Surface coverings containing recycled carpet material and processes of making the same

Abstract

A surface covering that is made using recycled carpet material. The surface covering includes a backing layer that is made from grinding recycled carpet material and mixing the recycled carpet material with a binder to form a slurry. The slurry is compression molded to form a log. The log is skived to form the backing layer of the surface covering.

Description

Attorney Docket No. 3620-219-01PCTSURFACE COVERINGS CONTAINING RECYCLED CARPET MATERIAL AND PROCESSES OF MAKING THE SAME

[0001] This application claims the benefit under 35 U.S.C. §119(e) of prior U.S. Provisional Patent Application No. 63 / 749,725, filed January 27, 2025, which is incorporated in its entirety by reference herein.

[0002] The present invention relates to backings for surface coverings, and more particularly relates to backings which contain recycled material as well as methods of making such products and incorporating them into surface coverings.BACKGROUND OF THE INVENTION

[0003] At the present time, most of the post-consumer vinyl and other polymer backed carpets and carpet manufacturing waste go to landfills or are destroyed by other means such as burning, the environment being of a global concern, the disposal of vinyl backed carpets and manufacturing waste which is currently done is not an acceptable option.

[0004] Further, recycling of vinyl backed carpets had been previously attempted but typically, manufacturers have taken recycled material and reduced it to liquid plastisol form in order to form a carpet backing with conventional coating and curing processes. However, such a process has limitations in that only very small amounts of recycled material can be incorporated into a plastisol mix, such as about 5% or less by weight, and because the oil absorption of recycled material is very high, high levels of plasticizers in plastisols are needed which can lead to further problems. With high levels of plasticizers and plastisols, further processing by conventional methods can become difficult, if not impossible.

[0005] Other methods of incorporating higher percentages of recycled carpet material into backing layers of surface coverings have limitations. For example, backing layers with higher percentages of recycled carpet material have a susceptibility to defects, thickness inconsistencies, and density variations. One such example of incorporating recycled carpetAttorney Docket No. 3620-219-01PCTmaterial into backing layers of surface coverings is provided in US6316075B1, incorporated in its entirety by reference herein.

[0006] In view of the foregoing, it is desirable to develop ways to use recycled carpet material such that large amounts of recycled carpet material can be incorporated into a backing layer of new carpet material to form, for the most part, consistent and defect free carpets.SUMMARY OF THE PRESENT INVENTION

[0007] Accordingly, a feature of the present invention is to provide a material, e.g., a surface covering, that contains recycled carpet material in one or more components or layers.

[0008] Another feature of the present invention is to provide a backing for a surface covering containing recycled carpet material.

[0009] An additional feature of the present invention is to provide a surface covering containing one or more backing layers and / or one or more intermediate layers which use recycled carpet material.

[0010] A further feature of the present invention is to provide a method of making a backing from recycled carpet material and incorporating the backing into surface coverings.

[0011] Additional features and advantages of the present invention will be set forth in part in the description that follows, and in part will be apparent from the description, or may be learned by practice of the present invention. The objectives and other advantages of the present invention will be realized and attained by means of the elements and combinations particularly pointed out in the description and appended claims.

[0012] One or more of the foregoing features have been accomplished in accordance with this invention by providing a method of making a backing for a surface covering comprising: obtaining recycled granules from a recycled carpet material by a process of grinding recycled carpet material and optionally shearing the recycled carpet material prior to grinding; formingAttorney Docket No. 3620-219-01PCTa slurry by mixing the recycled granules with at least one binder; compression molding the slurry by at least pressure treating the slurry to form a log of solid compressed backing material, optionally having a density of from about 1 g / cm3to about 1.8 g / cm3; and skiving the log to form at least one sheet forming the backing.

[0013] The present invention further relates to a backing layer for a carpet material, the backing layer comprising a sheet skived from a log of solid compressed backing material, the log formed by compression molding of a slurry comprising at least one binder and recycled granules ground from a recycled carpet material.

[0014] The present invention also relates to a carpet material comprising the backing layer, the backing layer comprising a sheet skived from a log of solid compressed backing material, the log formed by compression molding of a slurry comprising at least one binder and recycled granules ground from a recycled carpet material.

[0015] The present invention, in addition, relates to a log of solid compressed backing material, the log formed from compression molding of a slurry comprising recycled granules from a recycled carpet material and at least one binder, wherein the log optionally has a density of from about 1 g / cm3to about 1.8 g / cm3. Other densities below or above this range are options.

[0016] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are intended to provide a further explanation of the present invention, as claimed.

[0017] The accompanying drawings, which are incorporated in and constitute a part of this application, illustrate some of the features of the present invention and together with the description, serve to explain the principles of the present invention.BRIEF DESCRIPTION OF DRAWINGS

[0018] FIG. 1 is a flow chart showing one embodiment of a method of the present invention.Attorney Docket No. 3620-219-01PCT

[0019] FIGS. 2A-2E are cross-sectional views of surface coverings according to several embodiments of the present invention.DETAILED DESCRIPTION OF THE PRESENT INVENTION

[0020] The present invention relates to a backing (also known as a backing layer) and can be a secondary backing or an intermediate backing layer for a surface covering. The backing layer or intermediate backing layer contains recycled carpet material.

[0021] For purposes of the present invention, a surface covering can be any surface covering which makes use of a backing and / or intermediate layer, such as a floor covering, wall covering, ceiling covering, countertop covering, and the like. Examples of floor coverings include, but are not limited to, textile substrates, such as carpets, and resilient flooring, such as vinyl flooring or vinyl surface coverings or other polymer-based surface coverings. Particularly preferred examples of textile substrates are hard backed and cushion backed carpet tiles. While the present invention will be described with respect to the preferred embodiment which is floor coverings, and in particular carpet tiles, the present invention can be applied to other types of surface coverings containing backing and / or intermediate layers in view of the disclosure herein.

[0022] The present invention further relates to a method of making a backing for a surface covering. The method includes obtaining recycled granules from a recycled carpet material. The granules can be obtained by a process of grinding recycled carpet material and optionally shearing the recycled carpet material prior to grinding. The method further includes forming a slurry by mixing the recycled granules with at least one binder and compression molding the slurry by at least pressure treating the slurry to form a log of solid compressed backing material, optionally having a density of from about 1 g / cm3to about 1.8 g / cm3. The method further includes skiving the log to form at least one sheet forming the backing.Attorney Docket No. 3620-219-01PCT

[0023] FIG. 1 illustrates a flowchart of a method of the present invention. The method includes optionally shearing recycled carpet material 110, grinding recycled carpet material 120, forming a slurry by mixing recycled granules with at least one binder 130, compression molding the slurry to form a log 140, and skiving the log to form backing layers 150.

[0024] The recycled carpet material can be used carpet tiles, used carpet broadloom, and / or other carpet material that includes a backing layer and synthetic fibers.

[0025] As an option, prior to any grinding step, the recycled carpet material can be subjected to a shear operation to remove at least a portion, if not most of the face fiber that may be present on the carpet material. At least 50% (by volume) of the face fiber, or at least 75% of the face fiber can be removed, such as from 50% to 100%, from 75% to 100%, from 85% to 100%, from 90% to 100%, from 95% to 100%, or from 50% to 90%.

[0026] While there are various types of devices which can remove the face fibers, such as pure nylon fiber, which may be attached to the vinyl backed carpet, one preferred device is a shearing machine, such as one commercially available from Sellers, Inc. (United Kingdom). Other shearing machines that can be utilized include one or more from Kuster Shearing Machines (Germany) and Guarneri Technology (Italy). Rotary drum strippers are another option, such as from Cresswood Recycling Equipment (USA). Laser cutting machines can also be used, which include products from Trotec Laser (Austria / USA). Epilog Laser (USA) offers cutting systems capable of removing synthetic yarn materials. Waterjet cutters can be used, such as from OMAX Corporation (USA), and Flow International (USA). Surface grinding machines are another option, such as from 3M Abrasive Solutions (USA), which offers industrial -grade abrasives and surface grinders adaptable for yarn removal. Another option can include robotic arms with cutting tools, such as products from Fanuc Corporation (Japan), which develops robotic systems with customizable cutting attachments, and KUKA Robotics (Germany), providing robotic solutions tailored for automated textile and carpet processing.Attorney Docket No. 3620-219-01PCT

[0027] As an option, a shearing step is not used before any grinding step. Thus, the recycled carpet material is ground into polymer-based granules, such as PVC, and nylon fiber granules. The inclusion of face fibers, such as nylon fibers, demonstrates a holistic approach to material recovery and recyclability. Grinding and consolidating entire recycled carpet material, including the face fibers (e.g., nylon fibers), eliminates the need for labor-intensive separation of backing and fibers, and thus reducing processing steps and costs. As an option, the recycled granules can be a combination of polymer-based granules and face fibers (e.g., nylon fibers) from ground recycled carpet material.

[0028] Whether or not any face fiber is removed from the recycled carpet material, the carpet is fed into a grinder which breaks down the carpet into recycled granules. This step can be considered a granulation step.

[0029] As an option, the grinder can include a primary shredder and a granulator. The primary shredder is used for the initial size reduction of carpet tiles into smaller, more manageable pieces. These machines are typically equipped with robust, slow-speed rotary cutters that operate at low RPM (e.g., 20-150 RPM) to minimize heat generation and wear on the blades. The primary shredders can include single-shaft or dual-shaft shredders.

[0030] Examples of primary shredders include the Vecoplan VAZ Series, which is a singleshaft industrial shredder. This machine includes a low-speed high-torque cutting, replaceable cutting tools, and adjustable screen sizes for varying output of particle sizes. Another example is the WEIMA WLK Series, a heavy-duty single-shaft shredder designed for plastics, textiles, and industrial waste. This shredder operates at low speeds to reduce heat generation and includes rotor widths and knife configurations optimized for specific materials, with an integrated screen system for consistent granule size. The UNTHA XR Class Shredders are dual-shaft shredders designed for high-capacity material processing These shredders include energy-efficient drives, robust cutting systems for dense and thick materials, and haveAttorney Docket No. 3620-219-01PCTadjustable speed and torque for various materials. These shredders are ideal for pre-shredding rubber, carpet tiles, composites and other resilient flooring.

[0031] Once the material is pre-shredded, granulators are used for finer size reduction. Granulators typically include high-speed rotors with knives and a perforated screen to achieve a uniform granule size. Granulators receive pre-sized material from shredders to operate efficiently. Granulators operate at medium-to-high RPM (e.g., 300-600 RPM), depending on the hardness of the material and the desired granule size.

[0032] Examples of granulators include the ZERMA GSH Heavy-Duty Granulators, which are high-speed granulators designed for secondary size reduction of pre-shredded materials. These granulators can include hardened steel rotors and knives, adjustable screen sizes for granule output (e.g., 3-10 mm), and high throughput for dense materials. These granulators shred carpet tiles into uniform-sized granules. The Rapid Granulator Raptor Series includes modular granulators designed for high-speed, precision granulation. These granulators include variable rotor speeds (300-600 RPM) for diverse materials, multiple screen options for granule size control, and are easy to clean and maintain. The Cumberland Granulators (Series 1400X) are high-performance granulators designed for tough industrial applications, and include high-speed cutting action for uniform granules. The above-described granulators can be used for finer granulation of carpet tile components by processing preshredded carpet fibers and backing materials.

[0033] The grinders can further include combined systems that include integrated shredding and granulation. The Vecoplan V-ECO Series is a versatile machine that combines shredding and granulating in a single pass, streamlining the process. Another example is the ZERMA ZSS Shredder + ZERMA GSH Granulator Combination, which can be used in recycling lines to handle carpet tiles from start to finish.Attorney Docket No. 3620-219-01PCT

[0034] The particle size distribution of the recycled granules can be any particle size range, such as at least 5 mesh, at least 10 mesh, at least 20 mesh, at least 25 mesh, at least 30 mesh, from about 5 mesh to over 40 mesh, from about 5 mesh to about 40 mesh, from about 8 mesh to about 35 mesh, from about 10 mesh to about 30 mesh, from about 11 mesh to about 29 mesh, from about 12 mesh to about 28 mesh, from about 13 mesh to about 27 mesh, from about 14 mesh to about 26 mesh, from about 15 mesh to about 25 mesh, from about 16 mesh to about 24 mesh, from about 17 mesh to about 23 mesh, from about 18 mesh to about 22 mesh, from about 19 mesh to about 21 mesh, about 20 mesh, or any range based upon any two values described herein and / or any combination two or more of the size ranges described herein. The mesh size is US mesh sizing. The mesh ranges provided can be ranges where 100% by weight, or 95% by weight, or 90% by weight, or 85% by weight, or 80% by weight, or 75% by weight, or 50% by weight of the particle sizes are within that stated range.

[0035] The particle size of the recycled granules can range from about 300 microns to 4000 microns, about 350 microns to about 2400 microns, about 400 microns to about 2000 microns, about 420 microns to about 1800 microns, about 440 microns to about 1700 microns, about 460 microns to about 1500 microns, about 480 microns to about 1400 microns, about 500 microns to 1200 microns, about 520 microns to about 1000 microns, about 540 microns to about 850 microns, about 560 microns to 700 microns, about 580 microns to about 600 microns, or any range based upon any two values described herein. The range can be a range that is or includes less than 300 microns and / or more than 4000 microns. This particle size can be an average particle size range based on number or weight. Particle measurements in general can be based on the use of electron microscopy samples (e.g., samples may be prepared by embedding the particles in a viscous epoxy resin or sections taken from the log as described herein, which, after hardening, is sectioned by ultramicrotome methods to yield slices as thin as 25 nanometers.) These sections are suitable for study by TEM, SEM or a variety of otherAttorney Docket No. 3620-219-01PCTimaging methods like electron microprobe spectroscopy. Other well-established methods such as Coulter Counter, dynamic light scattering, laser light diffraction, and X-ray diffraction may be used to determine characteristics of the particle and material. Image J software or other imaging software can be used for such analysis.

[0036] The recycled carpet material can be ground by a grinder, as mentioned above, or a cryogenic grinding process. The cryogenic grinding process can be accomplished by spraying the recycled carpet material with liquid nitrogen and then subjecting the sprayed recycled carpet material to a grinding process. The cryogenic process can form finer powder because of the brittleness of the material resulting from the liquid nitrogen treatment and because of the reduced agglomeration of the material during the grinding process.

[0037] The method further includes forming a slurry by combining (e.g., mixing) the recycled granules with at least one binder. The slurry can be a liquid slurry with solid material dispersed therein. The at least one binder can be or include a polyurethane binder, an epoxy resin binder, a natural rubber binder, a natural latex binder, a silicone-based binder, an acrylic emulsion binder, a thermoplastic binder, a bio-based resin binder, a sulfur-based binder, a polyolefin binder, a starch-based binder, a lignin-based binder, or any combinations thereof.

[0038] The slurry formed is a mixture of at least the granules and binder. The granules are generally evenly dispersed or distributed throughout the binder. The distribution of the granules can be considered a uniform dispersion or substantially uniform dispersion (e.g., within 1%, 5%, 10%, 15%, 20%, 25%, 30%, or 35% by volume of being uniform).

[0039] As an option, the at least one binder is a polyurethane binder. The polyurethane binder can be a moisture-cured polyurethane binder. The polyurethane binder can include a polyol component, an isocyanate component, a catalyst, an additive and / or filler, a moisture scavenger, optionally a solvent and / or reactive diluent, and optionally a plasticizer.Attorney Docket No. 3620-219-01PCT

[0040] The polyol component can be from 40% to 80% (or less than 40% or more than 80%) by weight of the polyurethane binder, from 45% to 75% by weight of the polyurethane binder, from 50% to 70% by weight of the polyurethane binder, from 55% to 65% by weight of the polyurethane binder, from 58% to 60% by weight of the polyurethane binder, or any range based upon any two values described herein.

[0041] The polyol component is the backbone of the polyurethane network, providing flexibility, elasticity, and hydrophobicity. The polyol component can include at least one polyether polyol, polyester polyol, a bio-based polyol, or any combinations thereof. Examples of polyether polyols include polypropylene glycol (PPG) and polyethylene glycol (PEG). Examples of polyester polyols include those derived from adipic acid and ethylene glycol. Examples of bio-based polyols can include soy-based polyols derived from soybean oil.

[0042] The isocyanate component can be from 30% to 50% (or less than 30%, or less than 50%) by weight of the polyurethane binder, from 32% to 48% by weight of the polyurethane binder, from 34% to 46% by weight of the polyurethane binder, from 36% to 44% by weight of the polyurethane binder, from 38% to 42% by weight of the polyurethane binder, from 39% to 40% by weight of the polyurethane binder, or any range based upon any two values described herein.

[0043] The isocyanate component reacts with the polyol to form the polyurethane matrix. The isocyanate can be or include an aromatic isocyanate, an aliphatic isocyanate, a prepolymer, or any combinations thereof. Examples of an aromatic isocyanate include toluene diisocyanate (TDI) and methylene diphenyl diisocyanate (MDI). Examples of aliphatic isocyanates include Hexamethylene Diisocyanate (HDI), Isophorone Diisocyanate (IPDI), and Dicyclohexylmethane-4,4'-diisocyanate (HMDI). A prepolymer is a partially polymerized substance formed by reacting a polyol with an isocyanate, resulting in a material with reactiveAttorney Docket No. 3620-219-01PCTgroups that can undergo further polymerization. Any of the above listed isocyanates can be incorporated as a prepolymer.

[0044] The reaction between polyol and isocyanate forms polyurethane through a process called step-growth polymerization. Polyols contain multiple hydroxyl groups that react with isocyanates that have isocyanate groups (-NCO), to create urethane bonds (-NH-COO-), resulting in the formation of polyurethane.

[0045] A catalyst can be used to accelerate the reaction between polyol and isocyanate to form polyurethane. The catalyst can be from 0.1% (or less) to 1% (or more) by weight of the polyurethane binder, from 0.2% to 0.9% by weight of the polyurethane binder, 0.3% to 0.7% by weight of the polyurethane binder, 0.4% to 0.6% by weight of the polyurethane binder, 0.45% to 0.5% by weight of the polyurethane binder, or any range based upon any two values described herein.

[0046] The catalyst can be or include an amine catalyst, a metal-based catalyst, or a combination thereof. Amine catalysts can include Triethylenediamine (TEDA), Dimethylcyclohexylamine (DMCHA), N,N-Dimethylpiperazine, and Diazabicyclooctane (DABCO). Metal-based catalysts can include Dibutyltin Dilaurate (DBTDL), Stannous Octoate (Sn(Oct)2), Zinc Octoate, Bismuth-based catalysts, such as Bismuth neodecanoate, lead-based catalysts such as lead naphthenate, and the like.

[0047] As an option, the catalyst can be a cold-cure catalyst and the compression molding step occurs at a temperature of from about 10 deg C to about 50 deg C (other temperatures above or below this range is an option). Using a cold-cure catalyst accelerates the reaction between polyol and isocyanate at or about room temperature (e.g., 20 deg C to 25 deg C), avoiding the need for adjusting the temperature of the reaction and thus reducing energy consumption and emissions of the reaction.Attorney Docket No. 3620-219-01PCT

[0048] Cold-cure catalysts are designed to accelerate the reaction between polyols and isocyanates at lower temperatures, typically around room temperature. An example of coldcure catalysts includes tertiary amines. Tertiary amines can include, but are not limited to, Triethylenediamine (TEDA), N,N-Dimethylcyclohexylamine (DMCHA), Bis(dimethylaminoethyl)ether (BDMAEE), N-Methylmorpholine (NMM), and Dimethylaminopropylamine (DMAPA). TEDA, also known as DABCO TMR, can be employed in both flexible foam and rigid foam formulations. TEDA effectively catalyzes the urethane (polyol-isocyanate) and urea (water-isocyanate) reactions. DMCHA promotes the reaction between polyols and isocyanates at ambient temperatures and can be used for coldcure rigid foams. BDMAEE enhances reactivity in systems cured at room temperature and can be combined with other catalysts to tailor the reactivity. NMM is another low-temperature catalyst suitable for cold-cure polyurethane systems, and DMAPA is also effective in low-temperature applications for cold-cure reactions.

[0049] As an option, metal-based catalysts can be used as cold-cure catalysts for polyurethane systems. Metal-based catalysts can include, but are not limited to, Dibutyltin Dilaurate (DBTDL), Stannous Octoate (Tin(II) 2-ethylhexanoate), and Bismuth-based catalysts. DBTDL is a highly efficient organotin catalyst that facilitates both gelling (urethane formation) and cross-linking. Stannous Octoate promotes the reaction between isocyanates and hydroxyl groups at low (room) temperature. Bismuth-based catalysts, such as BiCAT, serve as a non-toxic alternative to tin catalysts and are suitable for cold-cure systems, offering low-temperature activation.

[0050] As an option, carbodiimide-based catalysts can be used as the cold-cure catalyst. Carbodiimide-based catalysts, such as modified carbodiimides, react with isocyanates to stabilize systems at ambient temperatures and can be employed in cold-cure polyurethane adhesives or coatings. Specialty catalysts such as JEFFCAT amine catalysts from Huntsman,Attorney Docket No. 3620-219-01PCTincluding formulations, such as JEFFCAT ZF-22, can be used as the cold-cure catalyst and are tailored for low-temperature reactivity. TEGOSTAB catalysts from Evonik can be used as the cold-cure catalyst and are amine-based catalysts specifically optimized for cold-curing applications in both rigid and flexible foams.

[0051] The benefits of cold-cure catalysts include reduced energy consumption by eliminating the need for heating the reaction, and lower emissions compared to high-temperature curing processes. Additionally, cold-cure catalysts provide greater flexibility in manufacturing processes. These catalysts can be used individually or in combinations to optimize the balance between reactivity and pot life.

[0052] The polyurethane binder can further include additives and / or fillers. The additives and / or fillers can be from 1% (or less) to 5% (or more) by weight of the polyurethane binder, from 1.2% to 4.8% by weight of the polyurethane binder, from 1.4% to 4.6% by weight of the polyurethane binder, from 1.6% to 4.4% by weight of the polyurethane binder, from 1.8% to 4.2% by weight of the polyurethane binder, from 2% to 4% by weight of the polyurethane binder, from 2.2% to 3.8% by weight of the polyurethane binder, from 2.4% to 3.6% by weight of the polyurethane binder, from 2.6% to 3.4% by weight of the polyurethane binder, from 2.8% to 3.2% by weight of the polyurethane binder, from 3.0% to 3.1% by weight of the polyurethane binder, or any range based upon any two values described herein.

[0053] The additives and / or fillers enhance mechanical, thermal, and / or processing properties. The additives and / or fillers can be or include talc, calcium carbonate, clay (e.g., kaolin), silica, a phosphate, a halogen free filler, a pigment, an antioxidant, an ultraviolet stabilizer, and the like.

[0054] Optionally, the polyurethane binder can further include a plasticizer. The plasticizer can be from 0% to 10% by weight of the polyurethane binder, from 0.5% to 9% by weight of the polyurethane binder, from 1% to 8% by weight of the polyurethane binder, from 2% to 7%Attorney Docket No. 3620-219-01PCTby weight of the polyurethane binder, from 3% to 6% by weight of the polyurethane binder, from 4% to 5% by weight of the polyurethane binder, or any range based upon any two values described herein.

[0055] The plasticizer improves flexibility and reduces hardness. The plasticizer can include at least one non-phthalate, a bio-based plasticizer, or any combinations thereof. For example, plasticizers can include, but are not limited to, DINCH (diisononyl cyclohexane- 1,2-di carb oxy late), DOTP (dioctyl terephthalate), ATBC (acetyl tributyl citrate), DEHT (di(2-ethylhexyl) terephthalate), TOTM (tri-octyl trimellitate), epoxidized soybean oil (ESBO), CITROFOL BII TM (Tri ethyl citrate), benzoate esters, and the like.

[0056] Optionally, the polyurethane binder can further include a solvent and / or reactive diluent. The solvent and / or reactive diluent can be from 0% to 10% (or more) by weight of the polyurethane binder, from 0.5% to 9% by weight of the polyurethane binder, from 1% to 8% by weight of the polyurethane binder, from 2% to 7% by weight of the polyurethane binder, from 3% to 6% by weight of the polyurethane binder, from 4% to 5% by weight of the polyurethane binder, or any range based upon any two values described herein.

[0057] The solvent and / or reactive diluent reduces viscosity for improved handling and processing. The solvent and / or reactive diluent can be or include, but is not limited to, acetone, methyl ethyl ketone, glycidyl ethers, and the like, or any combinations thereof.

[0058] The polyurethane binder can further include a moisture scavenger. The moisture scavenger can be from 0.5% (or less) to 2% (or more) by weight of the polyurethane binder, from 0.6% to 1.8% by weight of the polyurethane binder, from 0.8% to 1.6% by weight of the polyurethane binder, from 1% to 1.4% by weight of the polyurethane binder, from 1.2% to 1.3% by weight of the polyurethane binder, or any range based upon any two values described herein.Attorney Docket No. 3620-219-01PCT

[0059] The moisture scavenger prevents premature reaction with atmospheric moisture. The moisture scavenger can include a silica-based scavenger, a chemical scavenger, or a combination thereof. For example, the moisture scavenger can include, but is not limited to, Fumed Silica CAB-O-SIL TM (Cabot Corporation), AEROSIL TM (Evonik), Precipitated Silica HI-SIL TM (PPG Industries), ZEOSIL TM (Solvay), activated silica gel, functionalized silica, chemical moisture scavengers, and the like. Examples of chemical moisture scavengers include, but are not limited to, epoxides, isocyanates, calcium oxide (CaO), molecular sieves, alkoxy silanes, oxazolidines, carbodiimides, organometallic scavengers, and the like.

[0060] As an option, a blended system can include silica gel plus isocyanates and calcium oxide plus molecular sieves. The blended system containing silica gel, isocyanates, calcium oxide, and molecular sieves can provide control moisture, ensure proper curing, and / or enhance material performance. Silica gel absorbs water to prevent unwanted reactions between isocyanates and moisture, which could cause defects such as bubbles. Isocyanates react with polyols to form polyurethane or with water to create urea and CO2, and thus controlling moisture and this can permit more consistent curing. Calcium oxide removes residual moisture by reacting with water, a process that also generates heat, speeding up the curing process. Molecular sieves complement the reaction by trapping and holding moisture at a molecular level, providing long-term control.

[0061] Together, these components effectively manage moisture and promote efficient curing by eliminating or substantially eliminating water, and ensuring a smooth reaction between isocyanates and polyols. The above-described components reduce risks of defects, such as foaming, cracking, or inconsistent mechanical properties, and thus result in a durable, high-quality final product. The system is particularly useful for moisture-sensitive applications, such as adhesives, sealants, foams, coatings, and encapsulation materials.Attorney Docket No. 3620-219-01PCT

[0062] The binder can include epoxy resins in addition to or as an alternative of the polyurethane binder. Epoxy resins provide high strength, durability, and excellent adhesion. Epoxy resins are suitable for applications requiring strong chemical resistance and structural integrity.

[0063] The binder can include natural rubber or latex in addition to or as an alternative of the polyurethane binder. The natural rubber or latex is flexible, biodegradable, and sustainable. Natural rubber or latex is suitable for applications where flexibility and eco-friendliness are priorities.

[0064] The binder can include silicone-based binders in addition to or as an alternative of the polyurethane binder. The silicone-based binders are highly flexible, UV-stable, and resistant to extreme temperatures. Silicone-based binders are suitable for outdoor applications due to weather resistance properties.

[0065] The binder can include acrylic emulsions in addition to or as an alternative of the polyurethane binder. The acrylic emulsions are water-based, low-VOC (volatile organic compounds), and relatively flexible. Acrylic emulsions are suitable for indoor flooring or products with less stringent durability requirements.

[0066] The binder can include thermoplastic binders in addition to or as an alternative of the polyurethane binder. Thermoplastic binders can be or include, but are not limited to, ethylene vinyl acetate (EVA), polyvinyl chloride (PVC), and the like. Thermoplastic binders are re-meltable and recyclable, and are suitable for products that benefit from reprocessing.

[0067] The binder can include bio-based resins in addition to or as an alternative of the polyurethane binder. Bio-based resins can be or include, but are not limited to, soy-based resins, linseed-based resins, and the like. Bio-based resins are eco-friendly and sustainable. Suitable applications for bio-based resins include products that target green certification.Attorney Docket No. 3620-219-01PCT

[0068] The binder can be or include sulfur-based vulcanization systems in addition to or as an alternative of the polyurethane binder. The sulfur-based vulcanization systems create strong bonds with rubber through vulcanization. The sulfur-based vulcanization systems are suitable for heavy-duty industrial mats or seals.

[0069] The binder can be or include polyolefin binders in addition to or as an alternative of the polyurethane binder. The polyolefin binders can be or include, but are not limited to, polypropylene, polyethylene, and the like. Polyolefin binders are lightweight, durable, and cost-effective, and are suitable for sports mats and shock-absorbent layers.

[0070] The binder can be or include starch-based or lignin-based binders in addition to or as an alternative to the polyurethane binder. The starch-based or lignin-based binders are biodegradable and eco-friendly and are suitable for applications that are preferably sustainable and have a low environmental impact.

[0071] The at least one binder and the recycled granules are combined to form a slurry. The slurry can include from about 10 wt% (or less) to about 70 wt% (or more) of the at least one binder and from about 30 wt% (or less) to about 90 wt% (or more) of the recycled granules by weight of the slurry. The amount of the recycled granules, as an option, can be below 70 wt% (e.g., below 60 wt% or below 50 wt% or lower). For example, the slurry can include from about 15 wt% to about 25 wt% of the at least one binder and from about 75 wt% to about 85 wt% of the recycled granules by weight of the slurry. For example, the slurry can include from about 15 wt% to about 20 wt% of the at least one binder and from about 80 wt% to about 85 wt% of the recycled granules by weight of the slurry. For example, the slurry can include 20 wt% of the at least one binder and 80 wt% of the recycled granules by weight of the slurry. For example, the slurry can include 15 wt% of the at least one binder and 85 wt% of the recycled granules by weight of the slurry. For example, the slurry can include 70 wt% of the at least one binder and 30 wt% of the recycled granules by weight of the slurry. For example, the slurry canAttorney Docket No. 3620-219-01PCTinclude 60 wt% of the at least one binder and 40 wt% of the recycled granules by weight of the slurry. For example, the slurry can include 50 wt% of the at least one binder and 50 wt% of the recycled granules by weight of the slurry.

[0072] As an option, fiberglass and / or carbon fiber can be added to the slurry. The fiberglass and / or carbon fiber decreases the coefficient of thermal expansion and can improve overall stability of the backing layer. Further, the addition of fiberglass and / or carbon fiber to the slurry can be used in addition to or can replace the use of a fiberglass reinforcement scrim in the carpet tile. Fiberglass and carbon fiber can be added in the range of 1% (or less) to 5% (or more) of the slurry by weight.

[0073] The slurry is preferably compression molded by at least pressure treating the slurry to form a log of solid compressed backing material. For example, the slurry is placed into an open mold. The open mold is then closed and the closed mold is at least pressure treated. As an option, the closed mold is temperature treated (i.e., heated). The pressure treatment activates a curing process and after a period of time the slurry is solidified. The closed mold is then opened and the log of solid compressed backing material is removed from the open mold. As an option, excess material can be trimmed from the log.

[0074] As mentioned above, the compression molding of the slurry includes at least a pressure treatment. The pressure treatment includes subjecting the slurry in the closed mold to an elevated pressure, such as from about 500 psi to about 1,000 psi, from about 550 psi to about 950 psi, from about 600 psi to about 900 psi, from about 650 psi to about 850 psi, from about 700 psi to about 800 psi, from about 750 psi to about 780 psi, or any range based upon any two values described herein. Pressure amounts below or above any of these values can optionally be used.Attorney Docket No. 3620-219-01PCT

[0075] When using cold cure catalysts, the reaction can take place at or about room temperature (e.g., 20 to 25 deg C). Accordingly, the compression molding of the slurry can be absent of a temperature treatment when a cold cure catalyst is used.

[0076] When using heat activated catalysts, the compression molding of the slurry can further include a temperature treatment. The temperature treatment of the slurry in the closed mold can include subjecting the slurry to an elevated temperature (e.g., 100 deg C or higher), such as from about 140 deg C to about 180 deg C, from about 145 deg C to about 175 deg C, from about 150 deg C to about 170 deg C, from about 155 deg C to about 165 deg C, from about 158 deg C to about 160 deg C, or any range based upon any two values described herein. The temperature can be adjusted based on the type of catalyst used. The temperature can be an average temperature of the slurry based on the temperature of the slurry and / or can be a maximum temperature that the slurry is subjected to.

[0077] The compression molding process, at which the slurry is subjected to pressure treatment and optionally temperature treatment, occurs over a period of time (e.g., at least 10 minutes). The period of time can be from about 30 minutes to about 60 minutes, from about 35 minutes to about 55 minutes, from about 40 minutes to about 50 minutes, from about 42 minutes to 45 minutes, or any range based upon any two values described herein.

[0078] Once the curing process has been completed, the log of solid compressed backing material is removed from the mold. The log has a density. The log can have a density of below 1.2 g / cm3, or below 1.8 g / cm3, or above 1.2 g / cm3, or above 1.8 g / cm3, or from 1 g / cm3to about 1.8 g / cm3, from 1.2 g / cm3to about 1.75 g / cm3, from 1.3 g / cm3to about 1.7 g / cm3, from 1.35 g / cm3to about 1.65 g / cm3, from 1.4 g / cm3to about 1.6 g / cm3, from 1.45 g / cm3to about 1.55 g / cm3, from 1.47 g / cm3to about 1.5 g / cm3, from about 1.42 g / cm3to about 1.52 g / cm3, or any range based upon any two values described herein. The density of the log can be an averageAttorney Docket No. 3620-219-01PCTmeasured density (e.g., measured at 2 to 5 random locations of the log) and / or can be the maximum density measured for the log (e.g., measured at 2 to 5 random locations of the log).

[0079] The log can have a cylindrical shape or a substantially cylindrical shape. Others shapes of the log are possible and are an option.

[0080] The log can have any diameter and / or length. For instance, the log can have a length of from 50 inches (or less) to 90 inches (or more) and a diameter of from 10 inches (or less) to 40 inches (or more), a length of from 55 inches to 85 inches and a diameter of from 15 inches to 35 inches, a length of from 60 inches to 80 inches and a diameter of from 20 inches to 30 inches, a length of from 65 inches to 75 inches and a diameter of from 20 inches to 30 inches, a length of from 68 inches to 70 inches and a diameter of from 22 inches to 25 inches, a length of 74 inches and a diameter of 20 inches, or any range of lengths and diameters based upon any two values described herein.

[0081] The log itself, as formed herein, is considered one of the inventive aspects of the present invention. The log can be formed from compression molding of a slurry including recycled granules from a recycled carpet material and at least one binder, as described herein. The log can have a density as described herein, for instance, a density of from about 1 g / cm3to about 1.8 g / cm3.

[0082] The log of the present invention is processed to remove material such that at least one sheet is formed. For instance, the log can be skived to form at least one sheet, such as a plurality of sheets, of backing for the surface covering. Skiving is a process that involves shaving, slicing, or cutting layers from the log to achieve a desired thickness and shape of the backing for the surface covering. The skiving process can utilize blades, scrapers, manual or automatic skiving machines, a rotary skiving machine, heated blades, skiving rollers, conveyors, computer-controlled skiving machines, thickness gauges such as laser sensors or optical thickness gauges for real-time measurement, clamping jigs, and other tools that allowAttorney Docket No. 3620-219-01PCTfor the manufacture of consistent, high-quality sheets with uniform thickness that are cut from the log.

[0083] The sheet or plurality of sheets of backing can have a thickness, such as at least 0.5 mm, or from 2 (or less) mm to 5 (or more) mm, from 2.2 mm to 4.8 mm, from 2.4 mm to 4.6 mm, from 2.6 mm to 4.4 mm, from 2.8 mm to 4.2 mm, from 3 mm to 4 mm, from 3.2 mm, to 3.8 mm, from 3.4 mm to 3.6 mm, or any range based upon any two values described herein. The thickness can be an average thickness based on the measurement of 2 or more locations and / or can be a maximum thickness measured, based on 2 or more measurements (e.g., 2 to 6 random measurements).

[0084] The backing of the present invention can be considered “a backing layer” of a carpet material, such as a carpet tile. The present invention includes a backing layer including a sheet skived from a log of solid compressed backing material, as described herein. The log is formed by compression molding of a slurry including at least one binder and recycled granules ground from a recycled carpet material, as described herein.

[0085] The present invention can further include a carpet material that includes one or more backing layers described herein. The carpet material can be a tufted carpet tile or plurality of carpet tiles. Carpet tiles can include square or rectangular pieces of carpet that are installed individually to create a custom carpeted floor. The carpet tiles can be adhered to the floor and / or may interlock with one another.

[0086] The carpet material can have a fibrous face, a primary backing to which the textile fibers are secured, and a secondary backing secured to the primary backing. The backing or backing layer for purposes of the present invention can be any layer or substrate which has one or more additional layers adhered to a surface of the backing layer. Thus, the backing can be the layer which is in contact with the sub-surface, such as a sub-floor, or can be an intermediate layer with other layers above and below the intermediate backing layer.Attorney Docket No. 3620-219-01PCT

[0087] The layers of the carpet tile can be laminated together. The carpet tiles can each include plurality of layers and the backing layer is bonded to one of the plurality of layers by an extruded molten polymer. The extruded molten polymer can be, for instance, a polyvinyl chloride, an olefin-based compound, or a combination thereof.

[0088] As an option, a carpet tile can be made as follows. Unbacked carpet is placed on an unwinding station where this unbacked carpet is fed face down into a coating line designed to handle carpet. The unbacked carpet can be a primary backing with textile fibers extending upwardly from the backing and forming a surface. With the carpet face down in the machine, an adhesive or polymeric pre-coat is applied, for instance, by applying a dispersion grade or suspension grade thermoplastic resin onto the primary backing or unbacked carpet. This adhesive or polymeric pre-coat layer can be a 100% virgin dry blend or can be a mixture of virgin material along with recycled material. In lieu of a dry blend, a liquid grade resin can be applied as the adhesive or polymeric pre-coat layer. The adhesive or polymeric pre-coat layer is applied in conventional amounts, but preferably the amount is from about 15 ounces per square yard to about 60 ounces per square yard. The adhesive or polymeric pre-coat layer can be a dry blend of at least one PVC resin, at least one plasticizer, at least one stabilizer, and / or a latex based liquid adhesive.

[0089] The material can then be subjected to a process which will gel the adhesive or polymeric pre-coat layer, such as with the use of infrared heat. Then, a reinforcement material is applied onto the surface of the adhesive or polymeric pre-coat layer. Examples of reinforcement materials include, but are not limited to, a non-woven material or woven material, such as a non-woven fiber glass mat or fleece and the like. This reinforcement material is generally placed on the surface of the adhesive or polymeric pre-coat layer while the layer is still in a liquid or gel state. Prior to or after the reinforcement material is applied,Attorney Docket No. 3620-219-01PCTan intermediate backing layer can be applied. The intermediate backing layer can be a backing layer as described herein.

[0090] Once the reinforcement material is applied, the carpet can then be subjected to a suitable pressure to create a good bond between the individual fibers and / or yams, the adhesive or polymeric or pre-coat layer as well as the reinforcement material with the pre-coat layer. An application of pressure of this sort can be applied by a pressure roller or other suitable device. The unbacked carpet can then move to a station where a final backing layer of the present invention is applied. The backing layer can bond to the unbacked carpet by an extruded molten polymer, as described above. The carpet can then be subjected to a cooling zone and then rolled or fed to a cutter.

[0091] As an option, a process of making the carpet tile can include the following. A precoat, such as a polymeric precoat, such as a latex precoat is applied to a bottom of a tufted sheet. A first layer of extruded PVC is applied to the bottom of the tufted sheet and then a fiberglass reinforcement layer is applied to the extruded PVC prior to entering a first nip. Prior to or after the reinforcement layer is applied, an intermediate backing layer can be applied. The intermediate backing layer can be a backing layer as described herein. After exiting the first nip, a second layer of extruded PVC is applied to the fiberglass reinforcement layer and a backing layer, as described herein, can be applied to the extruded PVC prior to entering a second nip. The carpet is formed and then cut into tiles.

[0092] FIGS. 2 A through 2E depict various embodiments of an exemplary carpet tile of the present invention. In each embodiment in the Figure, fibers 65 are located on top and a backing layer 70 is located at the very bottom of the covering and a synthetic tufting substrate 66 secures the fibers 65. A non-woven structural layer 68 (reinforcement layer) can be located beneath a performance polymeric layer 67 and / or beneath an intermediate layer 71. An intermediate layer 69 can also be located beneath the non-woven structural layer 68. In eachAttorney Docket No. 3620-219-01PCTcase, each layer is affixed in some manner such as by casting, adhesive, or other means conventional in the art. Backing layer 70 and / or intermediate layers 69, 71 can be the backing layer as described herein.

[0093] The backing layers including recycled carpet material represents a novel innovation in material reuse, manufacturing efficiency, and sustainability within the flooring industry. The present invention provides a comprehensive recycling approach by integrating use of waste streams. Unlike traditional carpet tile backings, which primarily rely on virgin materials or limited recycling, the backing layer of the present invention can incorporate recycled PVC and nylon fibers from post-consumer carpet tiles into a single, high-performance layer. The inclusion of nylon fibers, typically separated for individual recycling, demonstrates a holistic approach to material recovery. Grinding and consolidating entire carpet tiles eliminates the need for labor-intensive separation of backing and fibers, reducing processing steps and costs. Further, the present invention advances the concept of a circular economy by using end-of-life carpet tiles as raw material for new products, significantly reducing landfill waste.

[0094] Further, the combination of ground carpet particles (PVC and nylon) with polyurethane binders results in a unique material with properties that outperform conventional recycled backings. Specifically, high-pressure consolidation ensures a dense, durable structure suitable for demanding commercial applications. Further, the polyurethane binder imparts flexibility while maintaining structural integrity, addressing performance requirements for modem carpet tiles. Moreover, adjusting the ratio of polyurethane to ground carpet allows manufacturers to tailor the backing's hardness, flexibility, and thickness for specific applications.

[0095] The present invention also reduces energy consumption. The log molding and skiving process uses significantly less energy compared to producing virgin backing materials, as it repurposes pre-existing compounds and eliminates certain raw material production steps.Attorney Docket No. 3620-219-01PCTThe present invention provides a lower carbon footprint by incorporating post-consumer waste. The present invention reduces reliance on virgin resources like polyvinyl chloride (PVC) and polyurethane, thereby minimizing the carbon footprint of carpet tile production.

[0096] The present invention further provides a novel manufacturing process. Specifically, the use of high-pressure log molding followed by precision skiving produces thin, uniform sheets which is a novel adaptation for carpet tile backing. The present invention also allows the inclusion of advanced alternatives, such as the option to incorporate moisture cured polyurethane binders or cold-cure catalysts as part of the curing process, which provides for an environmentally friendly alternative to traditional high-temperature curing.

[0097] Furthermore, the present invention uniquely combines recycled content, multimaterial integration, and enhanced performance, creating a product that is both environmentally responsible and commercially competitive. By reducing the need for virgin materials and simplifying the recycling process, the present invention can lower production costs compared to conventional methods, making it attractive for mass adoption.

[0098] The term “about” that is used herein to precede a stated value is defined herein as being the stated value or being within 1%, 2%, 3%, 4%, or 5% of the stated value.

[0099] Unless otherwise specified, all material proportions described as a percent herein are in weight percent.

[0100] The present invention will be further clarified by the following example which is intended to be only exemplary in nature.EXAMPLE

[0101] A log, as described herein, was made in a manner described above. Specifically, recycled carpet material was ground using a grinding machine without a step of shearing the nylon fibers. A polyurethane binder was formed by preparing and mixing together a polyol mixture including 81.9 grams of PLURACOL 816, 50 grams of PLURACOL 1062, and 30Attorney Docket No. 3620-219-01PCTgrams of castor oil. The polyol mixture was combined with 30 grams of di ethylene glycol, 4 grams of NIAX 5614, 0.1 grams of NIAX catalyst LC-5615, and 4 grams of V-IAD 320 (surfactant blend-rheology control agent). UL-6 is a catalyst that is added after mixing is completed to accelerate the curing process. The polyol mixture was then reacted with 126.6 grams of isocyanate to form the polyurethane binder. Three log samples were prepared using the polyurethane binder.

[0102] For Sample 1, 200 grams of the recycled granules were mixed with the polyurethane binder to form a slurry. The polyurethane binder to recycled granule weight ratio of the slurry was 63 / 37. The slurry was compression molded by pressure treatment to form the log of solid compressed backing material. The pressure treatment applied reduced the volume of the curing mold by about 50%. Sample 1 had a carpet size of 0.1875 inches, a carpet percentage of 38%, a Shore A Durometer range of 78 to 91, and a specific gravity range of 1.0037 to 1.100.

[0103] Sample 2 also had a carpet size of 0.1875 inches but a higher carpet percentage of 60.5%. Sample 2 had a Shore A Durometer range of 75 to 81, and a specific gravity of 1.225.

[0104] Sample 3 had a carpet size of 0.1875 inches, a carpet percentage of 59.5%, a Shore A Durometer range of 80 to 92, and a specific gravity range of 1.209 to 1.214.

[0105] The present invention includes the following aspects / embodiments / features in any order and / or in any combination:1. A method of making a backing for a surface covering comprising: obtaining recycled granules from a recycled carpet material by a process of grinding recycled carpet material and optionally shearing the recycled carpet material prior to grinding; forming a slurry by mixing the recycled granules with at least one binder; compression molding the slurry by at least pressure treating the slurry to form a log of solid compressed backing material, optionally having a density of from about 1 g / cm3to about 1.8 g / cm3; and skiving the log to form at least one sheet forming the backing.Attorney Docket No. 3620-219-01PCT2. The method of any preceding or following embodiment / feature / aspect, wherein the at least one binder comprises a polyurethane binder, an epoxy resin binder, a natural rubber binder, a natural latex binder, a silicone-based binder, an acrylic emulsion binder, a thermoplastic binder, a bio-based resin binder, a sulfur-based binder, a polyolefin binder, a starch-based binder, a lignin-based binder, or any combinations thereof.3. The method of any preceding or following embodiment / feature / aspect, wherein the at least one binder is a polyurethane binder.4. The method of any preceding or following embodiment / feature / aspect, wherein the polyurethane binder is a moisture-cured polyurethane binder comprising a polyol component, an isocyanate component, a catalyst, an additive and / or filler, a moisture scavenger, optionally a solvent and / or reactive diluent, and optionally a plasticizer.5. The method of any preceding or following embodiment / feature / aspect, wherein the polyol component is from 50% to 70% by weight of the polyurethane binder, the isocyanate component is from 30% to 50% by weight of the polyurethane binder, the catalyst is from 0.1% to 1% by weight of the polyurethane binder, the additives and / or fillers are from 1% to 5% by weight of the polyurethane binder, the plasticizer is from 0% to 10% by weight of the polyurethane binder, the solvent and / or reactive diluent is from 0% to 10% by weight of the polyurethane binder, and the moisture scavenger is from 0.5% to 2% by weight of the polyurethane binder.6. The method of any preceding or following embodiment / feature / aspect, wherein the polyol component comprises at least one polyether polyol, polyester polyol, or bio-based polyol, or any combinations thereof.7. The method of any preceding or following embodiment / feature / aspect, wherein the isocyanate component comprises an aromatic isocyanate, an aliphatic isocyanate, a prepolymer, or a combination thereof.Attorney Docket No. 3620-219-01PCT8. The method of any preceding or following embodiment / feature / aspect, wherein the catalyst comprises an amine catalyst, a metal-based catalyst, or a combination thereof.9. The method of any preceding or following embodiment / feature / aspect, wherein the catalyst is a cold-cure catalyst and the compression molding step occurs at a temperature of from about 10 deg C to about 50 deg C.10. The method of any preceding or following embodiment / feature / aspect, wherein the additive and / or filler comprises talc, a calcium carbonate, silica, a phosphate, a halogen free filler, a pigment, an antioxidant, an ultraviolet stabilizer, or any combinations thereof.11. The method of any preceding or following embodiment / feature / aspect, wherein the polyurethane binder further comprises the plasticizer and the plasticizer comprises at least one non-phthalate, a bio-based plasticizer, or any combinations thereof.12. The method any preceding or following embodiment / feature / aspect, wherein the polyurethane binder further comprises the solvent and / or reactive diluent, wherein the solvent and / or reactive diluent comprise acetone, methyl ethyl ketone, glycidyl ethers, or any combinations thereof.13. The method of any preceding or following embodiment / feature / aspect, wherein the moisture scavenger comprises a silica-based scavenger, a chemical scavenger, or a combination thereof.14. The method of any preceding or following embodiment / feature / aspect, wherein pressure treating the slurry comprises subjecting the slurry to a pressure of from about 500 psi to about 1,000 psi.15. The method of any preceding or following embodiment / feature / aspect, wherein the compression molding step further comprises temperature treating the slurry, wherein temperature treating the slurry comprises subjecting the slurry to a temperature of from about 140 deg C to about 180 deg C.Attorney Docket No. 3620-219-01PCT16. The method of any preceding or following embodiment / feature / aspect, wherein the compression molding occurs over a period of time of from about 30 minutes to about 60 minutes.17. The method of any preceding or following embodiment / feature / aspect, wherein a particle size distribution of the recycled granules is from about 10 mesh to about 30 mesh. 18. The method of any preceding or following embodiment / feature / aspect, wherein the recycled granules are a combination of polymer-based granules and nylon fibers from ground carpet tiles.19. The method of any preceding or following embodiment / feature / aspect, wherein the at least one binder is from 15% to 20% by weight of the slurry and the recycled granules are from 80% to 85% by weight of the slurry.20. The method of any preceding or following embodiment / feature / aspect, wherein the at least one sheet has a thickness of from 2 mm to 5 mm.21. The method of any preceding or following embodiment / feature / aspect, wherein the log has a density of from 1.2 g / cm3to about 1.8 g / cm3.22. The method of any preceding or following embodiment / feature / aspect, wherein the log has a density of from 1.42 g / cm3to 1.52 g / cm3.23. The method of any preceding or following embodiment / feature / aspect, wherein the log comprises a length of from 50 inches to 90 inches and a diameter of from 10 inches to 40 inches.24. A backing layer for a carpet material, the backing layer comprising a sheet skived from a log of solid compressed backing material, the log formed by compression molding of a slurry comprising at least one binder and recycled granules ground from a recycled carpet material.25. The backing layer of any preceding or following embodiment / feature / aspect, wherein the sheet has a density of about 1.2 g / cm3to about 1.8 g / cm3.Attorney Docket No. 3620-219-01PCT26. The backing layer of any preceding or following embodiment / feature / aspect, wherein the sheet has a density of from 1.42 g / cm3to 1.52 g / cm3.27. The backing layer of any preceding or following embodiment / feature / aspect, wherein the at least one binder comprises a polyurethane binder, an epoxy resin binder, a natural rubber binder, a natural latex binder, a silicone-based binder, an acrylic emulsion binder, a thermoplastic binder, a bio-based resin binder, a sulfur-based binder, a polyolefin binder, a starch-based binder, a lignin-based binder, or any combinations thereof.28. The backing layer of any preceding or following embodiment / feature / aspect, wherein the at least one binder is a polyurethane binder.29. The backing layer of any preceding or following embodiment / feature / aspect, wherein the polyurethane binder is a moisture-cured polyurethane binder comprising a polyol component, an isocyanate component, a catalyst, an additive and / or filler, a moisture scavenger, optionally a solvent and / or reactive diluent, and optionally a plasticizer.30. The backing layer of any preceding or following embodiment / feature / aspect, wherein the catalyst is a cold-cure catalyst and the compression molding occurs at a temperature of from about 20 deg C to about 50 deg C.31. The backing layer of any preceding or following embodiment / feature / aspect, wherein the recycled granules are a combination of polymer-based granules and nylon fibers from ground carpet tiles.32. The backing layer of any preceding or following embodiment / feature / aspect, wherein the compression molding comprises a pressure treatment comprising the slurry subjected to a pressure of from about 500 psi to about 1,000 psi.33. The backing layer of any preceding or following embodiment / feature / aspect, wherein the compression molding comprises a temperature treatment comprising the slurry subjected to a temperature of from about 140 deg C to about 180 deg C.Attorney Docket No. 3620-219-01PCT34. The backing layer of any preceding or following embodiment / feature / aspect, wherein a particle size distribution of the recycled granules is from about 10 mesh to about 30 mesh.35. The backing layer of any preceding or following embodiment / feature / aspect, wherein the sheet comprises a thickness of from 2 mm to 5 mm.36. A carpet material comprising the backing layer of any preceding or following emb odiment / feature / asp ect,37. The carpet material of any preceding or following embodiment / feature / aspect, wherein the carpet material is at least one carpet tile.38. The carpet material of any preceding or following embodiment / feature / aspect, wherein the at least one carpet tile comprises a plurality of layers, wherein the backing layer is bonded to one of the plurality of layers by an extruded molten polymer.39. The carpet material of any preceding or following embodiment / feature / aspect, wherein the extruded molten polymer is polyvinyl chloride, an olefin-based compound, or a combination thereof.40. A log of solid compressed backing material, the log formed from compression molding of a slurry comprising recycled granules from a recycled carpet material and at least one binder, wherein the log has a density of from about 1.2 g / cm3to about 1.8 g / cm3.41. The log of any preceding or following embodiment / feature / aspect, wherein the at least one binder comprises a polyurethane binder, an epoxy resin binder, a natural rubber binder, a natural latex binder, a silicone-based binder, an acrylic emulsion binder, a thermoplastic binder, a bio-based resin binder, a sulfur-based binder, a polyolefin binder, a starch-based binder, a lignin-based binder, or any combinations thereof.42. The log of any preceding or following embodiment / feature / aspect, wherein the at least one binder is a polyurethane binder.Attorney Docket No. 3620-219-01PCT43. The log of any preceding or following embodiment / feature / aspect, wherein the polyurethane binder is a moisture-cured polyurethane binder comprising a polyol component, an isocyanate component, a catalyst, an additive, and / or filler, a moisture scavenger, optionally a solvent and / or reactive diluent, and optionally a plasticizer.44. The log of any preceding or following embodiment / feature / aspect, wherein the catalyst is a cold-cure catalyst and the compression molding occurs at a temperature of from about 20 deg C to about 50 deg C.45. The log of any preceding or following embodiment / feature / aspect, wherein the recycled granules are a combination of polymer-based granules and nylon fibers from ground carpet tiles.46. The log of any preceding or following embodiment / feature / aspect, wherein the log has a density of from 1.42 g / cm3to 1.52 g / cm3.47. The log of any preceding or following embodiment / feature / aspect, wherein the log comprises a length of from 50 inches to 90 inches and a diameter of from 10 inches to 40 inches.48. The log of any preceding or following embodiment / feature / aspect, wherein the compression molding comprises a pressure treatment comprising the slurry subjected to a pressure of from about 500 psi to about 1,000 psi.49. The log of any preceding or following embodiment / feature / aspect, wherein the compression molding comprises a temperature treatment comprising the slurry subjected to a temperature of from about 140 deg C to about 180 deg C.50. The log of any preceding or following embodiment / feature / aspect, wherein a particle size distribution of the recycled granules is from about 10 mesh to about 30 mesh.51. The log of any preceding or following embodiment / feature / aspect, wherein the slurry further comprises fiberglass and / or carbon fibers.Attorney Docket No. 3620-219-01PCT

[0106] The present invention can include any combination of these various aspects, features, or embodiments above and / or below as set forth in sentences and / or paragraphs. Any combination of disclosed features herein is considered part of the present invention and no limitation is intended with respect to combinable features.

[0107] Applicants specifically incorporate the entire contents of all cited references in this disclosure. Further, when an amount, concentration, or other value or parameter is given as either a range, preferred range, or a list of upper preferable values and lower preferable values, this is to be understood as specifically disclosing all ranges formed from any pair of any upper range limit or preferred value and any lower range limit or preferred value, regardless of whether ranges are separately disclosed. Where a range of numerical values is recited herein, unless otherwise stated, the range is intended to include the endpoints thereof, and all integers and fractions within the range. It is not intended that the scope of the invention be limited to the specific values recited when defining a range.

[0108] It will be apparent to those skilled in the art that various modifications and variations can be made to the embodiments of the present invention without departing from the spirit or scope of the present invention. Thus, it is intended that the present invention covers other modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.

Claims

Attorney Docket No. 3620-219-01PCTWHAT IS CLAIMED IS:

1. A method of making a backing for a surface covering comprising:obtaining recycled granules from a recycled carpet material by a process of grinding recycled carpet material and optionally shearing the recycled carpet material prior to grinding;forming a slurry by mixing the recycled granules with at least one binder; compression molding the slurry by at least pressure treating the slurry to form a log of solid compressed backing material, optionally having a density of from about 1 g / cm3to about 1.8 g / cm3; andskiving the log to form at least one sheet forming the backing.

2. The method of claim 1, wherein the at least one binder comprises a polyurethane binder, an epoxy resin binder, a natural rubber binder, a natural latex binder, a silicone-based binder, an acrylic emulsion binder, a thermoplastic binder, a bio-based resin binder, a sulfur-based binder, a polyolefin binder, a starch-based binder, a lignin-based binder, or any combinations thereof.

3. The method of claim 1, wherein the at least one binder is a polyurethane binder.

4. The method of claim 3, wherein the polyurethane binder is a moisture-cured polyurethane binder comprising a polyol component, an isocyanate component, a catalyst, an additive and / or filler, a moisture scavenger, optionally a solvent and / or reactive diluent, and optionally a plasticizer.Attorney Docket No. 3620-219-01PCT5. The method of claim 4, wherein the polyol component is from 50% to 70% by weight of the polyurethane binder, the isocyanate component is from 30% to 50% by weight of the polyurethane binder, the catalyst is from 0.1% to 1% by weight of the polyurethane binder, the additives and / or fillers are from 1% to 5% by weight of the polyurethane binder, the plasticizer is from 0% to 10% by weight of the polyurethane binder, the solvent and / or reactive diluent is from 0% to 10% by weight of the polyurethane binder, and the moisture scavenger is from 0.5% to 2% by weight of the polyurethane binder.

6. The method of claim 4, wherein the polyol component comprises at least one polyether polyol, polyester polyol, or bio-based polyol, or any combinations thereof.

7. The method of claim 4, wherein the isocyanate component comprises an aromatic isocyanate, an aliphatic isocyanate, a prepolymer, or a combination thereof.

8. The method of claim 4, wherein the catalyst comprises an amine catalyst, a metal-based catalyst, or a combination thereof.

9. The method of claim 4, wherein the catalyst is a cold-cure catalyst and the compression molding step occurs at a temperature of from about 10 deg C to about 50 deg C.

10. The method of claim 4, wherein the additive and / or filler comprises talc, a calcium carbonate, silica, a phosphate, a halogen free filler, a pigment, an antioxidant, an ultraviolet stabilizer, or any combinations thereof.Attorney Docket No. 3620-219-01PCT11. The method of claim 4, wherein the polyurethane binder further comprises the plasticizer and the plasticizer comprises at least one non-phthalate, a bio-based plasticizer, or any combinations thereof.

12. The method of claim 4, wherein the polyurethane binder further comprises the solvent and / or reactive diluent, wherein the solvent and / or reactive diluent comprise acetone, methyl ethyl ketone, glycidyl ethers, or any combinations thereof.

13. The method of claim 4, wherein the moisture scavenger comprises a silica-based scavenger, a chemical scavenger, or a combination thereof.

14. The method of claim 1, wherein pressure treating the slurry comprises subjecting the slurry to a pressure of from about 500 psi to about 1,000 psi.

15. The method of claim 1, wherein the compression molding step further comprises temperature treating the slurry, wherein temperature treating the slurry comprises subjecting the slurry to a temperature of from about 140 deg C to about 180 deg C.

16. The method of claim 1, wherein the compression molding occurs over a period of time of from about 30 minutes to about 60 minutes.

17. The method of claim 1, wherein a particle size distribution of the recycled granules is from about 10 mesh to about 30 mesh.Attorney Docket No. 3620-219-01PCT18. The method of claim 1, wherein the recycled granules are a combination of polymer-based granules and nylon fibers from ground carpet tiles.

19. The method of claim 1, wherein the at least one binder is from 15% to 20% by weight of the slurry and the recycled granules are from 80% to 85% by weight of the slurry.

20. The method of claim 1, wherein the at least one sheet has a thickness of from 2 mm to 5 mm.

21. The method of claim 1, wherein the log has a density of from 1 g / cm3to about 1.8 g / cm3.

22. The method of claim 1, wherein the log has a density of from 1.42 g / cm3to 1.52 g / cm3.

23. The method of claim 1, wherein the log comprises a length of from 50 inches to 90 inches and a diameter of from 10 inches to 40 inches.

24. A backing layer for a carpet material, the backing layer comprising a sheet skived from a log of solid compressed backing material, the log formed by compression molding of a slurry comprising at least one binder and recycled granules ground from a recycled carpet material.

25. The backing layer of claim 24, wherein the sheet has a density of about 1 g / cm3to about 1.8 g / cm3.

26. The backing layer of claim 24, wherein the sheet has a density of from 1.42 g / cm3to 1.52Attorney Docket No. 3620-219-01PCT27. The backing layer of claim 24, wherein the at least one binder comprises a polyurethane binder, an epoxy resin binder, a natural rubber binder, a natural latex binder, a silicone-based binder, an acrylic emulsion binder, a thermoplastic binder, a bio-based resin binder, a sulfurbased binder, a polyolefin binder, a starch-based binder, a lignin-based binder, or any combinations thereof.

28. The backing layer of claim 24, wherein the at least one binder is a polyurethane binder.

29. The backing layer of claim 28, wherein the polyurethane binder is a moisture-cured polyurethane binder comprising a polyol component, an isocyanate component, a catalyst, an additive and / or filler, a moisture scavenger, optionally a solvent and / or reactive diluent, and optionally a plasticizer.

30. The backing layer of claim 29, wherein the catalyst is a cold-cure catalyst and the compression molding occurs at a temperature of from about 20 deg C to about 50 deg C.

31. The backing layer of claim 24, wherein the recycled granules are a combination of polymer-based granules and nylon fibers from ground carpet tiles.

32. The backing layer of claim 24, wherein the compression molding comprises a pressure treatment comprising the slurry subjected to a pressure of from about 500 psi to about 1,000 psi.Attorney Docket No. 3620-219-01PCT33. The backing layer of claim 24, wherein the compression molding comprises a temperature treatment comprising the slurry subjected to a temperature of from about 140 deg C to about 180 deg C.

34. The backing layer of claim 24, wherein a particle size distribution of the recycled granules is from about 10 mesh to about 30 mesh.

35. The backing layer of claim 24, wherein the sheet comprises a thickness of from 2 mm to 5 mm.

36. A carpet material comprising the backing layer of claim 24.

37. The carpet material of claim 36, wherein the carpet material is at least one carpet tile.

38. The carpet material of claim 37, wherein the at least one carpet tile comprises a plurality of layers, wherein the backing layer is bonded to one of the plurality of layers by an extruded molten polymer.

39. The carpet material of claim 38, wherein the extruded molten polymer is polyvinyl chloride, an olefin-based compound, or a combination thereof.

40. A log of solid compressed backing material, the log formed from compression molding of a slurry comprising recycled granules from a recycled carpet material and at least one binder, wherein the log has a density of from about 1 g / cm3to about 1.8 g / cm3.Attorney Docket No. 3620-219-01PCT41. The log of claim 40, wherein the at least one binder comprises a polyurethane binder, an epoxy resin binder, a natural rubber binder, a natural latex binder, a silicone-based binder, an acrylic emulsion binder, a thermoplastic binder, a bio-based resin binder, a sulfur-based binder, a polyolefin binder, a starch-based binder, a lignin-based binder, or any combinations thereof.

42. The log of claim 40, wherein the at least one binder is a polyurethane binder.

43. The log of claim 42, wherein the polyurethane binder is a moisture-cured polyurethane binder comprising a polyol component, an isocyanate component, a catalyst, an additive, and / or filler, a moisture scavenger, optionally a solvent and / or reactive diluent, and optionally a plasticizer.

44. The log of claim 43, wherein the catalyst is a cold-cure catalyst and the compression molding occurs at a temperature of from about 20 deg C to about 50 deg C.

45. The log of claim 40, wherein the recycled granules are a combination of polymer-based granules and nylon fibers from ground carpet tiles.

46. The log of claim 40, wherein the log has a density of from 1.42 g / cm3to 1.52 g / cm3.

47. The log of claim 40, wherein the log comprises a length of from 50 inches to 90 inches and a diameter of from 10 inches to 40 inches.Attorney Docket No. 3620-219-01PCT48. The log of claim 40, wherein the compression molding comprises a pressure treatment comprising the slurry subjected to a pressure of from about 500 psi to about 1,000 psi.

49. The log of claim 40, wherein the compression molding comprises a temperature treatment comprising the slurry subjected to a temperature of from about 140 deg C to about 180 deg C.

50. The log of claim 40, wherein a particle size distribution of the recycled granules is from about 10 mesh to about 30 mesh.

51. The log of claim 40, wherein the slurry further comprises fiberglass and / or carbon fibers.

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