight / weight), including both ends; Approximately 15% to approximately 80% (weight), including both ends / weight); Approximately 20% to approximately 80% (weight / weight), including both ends; Approximately 30% to approximately 80% (weight / weight), including both ends; Approximately 40% to approximately 80% (weight / weight), including both ends; Approximately 50% to approximately 80% (weight / weight), including both ends; Approximately 15% to approximately 70% (weight / weight), including both ends; Approximately 20% to approximately 70% (weight / weight), including both ends; Approximately 30% to approximately 70% (weight / weight), including both ends; Approximately 40% to approximately 70% (weight / weight), including both ends; Approximately 50% to approximately 70% (weight / weight), including both ends; Approximately 15% about 20% to about 60% (wt / wt), inclusive; about 30% to about 60% (wt / wt), inclusive; about 40% to about 60% (wt / wt), inclusive; about 50% to about 60% (wt / wt), inclusive; about 15% to about 50% (wt / wt), inclusive; about 20% to about 50% (wt / wt), inclusive; about 30% to about 50% (wt / wt), inclusive; or about 40% to about 50% (wt / wt), inclusive, weight percent of the precoat adhesive.

[0048] Fillers are often incorporated into precoat adhesives to add stiffness and weight, modify flow characteristics, improve tuft binding, impart desired characteristics such as flame resistance, and for economic benefits. Suitable fillers for precoats include any known organic or inorganic (e.g., mineral) filler materials. In some examples, the precoat filler includes natural, bio-based, or recycled filler materials, which can contribute to reducing the carbon footprint of the precoat and ultimately the floor covering. Additionally or alternatively, the precoat filler can include conventional filler materials. Useful precoat filler materials include fly ash, calcium oxide, calcium carbonate (e.g., limestone), silicates, silica, oxides of silica, carbonates, sulfates, oxides of antimony, 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), reclaimed, post-industrial, or recycled organic or inorganic materials (e.g., calcium carbonate, talc, clay, minerals, rubber, plastic, or fiber), and biochar. In some embodiments, the filler comprises high-purity biochar, referred to herein as enriched charcoal.

[0049] Precoat compositions contemplated for floor coverings described herein may be from about 0% to about 85% (wt / wt), inclusive; from about 0% to about 80% (wt / wt), inclusive; from about 0% to about 70% (wt / wt), inclusive; from about 0% to about 60% (wt / wt), inclusive; from about 0% to about 50% (wt / wt), inclusive; from about 10% to about 85% (wt / wt), inclusive; from about 10% to about 80% (wt / wt), inclusive; Approximately 10% to approximately 70% (wt / wt) including both ends; Approximately 10% to approximately 60% (wt / wt) including both ends; Approximately 10% to approximately 50% (wt / wt) including both ends; Approximately 0% to approximately 10% (wt / wt) including both ends; Approximately 2% to approximately 10% (wt / wt) including both ends; Approximately 20% to approximately 85% (wt / wt) including both ends; Approximately 20% to approximately 80% (wt / wt) including both ends; Approximately 20% to approximately 70% (wt / wt) including both ends; Approximately 20% including both ends ~60% (wt / wt); ~20% to ~50% (wt / wt) including both ends; ~30% to ~85% (wt / wt) including both ends; ~30% to ~80% (wt / wt) including both ends; ~30% to ~70% (wt / wt) including both ends; ~30% to ~60% (wt / wt) including both ends; ~30% to ~50% (wt / wt) including both ends; ~40% to ~85% (wt / wt) including both ends; ~40% to ~80% including both ends (wt / wt); about 40% to about 70% (wt / wt), inclusive; about 40% to about 60% (wt / wt), inclusive; about 40% to about 50% (wt / wt), inclusive; about 50% to about 85% (wt / wt), inclusive; about 50% to about 80% (wt / wt), inclusive; about 50% to about 70% (wt / wt), inclusive; or about 50% to about 60% (wt / wt), inclusive. In some embodiments, the precoat composition is filler-free.

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

[0051] Conventional precoats rely on a high mass of precoat material to encapsulate and bond the yarns. The embodiments described herein use a reduced mass of precoat material 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 fillers. Reducing or eliminating fillers also results in a more concentrated adhesive, requiring less application. In some examples, the mass of the precoat can be further reduced while maintaining performance by precisely applying the precoat to the tufting primary. For example, while conventional precoats have a weight of about 18 osy to about 32 osy, 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 example conventional precoat compositions to example embodiments of the inventive precoat compositions ("PCs") contemplated herein. [Table 2]

[0053] A typical carpet tile half cloth has a weight of approximately 50 osy (20 osy yarn, 4 osy tufting primaries, and 26 osy precoat). Implementation of some or all of the above suggested modifications can significantly reduce the weight of the half cloth. In some embodiments, the half cloth (yarn, tufting primaries, and precoat) has a weight of 14 osy to 35 osy, inclusive; 14 osy to 30 osy, inclusive; 14 osy to 25 osy, inclusive; 14 osy to 23 osy, inclusive; 14 osy to 21 osy, inclusive; 15 osy to 19 osy, inclusive; or 16 osy to 18 osy, inclusive.

[0054] Table 3 compares the construction of a conventional half-cross with the half-cross embodiments of the present invention contemplated herein. [Table 3] As reflected in Table 3, some embodiments of the half cloth of the present invention represent at least a 65% weight reduction; at least a 50% weight reduction; at least a 40% weight reduction; at least a 30% weight reduction; at least a 25% weight reduction; or at least a 20% weight reduction relative to the weight of a conventional half cloth. In some embodiments, the reduction in carbon footprint of the half cloth embodiments contemplated herein is at least -1 KG CO2 / m compared to the above conventional half cloth. 2 , at least -1.2KG CO2 / m 2 , at least -1.4KG CO2 / m 2 , at least -1.6KG CO2 / m 2 , at least -1.8KG CO2 / m 2 , at least -2.0KG CO2 / m 2 , at least -2.2KG CO2 / m 2 , at least -2.4KG CO2 / m 2 , at least -2.6KG CO2 / m 2 , at least -2.8KG CO2 / m2 , or at least -3.0KG CO2 / m 2 is.

[0055] Backing Layer In addition to the upper wear layer, floor coverings described herein typically include a backing layer underlying the upper wear layer. The backing layer is typically a backing composite comprising a backing formulation and one or more optional substrates. Floor covering embodiments described herein have a backing formulation comprising a binder and a filler. The filler can include high-purity biochar, referred to herein as enriched charcoal. The inclusion of enriched charcoal as a filler in the backing formulation dramatically reduces the carbon footprint of the floor covering by sequestering carbon. The effect of using enriched charcoal on the carbon footprint can be even more dramatic for floor coverings with a high filler content. For example, in modular flooring, such as carpet tiles, the backing composite must be rigid so that the tiles can function as free-laying floor tiles. Typically, modular flooring backing composites have a high filler content, which contributes to the required dimensional stability.

[0056] In addition to being dimensionally stable, the backing compositions and, optionally, backing composites described herein are flexible. Flexibility facilitates installation of the floor coverings described herein. The flexible backing compositions or backing composites described herein easily yield and bend without breaking. The force required to bend the flexible backing compositions or backing composites described herein is low; for example, sufficient force can be applied manually, without the use of machinery, when installing the surface covering.

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

[0058] Any of the enriched charcoals described herein are suitable for use in the backing formulations described herein. Optionally, the enriched charcoal is produced by pyrolysis of feedstock biomass having a carbon content of at least 50%, at least 60%, or at least 70% (wt / wt). Optionally, the biochar is produced by a pyrolysis process conducted at a temperature of at least 350°C, at least 400°C, at least 600°C, at least 800°C, 350°C to 1000°C, inclusive; 400°C to 1000°C, inclusive; 600°C to 1000°C, inclusive; or 800°C to 1000°C, inclusive.

[0059] The concentrated carbon in the backing formulation may be in the form of particles having a particle size of about 0.01 μm to about 3 mm, inclusive; about 0.01 μm to about 2.5 mm, inclusive; about 0.01 μm to about 2 mm, inclusive; or about 0.01 μm to about 1 mm, inclusive. In some embodiments, the concentrated carbon particles may have an average particle size of about 80 μm to about 120 μm, inclusive. The particles may be separated or sized to produce a desired average size. The concentrated carbon raw material may have a particle size greater than about 3 mm when introduced into the backing formulation. Typically, the concentrated carbon particles are reduced in size during production of the backing formulation.

[0060] The filler content in the backing formulations described herein can be 100% enriched carbon, but typically contains from about 0.1% to about 100% (wt / wt), inclusive, enriched carbon. In some examples, the filler content includes at least 2% (wt / wt), at least 10% (wt / wt), at least 15% (wt / wt), at least 20% (wt / wt), at least 25% (wt / wt), at least 30% (wt / wt), at least 35% (wt / wt), at least 40% (wt / wt), at least 45% (wt / wt), at least 50% (wt / wt), at least 55% (wt / wt), at least 60% (wt / wt), at least 65% (wt / wt), at least 70% (wt / wt), at least 75% (wt / wt), at least 80% (wt / wt), at least 95% (wt / wt), at least 90% (wt / wt), or at least 95% (wt / wt) of the concentrated charcoal. In some examples, the filler content includes enriched coal at any weight percent between about 2% and about 98% (wt / wt), inclusive; between about 10% and about 70% (wt / wt), inclusive; between about 20% and about 55% (wt / wt), inclusive; or between about 30% and about 50% (wt / wt), inclusive. When the filler content is less than 100% enriched coal, the filler also includes one or more additional filler materials.

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

[0062] The filler (including the enriched carbon and any additional filler material(s)) can have a particle size of 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 fillers of different shapes. Optionally, the inorganic filler can be combined with bio-based and / or recycled fillers, such as wood chips, natural fibers, plant husks, plant residues, synthetic fibers, glass fibers, recycled fibers, recycled rubber, recycled plastics, 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 enriched carbon disclosed herein.

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

[0064] In some embodiments, the backing formulations described herein comprise from about 0.1% to about 70% (wt / wt), inclusive; from about 0.5% to about 65% (wt / wt), inclusive; from about 1% to about 65% (wt / wt), inclusive; from about 1% to about 60% (wt / wt), inclusive; from about 10% to about 60% (wt / wt), inclusive; from about 10% to about 55% (wt / wt), inclusive; from about 10% to about 50% (wt / wt), inclusive; from about 15% to about 60% (wt / wt), inclusive; from about 20% to about 60% (wt / wt), inclusive; from about 20% to about 50% (wt / wt), inclusive; from about 25% to about 55% (wt / wt), inclusive; The weight percent of the concentrated carbon is about 30% to about 50% (wt / wt), inclusive; about 1% to about 15% (wt / wt), inclusive; about 1% to about 10% (wt / wt), inclusive; about 1% to about 5% (wt / wt), inclusive; about 5% to about 15% (wt / wt), inclusive; about 5% to about 10% (wt / wt), inclusive; about 10% to about 15% (wt / wt), inclusive; about 15% to about 50% (wt / wt), inclusive; about 15% to about 40% (wt / wt), inclusive; about 20% to about 40% (wt / wt), inclusive; about 25% to about 35% (wt / wt), inclusive; or about 30% to 40% (wt / wt), inclusive.

[0065] Binder: In addition to the filler, the backing formulations described herein further include a binder, which provides structure to the backing system. The binder comprises at least one of a bio-based ester, a bio-based oil, or a polymer, and may optionally include additives that facilitate production of the backing formulation or impart desired characteristics to the finished backing formulation. In some embodiments, the binder comprises 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 in a weight percentage of from about 5% to about 70% (wt / wt), inclusive; from about 5% to about 60% (wt / wt), inclusive; from about 5% to about 50% (wt / wt), inclusive; from about 6% to about 40% (wt / wt), inclusive; from about 8% to about 30% (wt / wt), inclusive; from about 10% to about 25% (wt / wt), inclusive; from about 12% to about 25% (wt / wt), inclusive; or from about 14% to about 23% (wt / wt), inclusive. In some examples, the binder portion of the backing formulation comprises at least about 40% (w / w) bio-based and / or recycled materials; for example, the binder content may comprise 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% (w / w) 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 and may have a melting point between about 65° C. and about 160° C. (e.g., between about 80° C. and 120° C.), allowing them to be handled at room temperature while still allowing the mixing and application process to occur at reasonable processing temperatures.

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

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

[0070] The oil in the backing formulation can act as a plasticizer, softening the backing formulation and making it more flexible. Including oil in the binder can increase the filler loading of the backing formulation, allowing for more concentrated carbon to be included in the backing formulation. Including oil in the binder can also reduce or eliminate the need for polymer. This combination of increasing the amount of filler and decreasing the amount of polymer in the binder is highly beneficial because most fillers have a relatively small environmental impact, while polymers have a relatively large environmental impact. Therefore, both increasing the amount of filler and decreasing the amount of polymer reduce the environmental impact of the binder.

[0071] The 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 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 oil, but may also be a non-fossil petroleum oil, for example, a plant-, animal-, or seaweed-derived oil. In some embodiments, the oil may be a synthetic oil, such as an oil synthesized to impart desired characteristics.

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

[0073] A polymer (e.g., thermoset, thermoplastic, or elastomeric) may also be included in the binder. Suitable polymers may be any polymer or copolymer, including block copolymers, known for use in backing formulations for floor coverings. Non-limiting examples of 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 may 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 include those having about 1% to about 50%, e.g., about 10% to about 40%, by weight of vinyl acetate, with the remainder being ethylene. Useful SBS polymers have a styrene content between 10% and 70% (w / w).

[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 ExxonMobil) and Mirel™ granules (a polyhydroxyalkanoate available from Metabolix).

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

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

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

[0078] In some examples, the backing formulation further comprises a hydrocarbon wax. The hydrocarbon wax may be present in a weight percent of the backing formulation of about 0% to about 15%. 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 one embodiment, the backing formulation comprises: (1) a first filler comprising about 2% to about 25% (wt / wt), e.g., about 5% to about 20% (wt / wt), more preferably about 7% to about 15% (wt / wt), even more preferably about 9% to about 13% (wt / wt), and still more preferably about 10% to about 12% (wt / wt) of concentrated charcoal; (2) about 35% to about 65% (wt / wt), e.g., about 40% to about 60% (wt / wt), about 45% to about 55% (wt / wt), about 50% to about 55% (wt / wt) of a second filler (i.e., not a concentrated coal); (3) about 2% to about 25% (wt / wt), e.g., about 5% to about 20% (wt / wt), more preferably about 7% to about 17% (wt / wt), even more preferably about 10% to about 15% (wt / wt), and still more preferably about 12% to about 14% (wt / wt) of bio-based esters; (4) about 1% to about 10% (wt / wt), e.g., about 2% to about 7% (wt / wt), about 2% to about 5% (wt / wt), about 2% to about 4% (wt / wt), about 3% to about 4% (wt / wt) of an oil (preferably, but not necessarily, a bio-based oil); and (5) about 2% to about 30% (wt / wt), for example about 5% to about 25% (wt / wt), more preferably about 10% to about 20% (wt / wt), and even more preferably about 15% to about 20% (wt / wt) of polymer Includes:

[0080] In one embodiment, the backing formulation comprises: (1) a first filler comprising about 20% to about 60% (wt / wt), e.g., about 25% to about 55% (wt / wt), more preferably about 30% to about 55% (wt / wt), even more preferably about 35% to about 50% (wt / wt), still more preferably about 40% to about 55% (wt / wt), and even more preferably about 40% to about 50% (wt / wt); (2) about 0% to about 10% (wt / wt), e.g., about 0% to about 5% (wt / wt), of a second filler (i.e., not concentrated coal); (3) about 5% to about 35% (wt / wt), e.g., about 10% to about 30% (wt / wt), more preferably about 15% to about 30% (wt / wt), even more preferably about 10% to about 25% (wt / wt), even more preferably about 15% to about 23% (wt / wt), and even more preferably about 18% to about 22% bio-based ester; (4) about 1% to about 10% (wt / wt), e.g., about 2% to about 7% (wt / wt), about 2% to about 5% (wt / wt), about 2% to about 4% (wt / wt), about 3% to about 4% (wt / wt) of an oil (preferably, but not necessarily, a bio-based oil); and (5) about 5% to about 35% (wt / wt), for example about 10% to about 30% (wt / wt), more preferably about 15% to about 30% (wt / wt), and even more preferably about 20% to about 30% (wt / wt) of polymer Includes:

[0081] In one embodiment, the backing formulation comprises: (1) a first filler comprising about 15% to about 50% (wt / wt), e.g., about 20% to about 45% (wt / wt), more preferably about 25% to about 40% (wt / wt), even more preferably about 30% to about 40% (wt / wt), and still more preferably about 32% to about 38% (wt / wt) of concentrated charcoal; (2) about 2% to about 30% (wt / wt), e.g., about 5% to about 25% (wt / wt), more preferably about 10% to about 20% (wt / wt), and even more preferably about 15% to about 20% (wt / wt) of a second filler (i.e., not concentrated coal); (3) about 15% to about 50% (wt / wt), e.g., about 20% to about 45% (wt / wt), more preferably about 25% to about 40% (wt / wt), even more preferably about 30% to about 40% (wt / wt), and still more preferably about 35% to about 40% (wt / wt) bio-based esters; (4) about 1% to about 15% (wt / wt), e.g., about 2% to about 10% (wt / wt), e.g., about 3% to about 9% (wt / wt), about 4% to about 8% (wt / wt), about 5% to about 7% (wt / wt), about 6% to about 7% (wt / wt) of an oil (preferably, but not necessarily, a bio-based oil); and (5) about 1% to about 15% (wt / wt), for example, about 2% to about 10% (wt / wt), about 3% to about 8% (wt / wt), about 4% to about 6% (wt / wt), or about 4% to about 5% (wt / wt) of polymer Includes:

[0082] In one embodiment, the backing formulation comprises: (1) a first filler comprising about 0% to about 10% (wt / wt), e.g., about 0% to about 5% (wt / wt), e.g., about 1% to about 3% (wt / wt), e.g., about 1% to about 2% (wt / wt), of concentrated charcoal; (2) about 35% to about 65% (wt / wt), e.g., about 40% to about 65% (wt / wt), about 45% to about 60% (wt / wt), about 50% to about 60% (wt / wt), about 55% to about 60% (wt / wt) of a second filler (i.e., not a concentrated coal); (3) about 2% to about 25% (wt / wt), e.g., about 4% to about 20% (wt / wt), more preferably about 5% to about 15% (wt / wt), even more preferably about 7% to about 12% (wt / wt), and still more preferably about 9% to about 11% (wt / wt) of oil (preferably, but not necessarily, a bio-based oil); and (4) about 10% to about 45% (wt / wt), for example about 20% to about 35% (wt / wt), more preferably about 25% to about 35% (wt / wt), and even more preferably about 27% to about 33% (wt / wt) of a blend of recycled PVC and recycled carpet. Includes:

[0083] As an example, a backing formulation of the present invention ("BC") was prepared having the composition shown in Table 4. Table 4 also compares the estimated TRACI 2.1 GWP of the backing formulation of the present invention with that of a conventional backing formulation. [Table 4-1] [Table 4-2]

[0084] The backing formulation can be characterized in several ways according to known industry standards. For 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, according to the method described in EN 1427:2007 Bitumen and bituminous binders - Determination of the softening point - Ring and Ball method. In preferred embodiments, the backing formulation has a ring and ball softening point, determined according to EN 1427:2007, within the range of 60-180°C, 70-160°C, 75-140°C, or 80-120°C.

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

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

[0087] Optionally, the backing layer may include one or more substrates that are adhered to the backing formulation or provided / embedded within the backing formulation to form a backing composite. The substrate may be, for example, a glass veil, a glass scrim, a foam layer, or a nonwoven covering (e.g., fleece). Optionally, a substrate, such as a protective layer (e.g., fleece) to prevent the backing formulation from sticking to or scratching the floor, may be applied to the underside 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 as measured in accordance with the TRACI 2.1 methodology. The GWP of several carpet tiles ("CT") consistent with certain embodiments described herein is 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 coverings are provided in individual tiles. For example, they may be provided in square tiles measuring 50 cm x 50 cm or 1 m x 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, countertops, backsplashes, etc.

[0090] The floor coverings described herein may meet the categories specified by European Classification EN 1307-2014: Textile floor coverings - Classification. This European standard specifies the requirements for the classification of all textile floor coverings and carpet tiles, excluding rugs and runners (see ISO 2424:2007 - Textile floor coverings - Vocabulary), into use categories relating to one or more of the following characteristics: wear, appearance retention, additional performance characteristics, and a category for luxury ratings.

[0091] The floor covering described herein can be prepared by standard methods known in the art. For example, the floor covering described herein can be prepared by providing a textile top cloth with a top surface comprising yarns or fibers and a bottom surface comprising a precoat layer, providing a 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 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 for removal of at least a portion of the floor covering, e.g., one or more tiles, without destroying the removed portion of the floor covering. In other embodiments, individual tiles of the floor covering are attached to each other but not to the underlying surface, creating a floating installation. For example, as disclosed in U.S. Pat. No. 7,464,510, adhesive-bearing connectors may be used to hold the tiles together. Alternatively, a mechanical fastening system may be formed along the edges of the modules (e.g., in the core) so that adjacent modules interlock with each other. An example of such a "click-fastening" system is disclosed in U.S. Patent Application Publication No. 2016 / 0208500, the entire contents of which are incorporated herein by reference. [Example]

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

[0094] (Example 2) 10. The floor covering of Example 1, wherein the enriched charcoal has a carbon content of at least 85%.

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

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

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

[0098] (Example 6) The floor covering of Example 5, wherein the concentrated charcoal is present in the backing formulation in a weight percent of about 10% to about 50% by weight.

[0099] (Example 7) The floor covering of Example 6, wherein the concentrated charcoal is present in the backing formulation in a weight percent of about 20% to about 50% by weight.

[0100] (Example 8) The floor covering of Example 7, wherein the concentrated charcoal is present in the backing formulation in a weight percent of about 30% to about 50% by weight.

[0101] (Example 9) 9. The floor covering of any one of Examples 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.

[0102] (Example 10) The floor covering of Example 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.

[0103] (Example 11) The floor covering of Example 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.

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

[0105] (Example 13) 13. The floor covering of example 12, wherein the bio-based ester comprises an esterified rosin, a hydrogenated rosin, a phenolic rosin, or a terpene rosin.

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

[0107] (Example 15) 15. The floor covering of any one of Examples 1 to 14, wherein the binder comprises an oil, and the oil comprises a plant, animal, or seaweed-derived oil.

[0108] (Example 16) 16. The floor covering of example 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.

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

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

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

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

[0113] (Example 21) The floor covering of any one of Examples 1 to 20, wherein the binder is essentially free of virgin PVC.

[0114] (Example 22) 22. The floor covering of any one of Examples 1 to 21, wherein the floor covering is a carpet tile and the upper wear layer comprises a half cloth comprising yarn tufted into a tufting primary fabric and a precoat provided on the underside of the tufting primary fabric.

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

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

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

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

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

[0120] (Example 28) The floor covering of 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 of any one of Examples 22 to 28, wherein the yarn has a tuft height of between 2 / 32 inch and 3 / 32 inch, inclusive.

[0122] (Example 30) The floor covering of any one of Examples 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.

[0123] (Example 31) The floor covering of any one of Examples 22 to 30, wherein the precoat comprises a filler comprising concentrated charcoal.

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

[0125] (Example 33) The floor covering of 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 of 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 of any one of Examples 1 to 34, wherein the floor covering comprises a backing composite comprising a backing formulation and a substrate, and the backing composite is flexible.

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

[0129] (Example 37) 37. The floor covering of 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) 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.

[0131] (Example 39) The floor covering of Example 38, wherein the backing composition comprises a binder and at least one filler, and the at least one filler comprises concentrated charcoal present in the backing composition in a weight percent of from about 1% to about 60% by weight.

[0132] (Example 40) 39. The floor covering of Example 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.

[0133] (Example 41) The floor covering of Example 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.

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

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

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

[0137] (Example 45) The floor covering of any one of Examples 39 to 44, wherein the binder is essentially free of virgin PVC.

[0138] (Example 46) 46. ​​The floor covering of any one of Examples 38 to 45, wherein the floor covering is a carpet tile and the upper wear layer comprises a half cloth comprising yarn tufted into a tufting primary fabric and a precoat provided on the underside of the tufting primary fabric.

[0139] (Example 47) 47. The floor covering of Example 46, wherein the half-cloth has a yarn areal weight of 18 osy or less.

[0140] (Example 48) 48. The floor covering of example 46 or example 47, wherein the yarn comprises recycled nylon 6 or nylon 6,6.

[0141] (Example 49) The floor covering of any one of Examples 46 to 48, wherein the yarn has a denier of 1200 to 1800, inclusive.

[0142] (Example 50) 50. The floor covering of any one of Examples 46 to 49, wherein the precoat comprises a filler comprising concentrated charcoal.

[0143] (Example 51) The floor covering of any one of Examples 46 to 50, wherein the precoat is devoid of filler.

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

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

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

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

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

[0149] (Example 57) 57. The flexible backing formulation of any one of Examples 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.

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

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

[0152] Although the descriptions of floor coverings disclosed herein may refer to one or more "layers," it will be understood that once the floor covering is processed and ready for installation, the floor covering may be a bonded, single, integral structure in which the individual layers or boundaries between the individual layers are not necessarily easily discernible and / or separate from one another.

[0153] While the subject matter of embodiments of the present invention is described herein with particularity to meet statutory requirements, this description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be embodied in other ways, may include different elements or steps, or may be used in conjunction with other existing or future technologies. This description should not be construed as implying any particular order or arrangement among or among the various steps or elements, unless the order of individual steps or arrangement of elements is explicitly recited.

[0154] Examples of the present invention are described for purposes of explanation and not limitation, and alternatives will become apparent to the reader of this patent. Thus, the present invention is not limited to the examples described above, and various examples may be made and changes may be made without departing from the scope of the present invention.

Claims

1. 1. A floor covering comprising an upper wear layer and a backing composition, wherein the backing composition comprises a binder and at least one filler material, the at least one filler material comprising biochar having a carbon content of at least 80% by weight, and the biochar is present in the backing composition at a weight percent of 1% to 60% by weight.

2. A floor covering as described in claim 1, wherein the biochar has a carbon content of at least 85%.

3. A floor covering as described in claim 1 or 2, wherein the biochar contains less than 40 ppm total polycyclic aromatic hydrocarbons (PAHs) and less than 15 ppm total heavy metals.

4. A floor covering described in any one of claims 1 to 3, wherein the biochar has a particle size of 0.01 μm to 3 mm.

5. A floor covering as described in claim 1, wherein biochar is present in the backing formulation at a weight percentage of 10% to 50% by weight.

6. A floor covering as described in claim 5, wherein biochar is present in the backing formulation at a weight percentage of 20% to 50% by weight.

7. A floor covering as described in claim 6, wherein biochar is present in the backing formulation at a weight percentage of 30% to 50% by weight.

8. 8. The floor covering of claim 1, wherein the at least one filler comprises a first filler comprising biochar 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.

9. 9. The floor covering of claim 8, wherein the first filler and the second filler are present in the backing formulation in a combined weight percent of 40% to 70% by weight.

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 50% to 70% by weight.

11. 11. The floor covering of claim 1, wherein the binder comprises a bio-based ester.

12. 12. The floor covering of claim 11, wherein the bio-based ester comprises an esterified rosin, a hydrogenated rosin, a phenolic rosin, or a terpene-based rosin.

13. 13. The floor covering of claim 11 or 12, wherein the bio-based ester is present in the backing formulation in a weight percent of 5% to 40% by weight.

14. 14. A floor covering according to any one of claims 1 to 13, wherein the binder comprises an oil.

15. 15. The floor covering of claim 14, 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.

16. A floor covering as described in claim 14 or 15, wherein the oil is present in the backing formulation in a weight percentage of 2% to 15% by weight.

17. 17. The floor covering of any one of claims 1 to 16, wherein the binder comprises a polymer.

18. 20. The floor covering of claim 17, wherein the polymer is present in the backing formulation in a weight percent of 30% or less by weight.

19. 19. The floor covering of claim 17 or 18, wherein the polymer comprises polyvinyl chloride (PVC) or ethylene vinyl acetate (EVA).

20. 20. The floor covering of any one of claims 1 to 19, wherein the binder is essentially free of virgin PVC.

21. 21. The floor covering of any one of claims 1 to 20, wherein the floor covering is a carpet tile and the upper wear layer comprises yarn tufted into a tufting primary backing and a precoat provided on the underside of the tufting primary backing.

22. 22. The floor covering of claim 21, wherein the upper wear layer has an areal weight of yarns of 610.3 g / m2 or less.

23. 23. The floor covering of claim 22, wherein the upper wear layer has an areal weight of yarns of 406.9 g / m2 or less.

24. 24. The floor covering of any one of claims 21 to 23, wherein the yarn comprises nylon 6 or nylon 6,6.

25. 25. A floor covering according to any one of claims 21 to 24, wherein the yarn has a denier of from 900 to 1800 inclusive at both ends.

26. 26. The floor covering of claim 25, wherein the yarn has a denier of 1200 to 1800 inclusive.

27. 27. The floor covering of any one of claims 21 to 26, wherein the top wear layer has a tuft density of 140 to 300 tufts per inch, inclusive.

28. 28. The floor covering of any one of claims 21 to 27, wherein the yarn has a tuft height of between 2 / 32 inch and 3 / 32 inch, inclusive.

29. 29. The floor covering of any one of claims 21 to 28, wherein the carpet tile achieves an abrasion 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.

30. 30. The floor covering of any one of claims 21 to 29, wherein the precoat comprises a filler comprising biochar having a carbon content of at least 80% by weight, and the biochar is present in the precoat in a weight percent of from 0% to 85% by weight.

31. 30. The floor covering of any one of claims 21 to 29, wherein the precoat is devoid of fillers.

32. 32. The floor covering of any one of claims 21 to 31, wherein the precoat has a weight of less than 610.3 g / m2.

33. 33. A floor covering according to any one of claims 21 to 32, wherein the upper wear layer has a weight of 476.7 g / m² to 1186.7 g / m².

34. 34. The floor covering of any one of claims 1 to 33, wherein the floor covering comprises a backing composite comprising a backing formulation and a substrate, and the backing composite is flexible.

35. 35. The floor covering of any one of claims 1 to 34, wherein the backing formulation has a negative Global Warming Potential (GWP), based on materials and calculated using TRAC1 2.1 methodology.

36. 36. A floor covering according to any one of claims 1 to 35, wherein the entire floor covering has a negative cradle-to-gate GWP, calculated using TRAC1 2.1 methodology.

37. 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 the TRAC1 2.1 methodology.

38. 38. The floor covering of claim 37, wherein the backing formulation comprises a binder and at least one filler, the at least one filler comprising biochar having a carbon content of at least 80% by weight, and the biochar is present in the backing formulation at a weight percent of 1% to 60% by weight.

39. 39. The floor covering of claim 38, wherein the at least one filler comprises a first filler comprising biochar 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.

40. 40. The floor covering of claim 39, wherein the first filler and the second filler are present in the backing formulation at a combined weight percent of 40% to 70% by weight.

41. 41. The floor covering of any one of claims 38 to 40, wherein the binder further comprises a bio-based ester present in the backing formulation at a weight percent of 5% to 40% by weight.

42. 42. The floor covering of any one of claims 38 to 41, wherein the binder comprises a bio-based oil present in the backing formulation in a weight percentage of from 2% to 15% by weight.

43. 43. The floor covering of any one of claims 38 to 42, wherein the binder comprises a polymer present in the backing formulation at a weight percent of 30% or less.

44. 44. A floor covering according to any one of claims 38 to 43, wherein the binder is essentially free of virgin PVC.

45. 45. The floor covering of any one of claims 37 to 44, wherein the floor covering is a carpet tile and the upper wear layer comprises yarn tufted into a tufting primary backing and a precoat provided on the underside of the tufting primary backing.

46. 46. ​​The floor covering of claim 45, wherein the upper wear layer has an areal weight of yarns of 610.3 g / m2 or less.

47. 47. The floor covering of claim 45 or 46, wherein the yarn comprises nylon 6 or nylon 6,6.

48. 48. A floor covering according to any one of claims 45 to 47, wherein the yarn has a denier of 1200 to 1800 inclusive.

49. 49. The floor covering of any one of claims 45 to 48, wherein the precoat comprises a filler comprising biochar having a carbon content of at least 80% by weight, the biochar being present in the precoat in a weight percent of from 0% to 85% by weight.

50. 49. The floor covering of any one of claims 45 to 48, wherein the precoat is devoid of fillers.

51. 51. The floor covering of any one of claims 45 to 50, wherein the precoat has a weight of less than 610.3 g / m2.

52. 52. A floor covering according to any one of claims 45 to 51, wherein the upper wear layer has a weight of from 476.7 g / m² to 1186.7 g / m².

53. 1. A flexible backing formulation comprising a binder and a filler, wherein the binder comprises a bio-based ester, a bio-based oil, and a polymer; and the filler comprises biochar having a carbon content of at least 80% by weight, wherein the biochar is present in the backing formulation at a weight percent of 1% to 60% by weight.

54. 54. The flexible backing formulation of claim 53, wherein the polymer is ethylene vinyl acetate.

55. 55. The flexible backing formulation of claim 53 or 54, wherein the binder does not include polyvinyl chloride.

56. 56. The flexible backing formulation of any one of claims 53 to 55, wherein the bio-based ester is present in the backing formulation at a weight percent of 10% to 40% by weight, the bio-based oil is present in the backing formulation at a weight percent of 2% to 10% by weight, the polymer is present in the backing formulation at a weight percent of 30% or less by weight, and the biochar is present in the backing formulation at a weight percent of 10% to 55% by weight.

57. 57. The flexible backing formulation of any one of claims 53 to 56, wherein the filler further comprises calcium carbonate.

58. 58. The flexible backing formulation of any one of claims 53 to 57, wherein the backing formulation has a negative Global Warming Potential (GWP), based on materials and calculated using TRAC1 2.1 methodology.

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