CN101501271A - Surface coverings and methods - Google Patents

Abstract

A surface covering comprises a show surface, decorative layer, or face and an optional backing layer. The show surface, decorative layer, or face can comprise a decorative textile or fabric layer that is optionally saturated, covered, and/or coated with a protective film or film-forming composition. The backing can optionally comprise an agglomerated mass of particles, a foam, foam and particles, a felt, or a combination thereof. Methods for producing such surface coverings are also disclosed.

Description

Surface Coverings and Methods

related application

This application claims priority and rights to US Patent Application Serial No. 60/812,718, filed June 12,2006.

technical field

The present invention may relate to processes, methods, uses, devices and/or products, such as surface coverings, such as floor coverings, wall coverings, furniture coverings, having a textile or fabric exposed surface, a decorative layer or face and optionally a backing things etc. Such textile exposed surfaces, layers or faces are selectively impregnated, covered and/or coated, or include protective coating compositions or abrasive surfaces, such as transparent resins or polymeric materials. In at least one exemplary embodiment, the textile exposed surface is in overlying relationship with a backing consisting of or comprising agglomerated contiguous particle components. In at least another exemplary embodiment, the textile exposed surface is in covering relationship with a backing that is comprised of or includes a foam cushion. In yet another exemplary embodiment, the textile exposed surface is in covering relationship with a backing that is a blend or combination of particles and foam. Specifically, but not exclusively, at least some embodiments of the present invention may relate to surface coverings, such as floor coverings, including but not limited to carpets, carpet tiles, floors, floor tiles, rugs, Carpet tiles, carpet strips, rugs, floor mats, stable broadloom, floor tiles, roll goods, etc. Tufted, viscose, knitted, woven, non-woven, needle punched, flocked and other textiles or fabric exposed surfaces, surface materials, decorative textile layers, etc. can be added to the surface covering. The textile layer may be impregnated, covered and/or coated with a film or film-forming composition that is desirably transparent or translucent when cured. Alternatively or additionally, the face yarn or fibers may include one or more coatings or layers, such as transparent, translucent and/or colored coatings or layers. For example, a face yarn may comprise a core yarn or core fiber or core filament or core material coated with one or more coatings, sheaths, sheaths, layers, wear layers, films, and/or the like. Additionally, it is desirable that the film or film-forming composition or one or more coatings or layers be abrasion resistant, stain resistant, stain resistant, aesthetically pleasing, fusible, and/or the like. In one embodiment, the textile face may be disposed in covering relation on an elastic and/or flexible backing composed of agglomerated masses of particles, examples of which are irregular particles such as new, recycled, recyclable renewable, natural, bio-based, biodegradable and/or other environmentally friendly or reliable materials such as recycled carpet, foam, rubber and/or cork. The textile face and the particulate backing are usually bonded together in contiguous relationship. Optional adhesive layers, adhesive films, stabilizing layers, textile backings and/or the like may be disposed on, in or below the particulate backing. Materials or coatings that increase friction, stickiness, or aid in fit may be added to the particle backing and/or to the underside of the particle backing. For example, the particle backing can include voids to increase lateral grip, reduce slippage, and the like. Alternatively or additionally, a textile or fabric backing with a friction increasing coating may be added under the particle backing, under the foam backing, or under a blend or combination of particles and foam. Methods of manufacture and recycling of these surface coverings are also provided.

Background technique

It is known to provide carpets or carpet tiles with a tufted or bonded pile carpet surface and with a backing layer made of so-called "fresh" or "filled" foam or irregular sheets of recycled foam fragments by bonding. A "rebond" foam is formed that holds the mixture together. These new or filled foam carpet structures are described, for example, in US Patent Nos. 5,545,276, 5,948,500, 6,203,881 and 6,468,623, each of which is hereby incorporated by reference as if fully set forth herein. These regenerated bonded carpet structures are described, for example, in U.S. Patent Application Nos. 09/721,871 and 09/993,158 (U.S. Application Publication No. US 2002/0132085) and 10/209,050 (U.S. Application Publication No. US 2004/0022991) and British Patent to Higgins et al. Disclosed in GB 2369294, each of the above patents and patent applications is hereby incorporated by reference as if fully set forth herein.

Furthermore, floor coverings in the form of mats or floor mats with a textile surface and a rubber backing are also known. Typically, these mats comprise a tufted textile surface bonded to a rubber backing sheet, eg polyamide (eg nylon), cotton, polypropylene or a blend of these fibers. Such mats are usually made by bonding a textile surface layer to an uncured rubber sheet in a heated press. The heat from the pressing vulcanizes (cures) the rubber, bonding it to the textile layers at the same time. These mats have very good dust control properties, efficiently remove dirt and moisture from the soles of pedestrians' feet, and have a good feel and appearance. Some of these mats are also washable, durable, soft, and lay flat on slippery floors.

A disadvantage of many of the structures described above is that they tend to be quite expensive due to the relatively high cost of new backing materials, they can be structurally complex, especially carpet tiles, they may not be easily recycled and/or they cannot contain recycled materials . Additionally, manufacturers and users often wish to increase the recycled content of finished products.

Contents of the invention

The present invention may relate to processes, methods, uses, devices and/or products, such as surface coverings, such as floor coverings, wall coverings, furniture coverings, having a textile or fabric exposed surface, a decorative layer or face and optionally a backing things etc. Such textile exposed surfaces, decorative layers or faces are selectively impregnated, covered and/or coated, or include protective coating compositions or abrasive surfaces, such as transparent resins or polymeric materials. In at least one exemplary embodiment, the textile exposed surface is in overlying relationship with a backing consisting of or comprising agglomerated contiguous particle components. In at least another exemplary embodiment, the textile exposed surface is in covering relationship with a backing that is comprised of or includes a foam cushion. In at least one further exemplary embodiment, the textile exposed surface is in covering relationship with a backing that is a blend or combination of particles and foam. In particular, but not exclusively, at least some embodiments of the present invention may relate to surface coverings, such as floor coverings, including but not limited to carpets, carpet tiles, floors, floor tiles, rugs, carpet tiles, long Carpets, rugs, floor mats, stable broadloom, floor tiles, rolls and more. Tufted, viscose, knitted, woven, non-woven, needle-punched, flocked and other textiles or fabric exposed surfaces, surface materials, decorative textile layers, etc. can be added to the surface covering. The textile layer may be impregnated, covered and/or coated with a film or film-forming composition that is desirably transparent or translucent when cured. Alternatively or additionally, the veil or fibers may include one or more coatings or layers, such as transparent, translucent and/or colored coatings or layers. For example, the face yarn may comprise a core yarn or core fiber or filament or core material coated with one or more coatings, sheaths, sheaths, layers, wear layers, films, and the like. In addition, it is also desirable for the film or film-forming composition or one or more coatings or layers to be abrasion-resistant, stain-resistant, stain-resistant, aesthetically pleasing, fusible, and/or similar. In one embodiment, the textile surface may be disposed in overlying relationship on an elastic and/or flexible backing composed of agglomerated clumps of particles, examples of which are irregular particles such as new, recycled, recyclable renewable, natural, bio-based, biodegradable and/or other environmentally friendly or reliable materials such as foam and/or rubber and/or cork. The textile surface and the particulate backing are usually bonded together in contiguous relationship. Optional adhesive layers, adhesive films, stabilization layers, textile backings, and/or the like may be disposed on, in, or below the particulate backing. Materials or coatings that increase friction, stickiness, or facilitate installation can be added to the particle backing and/or onto the underside of the particle backing. For example, the particle backing can include voids to increase lateral grip, reduce slippage, and the like. Alternatively or additionally, a textile or fabric backing (such as a nonwoven felt or scrim) with a friction-enhancing coating can be added under a particle backing, under a foam backing, or a blend of particles and foam or Under the combined backing. Methods of manufacture and recycling of these surface coverings are also provided.

In at least selected embodiments, the present invention addresses, provides advantages over, or provides an alternative to existing structures by providing surface coverings, examples of which are are floor coverings, including but not limited to carpets, carpet tiles, floors, tiles, rugs, carpet tiles, carpet strips, rugs, stable broadloom, floor tiles, rolls, etc., said surface coverings including For example, an upholstery textile or fabric face that defines the exposed surface and an optional backing, examples of which are foam and/or particle backings, such as made of, for example, new, recycled, recyclable, natural, biological Foam and/or particle backings of organic, biodegradable and/or renewable materials, such as natural and/or synthetic materials, such as new, natural or recycled surface coverings, rubber, foam, cork and/or particles or debris of the like. According to a possibly preferred embodiment, the backing comprises at least some recycled content, at least a portion of which is, for example, recycled upholstery textiles or surface fabrics, recycled backings, recycled surface coverings, or blends or combinations thereof Granules, chips, nubs, materials, etc. According to a specific example, used surface coverings of at least some selected embodiments of the present invention are ground into a backing or filler material or particles and used in the backing of a new surface covering. The decorative side of these used surface coverings is preferably formed from a relatively flat fabric or textile such as a woven, knitted or nonwoven structure.

The decorative surface may be formed from colored yarns or fibers or filaments with or without a transparent or translucent coating or layer. Alternatively or additionally, decorative images such as text, patterns, colours, images and/or graphics may be applied to the textile face by printing or dyeing. If desired, optionally after printing or dyeing, the upholstery fabric can be impregnated, covered and/or coated with a film or an effective film-forming amount of a protective film-forming composition, examples of which are are transparent or translucent abrasion, stain or stain resistant compositions such as transparent resins or polymers such as polyurethanes, acrylic polymers, polyesters, polyolefins, polyamides, high density polyolefins, high density polypropylene (HDPP) and blends or combinations thereof, etc. If desired, a stabilizing layer, for example, composed of glass (such as fiberglass, glass mat, glass scrim, woven glass, etc.) can be applied over, on, in and/or under the backing, or can be used as a backing. lining. In one possible preferred configuration, the stabilizing layer may be embedded in a particle and/or foam backing. A textile backing layer may also be applied on the underside of the backing. Friction increasing coatings or materials may be added to the underside of the particle and/or foam backing or on the underside of the textile backing.

Although according to at least selected embodiments, the surface covering has a particle backing, it is contemplated that the surface covering may have an adhesive, resin, polymer, fabric, textile, foam, and/or similar backing or backing layer. For example, floor tiles of at least some potentially preferred embodiments may have a hard base or backing particle, foam, adhesive, resin, polymer, fabric, textile, extrusion, film, and/or similar backing or backing layer, and one or more optional adhesive layers, adhesive films, stabilizing layers, textile backings, coatings or materials.

According to one possible aspect of the invention, there is provided a method of manufacturing a surface covering with a textile or fabric surface and an elastic and/or flexible backing containing a substantial percentage of recycled material. In a possibly preferred practice, the method comprises mixing particles of recycled material (such as particles of recycled surface coverings, rubber, foam, cork, and/or similar substances) with a binder and optionally adding one or more fillers, agents or compounds; depositing the particle/binder mixture as a layer; placing the impregnated, covered and/or coated textile surface material on said layer to form a multilayer structure; The multilayer structure is pressed while the binder is cured, eg with heat, thereby consolidating the particles to form an elastic and/or flexible backing. Typically, the elastic backing will include voids between the compressed particles, and the coated textile face material will be bonded to the backing. A coated textile surface material may be made of colored yarn or fiber or filament or material, and/or printed or dyed before it is coated or covered. One or more other protective, stain-resistant, stain-resistant or abrasion-resistant layers or films may be added to the coated textile surface material. Alternatively or additionally, yarns or fibers or filaments or materials of the surface material may be coated with these materials. For example, the face yarn may be a coated yarn, such as a polyolefin yarn extrusion coated with a colored polyolefin polymer material over which is coated a clear polymer wear layer. Coated veils are easier to recycle if they are made from a single polymer or material. For example, yarns with polyolefin cores and polyolefin coatings are easier to recycle than multi-polymer or multi-material yarns. In a particular example, preferred yarns may have a polypropylene core and a polypropylene coating.

Throughout this specification, the terms "granules", "powder", "fines", "chips" or "crumbs" are used to refer to new, renewable, recovered, recoverable, natural, Small pieces of biological, biodegradable and/or other environmentally friendly or reliable materials, such as by shredding, mechanical grinding, cryogenic grinding or other known techniques or suitable combinations of techniques known to those skilled in the art to "destroy "Small pieces of glass, cork, foam, rubber, flooring, trim, backing and/or similar substances. Thus, particles or chips of cork, foam or rubber employed in contemplated practice may be of any size, including powders, granules and chips. For purposes of describing at least selected embodiments herein, the term "powder" means particles or debris that, as required herein, pass through a 2mm mesh or have a maximum dimension of 2mm in at least one dimension. "Fines" means particles or debris which, as required herein, pass through a 6mm mesh or have a maximum dimension of 6mm in at least one dimension. Fines generally include some powder but are generally larger than powder and have a weight average size close to the maximum value of the fine particle size specification. "Fragments" means particles or debris that are larger than granules. That is, greater than 6 mm in at least one dimension, as required herein. Regardless of actual size, it is envisaged that the particles or debris are preferably characterized by a substantially irregular surface structure, although other shapes or structures such as cylinders, pellets, ovals, discs, rods, spheres, etc. may also be used .

It should be noted that any batch of particles will generally contain fractions smaller than the nominal particle size. Thus, for example, it has been found that, as measured by using standard "Endecott" test sieves (ISO3310-1:2200, BE410-1:2000, ASTM E11:95), using an The rubber granules produced by the granulator had the following size distribution comprising: 72.82% by weight of particles with a diameter of 1.0-2.0mm, 17.45% by weight of particles with a diameter of 0.71-1.0mm, and 6.90% by weight of particles with a diameter of 0.5-0.71mm , 2.65% by weight has a particle size of 0.25-0.5mm, and 0.18% by weight has a particle size of 0-0.25mm. Therefore, in this specification when we refer to a crumb or particle size of 1.5mm, we mean granules formed using a granulator with a 1.5mm screen. Likewise, it will be understood that when referring to "curing" an adhesive we mean any suitable method of curing the adhesive, for example using a method such as curing, hardening, setting or heat curing the adhesive. technology. Those skilled in the art know which technique to use for curing depending on the nature of the adhesive. The binder may be selected from heat-curing and water-curing polymeric materials, adhesives or mixtures thereof. Alternatively, the adhesive may be selected from thermoplastic polymeric materials, hot melt adhesives, adhesives, extrudable materials and mixtures thereof.

According to another contemplated practice, the assembled layer is pressed at a temperature of from about 50°C to about 200°C, preferably from about 110°C to about 180°C, most preferably from about 125°C to 177°C.

The assembly can be pressed in multiple stages including a low temperature stage and a high temperature stage. A low temperature stage can be used first and then a high temperature stage, or vice versa, as desired. For example, if the binder is selected from heat-curing or water-curing polymeric materials and mixtures thereof, the assembly is preferably pressed in stages comprising at least one low temperature stage followed by at least one high temperature stage. Or, for example, if the adhesive is selected from thermoplastic polymeric materials, hot-melt adhesives and mixtures thereof, the assembly is preferably in multiple stages comprising at least one high temperature stage followed by at least one low temperature stage or cooling stage to suppress.

Assemblies can be pressed between a pair of opposing press belts (two-belt laminator), although other equipment such as a choice between rollers and assemblies can be used when it is desired to cure the assembly under pressure One or more rolls, optionally with film or fabric, or a press with expandable diaphragms.

A continuous sheet of textile material may be placed on the particle/binder layer. The placed textile material is a selectively impregnated, covered or coated textile material. Instead of or in addition to the continuous sheet, separate textile components may be placed continuously on the particle/binder layer. If desired, adhesive layers such as adhesive films, dry adhesives or other elastic adhesives can be placed between the textile face and the particle/adhesive layer, between the textile face and the stabilizing layer or material, between the stabilizing layer or material and the granule/adhesive between backings, and/or under particle/adhesive backings, to facilitate interlayer adhesion.

Where rubber particles are used, these rubbers are preferably recycled EPDM or nitrile rubber. EPDM is the term used to refer to rubber compounds whose main polymerized component is ethylene-propylene-diene rubber monomer. It may also contain fillers, plasticizers and other auxiliary ingredients known in the rubber synthesis industry. EPDM particles can be foam or solid particles. Nitrile rubber is the term used to describe hybrid rubber compounds whose main polymeric component is acrylonitrile-butadiene copolymer. It may also contain one or more fillers such as carbon black, curing systems, plasticizers and other auxiliary ingredients. Other rubber materials may also be used, such as SBR rubber granules, recycled tire crumbs, recycled mat crumbs, recycled mat backing crumbs, rubber blends, and combinations thereof.

Where foam particles are used, this foam is preferably recycled polyurethane foam or EPDM foam. Such foams, especially polyurethane foams, can be mechanically and/or chemically blown and can have an open-cell or closed-cell structure. Other foams can also be used such as recycled bonded foam, waste recycled bonded foam, nitrile foam, SBR foam, recycled cushion scraps, recycled foam cushion backing, recycled foam lined flooring, recycled floor foam backing, Other recycled foam materials, blends thereof, combinations thereof, and the like.

In at least one embodiment, the particle/binder backing has a density of less than about 1 g/cm ³ . In at least one embodiment, the particle/binder backing has a density of about 0.5 to about 0.9 g/cm ³ , more preferably about 0.7 to about 0.9 g/cm ³ .

In at least one embodiment, the particle/adhesive backing exhibits a tear strength of at least about 0.8 N/mm ² , more preferably the particle/adhesive backing has a tear strength of about 1.5 N/mm ² or higher.

Advantageously, according to at least selected embodiments, the textile surface or face comprises a relatively flat textile or fabric structure, such as a tufted, flocked, needle punched, nonwoven, knitted or woven textile structure. These materials may, if desired, be formed, woven, knitted, printed and/or spray dyed with a decorative surface pattern. These textile materials are preferably impregnated, covered or coated with at least one clear protective film or film-forming composition [such as polyurethane, acrylic polymer, polyester, etc. (preferably at least transparent or translucent after curing)] . Textile materials may be saturated before or after printing, dyeing, manufacturing, backing, etc. In at least one embodiment, the textile material is preferably printed or dyed prior to impregnation. Using one or more sublimation printing techniques, the textile material can be printed, for example after being saturated, covered or coated with a transparent material. To saturate or to saturate completely means to saturate, penetrate or soak the textile and cover it sufficiently to form a protective outer film, coating, etc. The textile surface or face can be completely saturated or coated in one go by, for example, a dip coater, or it can be coated and saturated by coating one side first and then the other side (upper and lower), for example on each side Use a roller coater on top, then use a pinch roller. Complete impregnation can be accomplished in multiple steps or in one step. In addition, one material such as opaque hot melt, adhesive, latex material or methylene diphenyl diisocyanate (MDI) adhesive can be applied on the bottom of the textile and another material such as clear polyurethane, Polyester, Acrylic etc. Alternatively, one or more films may be placed on top and/or bottom of the textile surface or facing material. For example, clear, transparent or translucent resinous or polymeric films or multilayer films such as polyesters, polyurethanes, polyolefins, blends thereof, combinations thereof, and the like are preferred in selected embodiments. For example, a first polyurethane film can be placed or extruded on top of the textile and then a polyester film can be placed or extruded over the polyurethane film. In other selected embodiments, one or more layers of colored, white graphic, printed or other opaque films may be used. For example, a white film is placed or extruded onto a textile, printed and then covered with one or more layers of transparent film. When cured or heated, the multiple film layers will fuse to form a single structure. As another example, the top of the textile may be covered with a first film adhesive, a second opaque film, and a third transparent film or wear layer. Likewise, the bottom of the textile facing material may also have one or more films or coatings on its bottom, such as one or more layers of adhesive films, stabilizing films, combinations thereof, and the like. Depending on the film or coating used, one or more of these can be used, for example, as a wear layer, cover layer, aesthetic layer, graphic or print layer, moisture barrier layer, adhesive layer, stabilization layer, backing, and the like. Thus, a textile face or surface material may be coated, covered or saturated with one or more materials in one or more steps. One or more further, preferably transparent, stain-resistant, stain-resistant and/or abrasion-resistant layers may be added to the coated textile surface material. Alternatively or additionally, the yarns or fibers of textile or fabric surface materials may be coated with these materials. For example, the veil may be coated natural and/or synthetic fibers or yarns, such as polyester or polyolefin monofilament or multifiber white or polyolefin extrusion coated with clear colorless or colored polyolefin or PVC polymeric material Colored yarn coated with a clear polymer wear layer or film such as high density polypropylene, polyester, acrylic, polyurethane, blends thereof, on said clear colorless or colored polyolefin or PVC polymeric material Compounds, combinations thereof, etc.

According to at least one embodiment, the present invention may relate to surface coverings, such as floor coverings, wall coverings, furniture coverings, etc., having a coated yarn textile exposed surface or face and an optional backing. The coated yarn textile exposed surface or face is selectively impregnated, covered, coated, or includes a protective coating composition or abrasive surface, such as at least one transparent resin or polymeric material. In at least one exemplary embodiment, the coated yarn textile exposed surface is in overlying relationship with a backing that consists of or includes agglomerated contiguous particle components. In at least another exemplary embodiment, the coated yarn textile exposed surface is in covering relationship with a backing that is comprised of or includes a foam cushion. Specifically, but not exclusively, the coated yarn textile surface covering is preferably a floor covering including but not limited to carpets, carpet tiles, floors, floor tiles, carpet tiles, rugs, carpet strips, mats, floor mats, Stabilizes broadloom carpet, laminate flooring, rolls and more. Tufted, visored, knitted, woven, nonwoven, needle punched, flocked, etc. decorative coated yarn textile layers may be included in the surface covering. The coated yarn textile layer can be impregnated, covered and/or coated with at least one film or film-forming composition that is desirably transparent or translucent when cured. Alternatively or additionally, surface-coated yarns or fibers may include one or more coatings or layers, such as transparent, translucent and/or colored coatings or layers. For example, a veil may comprise single or multiple fibers (staple or continuous), filaments (including filaments and ) or core material coated with one or more coatings, claddings, shells, wear layers, etc. Additionally, it is also desirable that the film or film-forming composition or one or more coatings or layers be abrasion resistant, stain resistant, stain resistant, aesthetically pleasing, fusible, and/or the like. In one embodiment, the coated yarn textile surface may be disposed in overlying relationship on an elastic and/or flexible backing composed of agglomerated clumps of particles, examples of which are irregular particles such as new, recycled recycled, renewable, natural, and/or other environmentally friendly or reliable materials such as new and/or recycled carpet, floor tiles, rugs, tires, weatherstripping, coated yarn surface coverings , foam, rubber, cork, glass, blends thereof, combinations thereof, etc. The textile surface and the particulate backing are usually bonded together in contiguous relationship. Optional adhesive films or layers, stabilizing layers, textile backings and/or the like may be placed on, in or under the elastic backing. Materials or coatings that increase friction, stickiness, or facilitate installation can be incorporated into the backing and/or onto the underside of the backing. For example, the particle backing can include voids to increase lateral grip, reduce slippage, and the like. Alternatively or additionally, a felt backing with a friction increasing coating, material, pattern, etc. may be added under the particle backing or under the foam backing. The coated veil may be a coated natural and/or synthetic fiber or silk or material yarn, such as single or multi-fiber, silk or poly Transparent colorless, white or colored yarns of ester or polyolefin material coated with a transparent colorless polymeric wear layer or film such as High density polypropylene. Methods of manufacture and recycling of these surface coverings are also provided.

Description of drawings

At least some exemplary embodiments or aspects of the invention are described, by way of example, with reference to the accompanying drawings, which are briefly described as follows:

Figure 1 is a side cross-sectional view of an exemplary surface covering component having a fiber-exposing surface, depicting a layered component component and an optional additional upper side film or layer (such as a protective layer) and an optional lower side film or layers (such as friction-enhancing layers or adhesive layers);

Figure 2 is a side view of an exemplary production line for the manufacture of a surface covering (such as that of Figure 1, etc.) comprising, for example, a fabric exposed surface and a particle backing (such as rubber particles and adhesive) backing);

FIG. 2A is a side view similar to FIG. 2 depicting an exemplary production line for manufacturing a surface covering, such as the surface covering of FIG. 7 with or without a textile backing 452, etc. Materials include, for example, fabric exposed surfaces, optional adhesive layers, and preformed particle backings (e.g., recycled adhesive foam);

2B is a side view similar to FIG. 2 depicting another exemplary production line for manufacturing a surface covering, such as that of FIG. 1 , etc., having a fabric exposed surface and a particle backing. lining;

3 is a cross-sectional side view similar to FIG. 1 depicting another exemplary surface covering component having a fabric surface adhesively bonded to a backing of stabilizing particles, the stabilizing particles Backing with a bottom backing sheet and optionally other upper and/or lower layers;

4 is a side view of an exemplary production line for manufacturing a surface covering (such as a surface covering having a layered structure as shown in FIG. 11 or FIG. 3 , etc.) comprising a fabric exposed surface and a particle backing Lining, or comprising a fabric surface adhesively bonded to a stable particle backing (such as a backing of rubber particles and adhesive) with optional upper and lower layers;

4A is a side view similar to FIG. 4 depicting an exemplary production line for manufacturing a surface covering, such as having a layered structure as shown in FIG. 3 , comprising preformed stabilizing particles a fabric exposed surface adhesively bonded to the backing (e.g., a recycled adhesive foam backing having, for example, two preformed recycled adhesive foam layers and optionally additional layers);

Figure 5 is a cross-sectional side view similar to Figure 1 of an exemplary surface covering comprising a textile backing such as a fibrous backing sheet;

Figure 6 is a cross-sectional side view of an exemplary surface covering component similar to Figure 3, Figure 5, or Figure 7, depicting another structure having a fabric exposed surface adhesively bonded to a stabilizing particle backing, said Stabilized particle backing with an underlying backing sheet and optional additional layers;

Figure 7 is a cross-sectional side view of an exemplary surface covering component similar to Figure 3, Figure 5, or Figure 6, depicting an exemplary structure having a fabric exposed surface adhesively bonded to a particle backing Backing with an underlying backing sheet and optional additional layers;

Figure 8 is a cross-sectional side view similar to Figure 1 , Figure 5, or Figure 7 of an exemplary surface covering component comprising an adhesive layer bonding a fibrous backing sheet;

9 is a cross-sectional side view similar to FIG. 8 or FIG. 7 of an exemplary surface covering component including an adhesive layer on either side of a particle backing layer;

10 is a cross-sectional side view depicting an exemplary surface covering component having a structure similar to that of FIG. 6 including a combination of stabilizing layers such as a glass mat and a scrim stabilizing layer therein;

Figure 11 is a cross-sectional side view of an exemplary surface covering component similar to Figure 3, but excluding at least some of the additional layer of adhesive;

12 is a top view of an exemplary surface covering component (such as a floor tile product) including a decorative exposed surface and an optional upper layer [such as one or more other protective layers and texture (such as embossed flower)]);

Figure 13 is a side view taken along line 13-13 in Figure 12, which depicts the surface covering component of Figure 12 with a backing and an optional bottom layer;

14 is a top view of an exemplary surface covering component, such as a floor tile product, including a decorative exposed surface with an outer margin region and an optional upper layer [one or more other protective layers and texture (such as embossing)];

Figure 15 is a side view taken along line 15-15 in Figure 14, which depicts the surface covering component of Figure 14 with a backing and an optional bottom layer;

Figure 16 is an enlarged cross-sectional end view illustrating an exemplary coated yarn according to one embodiment of a face structure of the present invention;

Figure 17A is an enlarged cross-sectional end view illustrating an exemplary coated yarn according to another embodiment of a face structure;

Figure 17B is an enlarged cross-sectional side view taken along line 17B-17B in Figure 17A, which depicts a section of the coated yarn of Figure 17A;

Figure 18 is an enlarged cross-sectional end view illustrating yet another exemplary coated yarn, fiber, filament or material according to yet another embodiment of a face structure;

Figure 19 is an enlarged cross-sectional end view illustrating another exemplary coated yarn, fiber, filament or material according to another embodiment of a face structure;

Figure 20 is an enlarged cross-sectional end view illustrating another exemplary coated yarn (or yarns) having a plurality of core yarns according to yet another embodiment of a face structure;

21A-21D are enlarged cross-sectional end views, each depicting an exemplary face fiber, filament, or material shape according to an embodiment of a corresponding face structure;

Figure 22 is a cutaway side view of an exemplary embodiment of a woven surface covering, such as a woven flooring structure;

Figure 23 is a cutaway side view of an exemplary woven face surface covering comprising a possibly preferred foam backing structure;

Figure 24 is a cutaway side view of an exemplary tufted face surface covering comprising a possibly preferred foam backing structure;

Figure 25 is a cutaway side view of another tufted surface covering similar to Figure 24 with short cut pile;

Figure 26 is a cutaway side view of another tufted face surface covering similar to Figure 24 with short or tight loop piles;

Figure 27 is a cross-sectional side view of another nonwoven surface covering similar to Figure 22; and

FIG. 28 is a cross-sectional side view similar to FIG. 22 of an alternative needled or needle punched face surface covering.

Detailed ways

The present invention may relate to processes, methods, uses, devices and/or products, such as surface coverings, such as floor coverings, wall coverings, furniture coverings, having a textile or fabric exposed surface, a decorative layer or face and optionally a backing things etc. The textile exposed surface, layer or face is selectively impregnated, covered and/or coated, or includes a protective coating composition or an abrasive surface, such as a transparent resin or polymeric material. In at least one exemplary embodiment, the textile exposed surface is in overlying relationship with a backing that consists of or includes agglomerated contiguous particle components. In at least another exemplary embodiment, the textile exposed surface is in covering relationship with a backing that is comprised of or includes a foam cushion. In another exemplary embodiment, the textile exposed surface is in covering relationship with a backing that is a blend or combination of particles and foam. Specifically, but not exclusively, at least one embodiment of the present invention relates to surface coverings, such as floor coverings, including but not limited to carpets, carpet tiles, floors, floor tiles, rugs, carpet tiles, carpet strips, mats, Floor mats, stable broadloom carpets, floor tiles, rolls, etc. Tufted, viscose, knitted, woven, non-woven, needle punched, flocked and other textiles or fabric exposed surfaces, surface materials, decorative textile layers, etc. can be added to the surface covering. The textile layer may be impregnated, covered and/or coated with a film or film-forming composition which is desirably transparent or translucent when cured. Alternatively or additionally, the veil or fibers may include one or more coatings or layers, such as transparent, translucent and/or colored coatings or layers. For example, the face yarn may comprise a core yarn or core fiber or filament or core material coated with one or more coatings, sheaths, sheaths, layers, wear layers, films, and the like. It is also desirable that the film or film-forming composition or one or more coatings or layers be abrasion resistant, stain resistant, stain resistant, aesthetically pleasing, fusible, and/or the like. In one embodiment, the textile surface may be disposed in overlying relationship on an elastic and/or flexible backing composed of agglomerated clumps of particles, examples of which are irregular particles such as new, recycled, recyclable renewable, natural, bio-based, biodegradable and/or other environmentally friendly or reliable materials such as new or recycled surface materials, backing materials, surface coverings, foam, rubber, cork, Blends thereof, combinations thereof, and the like. The textile surface and the particulate backing are usually bonded together in contiguous relationship. Optional adhesive layers, adhesive films, stabilizing layers, textile backings and/or the like may be disposed on, in or under the elastic backing. Materials or coatings that increase friction, adhesion, or aid in fit may be added to the particle backing and/or to the underside of the particle backing. For example, the particle backing can include voids to increase lateral grip, reduce slippage, and the like. Alternatively or additionally, a textile or fabric backing with a friction-enhancing coating may be affixed under the particle backing, under the foam backing, or under a mix or combination of particles and foam. Methods of manufacture and recycling of these surface coverings are also provided.

In at least selected embodiments, the present invention addresses, provides advantages over, or provides an alternative to existing structures by providing surface coverings, examples of which are are floor coverings, including but not limited to carpets, carpet tiles, floors, tiles, rugs, carpet tiles, carpet strips, rugs, stable broadloom, floor tiles, rolls, etc., said surface coverings including Such as an upholstery textile or fabric face defining a revealing surface and a rigid or padded backing, examples of which are foams constructed of, for example, new, recycled, recyclable, natural, and/or renewable materials and/or particle backing, examples of said renewable materials are natural and/or synthetic materials such as preferably recycled materials and fillers (e.g. recycled surface coverings, floors, surface fabrics, backings, rubber, foam, cork, blends thereof, combinations thereof and/or the like) particles (powders, granules and/or crumbs). The decorative surfaces of these surface coverings are preferably formed from flat fabrics or textiles of woven, knitted or nonwoven construction, but tufted, flocked or needled constructions may also be used. The decorative surface may be formed from colored yarns or fibers or filaments or materials with or without a transparent or translucent coating or layer, or, or in addition, decorative motifs such as printed text, patterns, colours, images or graphics may be printed or dyed onto the textile surface. If desired, optionally after printing or dyeing, the decorative fabric is impregnated, covered and/or coated with a film or an effective film-forming amount of a protective film-forming composition, examples of which are Abrasion-, stain- or stain-resistant compositions that are transparent or translucent such as transparent resins or polymers, such as polyurethanes, acrylic polymers, polyesters, polyolefins, polyamides, high-density polyolefins, high-density polypropylene, etc. . If desired, a stabilizing layer, eg, composed of glass (eg, fiberglass, fiberglass, glass mat, glass scrim, etc.) can be applied on or in the backing, or can be used as the backing. . In one possible preferred configuration, the stabilizing layer can be embedded in the particulate backing. A textile backing layer may also be applied on the underside of a foam or particle backing. A friction increasing coating or material may be added to the underside of the particle and/or foam backing or the underside of the textile backing.

Although according to at least selected embodiments, the surface covering has a particle backing, preferably an elastic or flexible particle backing, it is contemplated that the surface covering may have other adhesives, resins, polymers, fabrics, textiles, foams, and/or the like backing or backing layer. For example, at least some of the possible preferred embodiment floor tiles have a hard substrate or cushion backing, particles, foams, adhesives, resins, polymers, fabrics, textiles, and/or similar backings or backing layers, and a layer or Multiple optional stabilizing, backing or friction increasing layers.

Referring to FIG. 1 , an exemplary embodiment of a surface covering 10 , such as a floor covering, such as carpet, carpet tile, floor, floor tile, floor tile, carpet tile, rug, carpet strip, mat, is depicted in cross-section. , floor mats, rolls, stable broadloom carpets, etc. It should be understood that the various layers will be depicted on an exaggerated scale for ease of understanding. Thus, the dimensions described do not necessarily correspond to final relative thickness levels in layers or in the final structure.

As shown, in the exemplary embodiment shown in FIG. 1 , the surface covering 10 includes an outer composite layer 18 comprising a preferably substantially flat woven, nonwoven, or knitted fabric or textile construction. The exposed surface 12, which is preferably impregnated or coated with an optional abrasion resistant film-forming composition 16, defines an enclosed protective barrier on the textile exposed surface 12. Composite layer 18 may include one or more optional protective, abrasion, stain, stain and/or similar additional layers, films, coatings or the like 17 . The outer composite layer 18 is disposed in overlying relationship on a single or multi-layer optional backing structure 14, as further described hereinafter, comprising, for example, new, recycled, recyclable , natural, bio-based, biodegradable and/or other environmentally friendly or reliable materials such as recycled flooring, foam, rubber, cork and/or agglomerated particle blocks of glass particles. As will be appreciated, the term "flat" as used in reference to the textile exposure surface is intended to refer to the preferably nap-free or low-pile surface profile on the exposure surface 12, rather than to any particular shaping technique. In this regard, it should be understood that flat fabrics may include fabrics with a relatively low surface pile level, such as plush, pile, or frosted surface fabrics. The textile or fabric 12 may be eyelet, mesh, open weave, close weave, short loop, short dense loop, short pile, super short pile, needle punched, viscoeled, tufted, flocked, woven, nonwoven, knitted, Tufted, multi-level, weave, pattern and/or the like. By way of example and not limitation, a process for forming a woven or knitted plush fabric is disclosed in US Pat. No. 5,916,273, the contents of which are incorporated herein by reference. The type of fabric disclosed in US Pat. No. 5,916,273 is suitable for use in at least some embodiments of the surface coverings of the present invention. When it is desired to use a ribbed fabric, a substantially flat surface is preferred, such as plain weave, single layer woven, nonwoven, needle punched and warp knitted fabrics. Of course, these fabrics necessarily have a certain degree of irregularity in their surface due to, for example, yarn intersections, patterns, and the like. The exposed surface 12 is preferably visible through the transparent or translucent film formed by the penetrable film-forming composition 16 and any other layers 17, so that the exposed surface 12 is invisible to the product user or purchaser. are visible to those.

In at least selected embodiments, the textile revealing surface 12 is preferably a woven or knitted material, such as a natural and/or synthetic yarn, fiber, filament or material, such as polyester of multifilament segment yarn construction, more desirably is the type wherein the yarn is characterized by a linear density level of from about 50 to about 2500 denier. For example, one contemplated textile revealing surface is an office panel fabric having a jacquard structure formed from 150 denier textured polyester with a structure of about 128 ends per inch (2.54 cm) and About 42 picks per inch (2.54 cm), with a mass per unit area of about 6.1 ounces per square yard (205.88 g/m ² ) before soaking. Another contemplated textile revealing surface is an office panel fabric having a jacquard structure formed from a textured polyester of 150 denier with a structure of about 132 ends per inch (2.54 cm) and a per inch ( 2.54 cm) about 51 weft yarns, with a mass per unit area of about 5.4 ounces per square yard (182.25 g/m ² ) before soaking. Yet another contemplated textile revealing surface is an airtight fabric of knit construction formed of 1/800/1 elastic polyester and 3/150/36 textured polyester with a formation of approximately 14 wales per inch (2.54 cm) and About 20 rows per inch, with a mass per unit area of about 13.5 ounces per square yard (455.53 g/m ² ) before soaking. The textile revealing surface 12 may be integrally dyed, or have decorative colors, images, patterns or graphics woven, tufted, molded, printed or dyed thereon. For example, images, patterns, colours, graphics, etc. may be formed by using colored fibers or yarns such as yarn dyed or solution dyed, by dyeing pieces of cloth, by dyeing yarns or fibers made of white or pastel or light colored Textiles made of silk or materials are exposed on the surface by printing or spraying. Any printing, dyeing or other coloring is desirably done before soaking. Alternatively, the exposed surface of the textile is printed or dyed after soaking using one or more sublimation printing techniques.

As previously indicated, exposed surface 12 is preferably saturated, permeated, sealed, coated or covered with a preferably abrasion resistant transparent film selected from a suitable film forming composition 16 and one or more layers Optional additional layers, films, coatings or similar structures 17 are formed which define an airtight protective barrier on the textile exposed surface 12. The terms "fully saturated" or "fully saturated" as used herein in reference to the described embodiments are used to refer to the use of an amount effective to saturate, penetrate or soak the textile or fabric 12 and form a film on both sides thereof. film-forming composition. To form an effective barrier, the film-forming composition 16 is preferably applied to an extent sufficient to fully saturate to form a film on at least both sides (front and back) of the fabric, thereby forming the textile-exposing surface 12 . Full saturation and penetration is preferred because it prevents color shifts, strengthens the surface, increases durability, increases dimensional stability, and/or similar benefits. The film-forming composition 16 and any other layers 17 are preferably sufficiently transparent in the final cured state to avoid interfering with the decorative features of the exposed surface of the textile. The additional layer and film-forming composition is preferably extrudable or liquid, such as polyester, polyurethane or acrylic polymers, etc., such as are readily used to coat hardwood floors, etc., although other suitable transparent or translucent materials can also be used if desired. Protective films or film-forming compositions such as polyesters and the like. The added weight of composition or material 16 should preferably be sufficient to fully saturate and penetrate the textile-exposing surface 12, thereby surrounding and sealing the textile-exposing surface.

As previously mentioned, the backing structure 14 is preferably constructed of particulate matter, such as renewable, recyclable and/or recycled solid or foam particles, such as virgin, natural or recycled cork, foam, rubber and/or other Granules or blends or combinations thereof that are adhered together using at least one binder material, such as an elastic or hard binder, alone or with other substances , reagents, fillers, additives and/or the like together bind each particle to adjacent particles. The particles preferably have a substantially irregular chip surface geometry to provide a high surface area for binding. However, spheres, pellets, cylinders, disks, rods, ellipses, and/or other relatively smooth surface geometries may also be used, if desired. For example, compressible and/or incompressible spherical particles such as rubber or ceramic spheres may be used. In the depicted embodiment, the adhesive may also bond backing structure 14 to protective or film-forming composition 16 on the bottom side of outer composite layer 18 . It should be understood that in the backing structure there may be voids between the particles and some of these voids may be partially or completely filled with binders, fillers, additives, and the like. Leaving voids and/or using elastic adhesives can provide considerable elasticity and cushioning, if desired. A certain amount of clearance may also reduce mass, reduce cost, increase flexibility, enhance lateral grip, reduce slippage, and/or the like. Preferably, at least when a liquid adhesive is used, each backing particle is encapsulated in at least one thin layer of adhesive. This helps to bind the particles together and to bond the backing 14 to the facing composite 18 .

In case the backing structural particle is rubber, nitrile rubber or EPDM is preferred. By way of example, one conceivable source of EPDM is recycled weatherstripping. These EPDMs can be of rigid or elastic (foam) character. By way of example only, one contemplated source of nitrile rubber comes from industrial mats. The rental industrial segment is also an ideal source of rubber granulate raw material, as this ensures that low-fading, low-pigmented nitrile rubber is used as a starting point for the production of surface coverings. Rubber from recycled tires can also be used if desired. Recycled SBR rubber can also be used. Where the backing structural particles are foams, cellular polyurethane foams are preferred. Other rubber materials (solid or foamed) may also be used. Also, other recycled fillers or materials may be used, such as ground or recycled surface coverings, exposed surfaces, backings, flooring, glass, fly ash, gypsum, bone meal, used foundry sand, and blends thereof. Compounds and combinations thereof. According to at least one embodiment, the filler is preferably ground to a size of less than 50 mesh, more preferably less than 100 mesh, most preferably less than 350 mesh.

It is contemplated that the size of the backing structure particles employed, such as foam, rubber or cork particles, is preferably from about 0.01 to about 15 mm. However, larger or smaller particle sizes can also be used if desired.

In general, the largest possible size is chosen to suit the desired use and properties. It has been found that the particle size can be selected to obtain varying degrees of elasticity in the product. Larger particles generally provide higher elasticity. Granules of the desired size can be mixed with powders of the same material or a different material for better tear strength. Powder increases tear strength for a given level of binder. The use of other additives in powder or liquid form may provide the same or different advantages. Suitable additives include, but are not limited to, magnetic or magnetizable particles, antimicrobial materials, flame retardant additives, flavor enhancers, colorants or pigments such as iron oxide powder, antistatic additives such as carbon fibers, fillers, and/or other common additives.

Likewise, hard and elastic chips, granules or chips of the same material or of different materials may be combined. For example, EPDM particles can be mixed with solid filler particles and a binder.

The adhesive used to attach the particles of the backing 14 may be, for example, one of the water-curable, heat-curable, and/or thermoplastic types. Depending on the backing manufacturing process employed, the binder can be in liquid or powder form. Preferably the adhesive is selected from one of the following types: polyurethane reactive hotmelts, copolyester or copolyamide reactive thermoplastic hotmelts and 4,4-methylene di-p-phenylene isocyanate (MDI) polyurethane monogroups One-part and two-component adhesives. The binder may be on or in the particles or fillers or the like used in the backing, or as part of such particles or fillers or the like. For example, agglomerated particles of recycled carpet tile having at least one layer of hot melt in the carpet tile can form granules and binders (self-bonding particles).

It is important that the binder has good binding properties to ensure that the particles are well bonded together, and it is also desirable to provide sufficient free binder to be able to bond with, for example, the face composite layer 18, stabilizing layer 142, backing 152, etc. The outer surface forms a physical or chemical bond. The adhesive should also ideally exhibit sufficient cohesive strength to provide sufficient strength to the backing. The adhesive may contain any known crosslinkers or cure accelerators to suit the process and desired characteristics of the product being manufactured and the microparticles used.

According to a possible preferred embodiment, the particle backing or hybrid particle/foam backing is formed by adding particles, chips, fillers and/or similar substances to a polymer foam to form a composition or puddle. For example, adding particles of recycled carpet tile, flooring, and/or other surface coverings to a liquid polyurethane foam-forming base employs a foam-forming composition (which typically forms a foam cushion) as a binder or carrier for the added particles. composition, thereby forming a hybrid backing.

In the embodiment shown in FIG. 1 (and with reference to, for example, FIGS. 2 and 2B ), the binder performs the dual function of holding the particles together to form the backing 14 and bonding the backing 14 to the bottom of the outer composite layer 18. . To perform both functions, the binder level is preferably from about 2% to about 20% by weight of the granules. Using a smaller particle size can mean using a higher percentage of binder because it has a greater surface area. In particular, use of fine powders with a size of less than about 0.5 mm may require about 20% or more binder.

Generally, there is an inverse relationship between binder content and particle size, and between binder content and the pressure applied to the binder/particle mixture in forming backing structure 14 . Therefore, binder content generally decreases as particle size and pressure increase. The optimum binder level also depends on other factors, such as binder type, particulate material used and fabric type, and can be determined by routine experimentation.

For example, the binder may be a liquid polyurethane MDI binder, for example, wherein if the backing consists primarily of chips or pellets, the binder is preferably present at a level of from about 4% to about 12% by weight. The adhesive may further contain additives, desirably in liquid form and compatible with the adhesive, such as colorants, plasticizers and fragrances. The binder may also contain other additives as long as they are suitable for incorporation into the liquid medium.

Alternatively, the binder may be a thermoplastic or thermosetting hot melt powder, in which case the binder is preferably present at a level of about 3% to 10% by weight, for example if the backing consists essentially of chips or particles. The powder binder may also contain other additives as long as they are suitable for incorporation into the powder medium.

According to at least selected embodiments, the preferred range of binder content can be summarized as follows:

Chip/Particle Backing: Binder content from about 2% to about 20% by weight, preferably from about 4% to about 12% by weight, for example from about 3% to about 10% by weight with MDI binder , or, for example, from about 3% to about 10% by weight when using a hot melt adhesive.

Backing with about 10% powder: binder content from about 9% to about 20% by weight, preferably about 14% by weight or more.

In particular cases, a binder content of about 25% by weight or more may be employed, although this may result in skin formation.

The manufacturing process of the surface covering 10 of FIG. 1 having a backing structure of granular particles such as foam, cork or rubber will now be described with reference to FIG. 2 , which is a schematic view of an integrated production line. In the described process, a mixture of granules or crumbs P (such as foam, rubber or cork granules in blending relationship) and the desired binder B is conveyed from a tank for blending granules and binders to Motor-driven conveyor belt 22. To help form an even deposit of particles and binder on the conveyor belt 22 , a scraper 23 or other suitable leveling device may be placed downstream of the dispenser 20 .

The conveyor belt 22 is made of a non-stick surface such as woven fiberglass coated with polytetrafluoroethylene (PTFE) to prevent deposited material from adhering thereto. Alternatively, the conveyor belt 22 may be coated with a release layer or covered with a liner to facilitate release from the backing. For example, the backing sheet may be sandwiched between the conveyor belt 22 and the backing 14 . In use, the conveyor belt advances in the direction of the arrows shown. Depending on the nature of the product being formed, the movement can be stepped or continuous. As shown, a conveyor belt 22 is positioned opposite a motor-driven pressurized belt 24 that moves at an opposite angle relative to the conveyor belt to create a pressure between the belts near a heated (or cooled) member or platen 26. material area. The material deposited on the conveyor belt is thereby subjected to a certain degree of compression between the conveyor belt 22 and the pressure belt 24, and may be heated or cooled at the same time.

In the process shown, the fabric forming the exposed surface 12 is conveyed by a roll 30 through a coater 32 (eg, a dip roll coater, etc.), wherein the film-forming composition 16 is applied preferably in a manner that saturates the fabric of the textile exposed surface. The film-forming composition 16 is preferably, for example, a liquid polyurethane that is readily used to coat hardwood floors and the like, although polyesters, acrylic polymers, and other suitable protective coating or film-forming compositions can also be used if desired. For example and without limitation, a suitable film-forming protective composition may be polyurethane sold under the tradename STREETSHOE SUPER MATTE by Matrix Coatings, Inc. of Des Moines, Iowa. Such compositions contain 20% solids by weight and are preferably applied wet at a level of from about 2 to about 100 oz/square yard (about 67.5 to about 3375 g/m ² ) to form about 0.4 Dry gain to about 20 oz/square yard (about 13.5 to about 675 g/m ² ), thereby developing the preferred requisite wet-out and film-forming characteristics. Of course, such levels are exemplary only and depend on the nature of the fabric being impregnated or coated. By way of example only, for a jacquard structure formed from a textured polyester yarn of 150 denier, which forms a structure of about 132 warp yarns per inch (2.54 cm) and about 51 weft yarns per inch (2.54 cm), the front unit of saturation The areal mass is about 5.4 ounces per square yard (182.25 g/m ² ). It has been found desirable that a wet coating of about 8 oz/yd2 (270 g/ ^m2 ) dry to give a dry gain of about 1.0 oz/yd2 (54 g/ ^m2 ).

After exiting the coater 32, the saturated fabric then passes through a curing device 34 (eg, heater, oven, fan, etc.) to cure the applied film-forming composition 16 to form the outer composite layer 18 as previously described. The fabric with cured coating is then conveyed in overlay relation onto the granulate/binder composition on the conveyor belt for subsequent compression between conveyor belt 22 and pressure belt 24 . Of course, it will be appreciated that the coating of the surface-revealing fabric need not be performed on the same line as the hot pressing, in fact these steps could be performed on a different line, thereby facilitating process freedom. For example, a roll 30 of saturated fabric 18 may be conveyed to a production line (range) shown in FIG. 2 .

With continued reference to FIG. 2 of the drawings, a roll coater 60 (such as a reverse roll coater) or other coating device such as an extruder or film delivery system, etc., may also be used to add the adhesive or coating or film 50 to the fabric 12 Or saturate the back of the fabric 18. Also, a roll coater 19 (such as a reverse roll coater) or other coating apparatus such as an extruder or film delivery system, etc. may also be used to add one or more additional layers or films 17 to the composite layer 18 or to Material 16 is added to the top surface of fabric 12 and the like. Depending on the desired configuration, roll coaters 60 and/or 19 or roll coater 32 may or may not be used. Additionally, material 16 may be added in one or more steps, or in one or more layers. For example, coater 32 may add first coating 16 while coater 19 may add a second coat of material 16 . Similarly, roll coater 60 may add a second coat of material 16 to the bottom of fabric 12 . Thus, each of applicators 32, 60, and 19 may be used or not, and may be used to add material 16, 50, or 17, as desired. Materials 16, 50 and 17 may be the same or different materials. For example, materials 50 and 17 may be the same as material 16, or, for example, material 17 may be a polyester wear layer while material 16 is a polyurethane coating. It is contemplated that other ovens, heaters, fans, curing devices, etc. may be added downstream of the coaters 60 and 19 as necessary. If material 17 is a film, the heat from heated platen 26 is sufficient to fuse film 17 to coating 16 . In addition, a release liner or film may be interposed between the belt 24 and the material 16 or 17 if desired.

After orienting the outer composite layer 18 on top of the particulate binder composition, pressure and heat (or cooling when required) applied between the opposing belts 22, 24 causes the binder to bond or fuse the particulate binder together. , thereby forming a stable backing structure 14 with desired thickness and elasticity. In these aspects, the applied pressure is preferably from about 0.01 to about 50 psig or greater (about 0.06895 kPa to about 344.75 kPa), and the temperature is preferably from about 300°F to about 375°F (about 148.9°C to about 190.6 °C), although higher or lower temperatures may be used depending on the material structure and pressure employed. The combination of soakable film-forming composition 16 or adhesive 50 in backing structure 14 and adhesive B together bond outer composite layer 18 to backing structure 14 . The formed layered structure preferably has a structure as shown in FIG. 1 . It will be appreciated that a percentage of the outer composite layer 18 may be pressed into and below the surface of the backing structure 14 if desired. After forming, the resulting structure is conveyed to a tile cutter 31 (or a tile cutter, tile cutter, or tile cutter) if used in a modular installation (or as a rug, strip or rug), If used in longer length segments such as rolls, strips, broadlooms such as 6 foot widelooms or cut later, the resulting structure is wound on rolls.

Of course, an additional layer of adhesive 50 such as hot melt polyurethane, polyester, polyamide, etc. or primer or solvent may be interposed between the particle/adhesive composition and outer composite layer 18 if desired. This adhesive further stabilizes the structure and provides enhanced protection against delamination. If used, such adhesive layers are sequentially applied, for example, to the bottom of the outer composite layer 18 using, for example, a roll coater 60 or other coating or application techniques such as spraying, extrusion, film adhesive delivery, powder adhesive delivery, etc. It can also be applied on top of the backing structure 14 if desired by a sprayer, air knife, or other coating or application methods. The production line or lamination range of Figure 2 can also be used to manufacture other structures such as those shown in Figures 7, 12 and 14, etc.

In addition to in situ fused particles such as rubber, foam and adhesives, it is also contemplated that at least selected embodiments of the surface coverings of the present invention comprise a backing structure of so-called "rebond" foam, described in " In "recycled bonded" foam, relatively small pieces or pieces of crumb foam are formed into sheets using an elastic adhesive between foam blocks. FIG. 2A depicts a production line for adding such pre-formed recycled adhesive foam or other pre-formed backings to the layered structure as shown in FIG. 1 . In FIG. 2A , components corresponding to those described in FIG. 2 will be identified by corresponding single-quoted numerals.

The process described in FIG. 2A is essentially the same as that described in FIG. 2, except that the deposited mass of particles and binder is replaced by a preformed sheet 14' of particles and binder, such as recycled adhesive foam or other adhesive. granules or mixtures of granules or foams or elastomeric materials. In order to fix the outer composite layer 18' on the preformed sheet 14', a layer of adhesive 50' (such as polyurethane, polyester, polyamide, etc.) Overlies the bottom surface of the outer composite layer 18'. Upon entering the nip between the opposing belts 22', 24', the applied pressure and heat cause the foam block to be partially compressed. The binder between the foam particles fuses the particles together in a partially compressed state to form a stable backing structure with the desired thickness and elasticity. In this regard, greater compression will result in a lower level of cushioning elasticity. The outer composite layer 18' is simultaneously bonded to the backing structure by an intermediate layer of adhesive 50'. After forming, the resulting structure is conveyed to a brick cutter 31' if used in a standard piece installation, or wound on rollers if used in longer length segments or cut later. A surface covering such as a floor, tile or floor covering manufactured by the process of FIG. 2A may look similar to the product of FIG. 7 with or without backing sheet 452 .

Another process that can be used to form the depicted and described structures is shown in Figure 2B. In FIG. 2B, components corresponding to those described in FIG. 2 will be identified with corresponding double-quoted numbers. During this process, the granule/adhesive composition P, B is transported from the reservoir 20" located downstream of the dam body to the conveyor belt 20", and the pressing material between the scraper roller or pressure roller 37" and the conveyor belt 22" The zone forms a deposit or puddle of particle/binder composition. The pressure rollers 37" press the outer composite layer 18" with or without the layer 17" into a pellet/binder mass while controlling the thickness of the pellet/binder material. During this pressing, the components are preferably heated The bottom half of the 26" raises the layer temperature to initiate fusion bonding. The formed structure is then passed between the conveyor belt 22" and the downstream pressure belt 24" to complete the bond. After forming, the resulting structure is conveyed to a brick cutter 31' if used in a standard piece installation, or wound on rollers (not shown) if cut in longer length pieces or later. )superior.

It is contemplated to selectively add one or more friction increasing materials or layers 15 to the bottom of the backing 14 of the surface covering member 10 of FIG. 1 . These friction increasing materials are described, for example, in US Patent Application 10/209,050 (US Application Publication No. US 2004/0022991 ), which is hereby incorporated by reference. Preferably these friction increasing materials provide additional lateral grip and some vertical attachment. Likewise, the backing 14 and/or material 15 may include magnetic or magnetisable particles or materials to provide attraction to, for example, metal floors or metal raised access floors. Additionally, material 15 may be covered with a releasable, removable cover sheet, thereby providing a peel-n-stick surface covering product. It can be upstream of the granulate/binder conveying, between the belt 24 and the brick cutter 31, downstream of the brick cutter 31, when packaging the product, or when winding the formed composite layer, for example in FIG. 2 or FIG. An optional underlayer, coating or membrane 15 is applied within the scope of 2A.

At least some embodiments are also readily adaptable to structures requiring a relatively high level of internal dimensional stability. One exemplary construction of a surface covering 110 intended to have such internal dimensional stability is depicted in FIG. 3 , where components corresponding to those depicted in FIG. 1 will be identified with corresponding numbers incremented by 100 . As shown, in the embodiment of FIG. 142 (such as woven or nonwoven glass or fiberglass material), examples of said particle and binder layer are recycled surface coverings, cork, as previously described, bound together with one or more binders , foam, rubber, blends thereof, combinations thereof or similar particles. Additionally, an additional layer of adhesive 150 , such as hot melt polyurethane, polyester, polyamide, etc., may be positioned between outer composite layer 118 and the upper surface of backing structure 114 . An optional backing sheet, textile or material 152 such as a woven or nonwoven structure may be located on the bottom surface with or without an intermediate adhesive layer and lower friction increasing material layer 115 if desired. Backing materials such as nonwoven felts not only serve as a release layer but also provide moisture wicking, evaporation or vapor transport properties to the product. Felt 152 tends to wick water or moisture from the bottom of the flooring product to the seams. Likewise, the felt 152 can also transport steam from the bottom of the floor to the seams.

Reference is now made to FIG. 4 to describe the manufacturing process of the surface covering 110 of FIG. 3 having a face 118 and granular particles comprising, for example, recycled surface covering, foam, cork, glass, fly ash, and/or rubber. The backing structure 114 of FIG. 4 is a schematic diagram of a complete production line (similar to FIG. 2 ). In the process, a backing sheet 152 , such as a woven or nonwoven textile material, is conveyed in covering relation onto the conveyor belt 122 . By way of example only, the backing sheet preferably comprises a nonwoven felt material having polyester and/or polypropylene fibers in any desired proportion from 100% polyester to 100% polypropylene. The friction increasing material 115 may be added to the backing 152 after the product is formed, before the product is formed, or the like. At a downstream location, a first mixture of particles P blended with the desired binder B is delivered from a first reservoir 120 where the particles and binder are blended and deposited onto the backing 152 . Downstream of the first reservoir 120, a doctor blade 123 or other suitable leveling device is provided to aid in the formation of a uniform deposit of particles and binder on the backing 152. A layer 142 of stabilizing material such as woven or nonwoven glass is then applied adjacent to the first particle and binder layer. Once the stabilizing layer 142 is in place, a second mixture of particles P blended with the desired binder B is delivered onto the stabilizing layer 142 from the second reservoir 121 where the particles and binder are blended and deposited. Downstream of the second reservoir 121, a scraper 125 or other suitable leveling device is provided to aid in the formation of a uniform deposit of particles and binder. The deposit heads of the dispensers 120, 121 of FIG. 4 and the dispenser 20 of FIG. 2 may, for example, be moved back and forth on the conveyor belts 122 and 22, respectively, thereby coating the particle and binder mixture on the conveyor belts.

Like the drive belt 22, the conveyor belt 122 is made of a non-stick surface such as woven glass fabric coated with polytetrafluoroethylene (PTFE) to prevent deposited material from adhering thereto. In operation, the belt advances in the direction of the arrows shown. Depending on the nature of the product being formed, the movement can be stepped or continuous. As shown, a conveyor belt 122 is positioned opposite a motor-driven pressurized belt 124 that runs at an opposite angle relative to the conveyor belt, thereby forming a nip between the belts near a heating (or cooling) element 126 . The material deposited on the conveyor belt is thereby subjected to a degree of compression between the conveyor belt 122 and the pressure belt 124, while being heated or cooled.

In the process shown, the fabric forming the exposed surface 112 is conveyed by a roll 130 through a first coater 132 (e.g., a dip roll coater, etc.), wherein the film-forming composition 116 is applied to the textile exposed surface fabric in a saturated relationship. . The film-forming composition is preferably a liquid polyurethane such as is readily available for coating hardwood floors and the like, although acrylics, polyesters, polyamides and other suitable protective film-forming compositions may likewise be used if desired. After exiting the coater 132, the saturated fabric preferably then passes through a curing device 134 (e.g., heater, oven, fan, etc.) to cure the applied film-forming composition 116 to form the outer composite as previously described. Layer 118. The outer composite layer 118 is then conveyed to a second coater 160 (eg, a reverse roll coater, etc.) to apply the adhesive layer 150 to the bottom surface. The surface composite layer 118 is then passed through a coater 119, such as a reverse roll coater, to apply, for example, additional wear layers, anti-fouling layers, anti-stain layers, other composite layers 116, and the like. The fabric with cured coating 116 and applied adhesive 150 and optional layer 117 is then applied in covering relation over the upper layer of particle/adhesive composition for subsequent compression and heating and / or cooling. Of course, it will be appreciated that the coating of the surface-revealing fabric need not be performed on the same line as the hot pressing, and in fact these steps could be performed on a different line, thereby facilitating process freedom. For example, a roll 30 of saturated fabric 18 may be conveyed to a production line (area) shown in FIG. 2 . Thus, outer composite layer 118 may be provided in roll form with or without layers 150, 117, and/or the like. It is contemplated that one or more coaters 132, 160, and 119 may or may not be used in a particular configuration, and that each may coat different materials.

After the outer composite layer 118 is oriented on top of the particulate binder composition, pressure and heat (and/or cooling) applied between the opposing belts 122, 124 fuse the binder and particulate together, adhering to the stabilizing layer 142 stabilizing backing structure 14 on both sides. In this regard, the pressure applied is preferably from about 0.01 to about 50 psig, preferably from about 0.1 to about 20 psig, and the temperature is preferably from about 300°F to about 375°F. The outer composite layers 118 , 117 are simultaneously bonded to the backing structure 114 by an adhesive in combination with an optionally applied adhesive 150 . After forming, the resulting structure is conveyed to the brick cutter 131 if used in a modular installation, or wound on rollers (not shown) if used in longer length pieces or cut later. )superior.

In addition to fused particles of recycled, recyclable, renewable, natural, bio-based, biodegradable or other materials such as recycled surface coverings, cork, rubber and/or foam, at least The surface coverings of selected embodiments of the invention comprise a backing structure formed of, for example, so-called "regenerated bonded" foam, wherein relatively small pieces or pieces of crumb foam are held in place by an elastic adhesive between foam pieces. for the sheet. FIG. 4A depicts a production line for adding preformed recycled adhesive foam such as this or other granules or other preformed material into the layered structure shown in FIGS. 3 , 2A and 11 . In FIG. 4A, components corresponding to those described in FIG. 4 will be identified by corresponding single-quoted numerals.

The process depicted in Figure 4A is essentially the same as that described with respect to Figure 4, except that the deposited layer of particles and binder is replaced by a preformed sheet 140' of particles and binder, such as recycled adhesive foam. In the process, a layer of adhesive, such as polyurethane adhesive, hot melt adhesive, etc., is applied between the preformed recycled adhesive foam sheet 140' and the adjacent layer by applicators 161' and 160' to promote adhesion. Upon entering the nip between opposing belts, the applied pressure and heat (and/or cooling) cause the foam block to be partially compressed. The binder between the foam particles fuses the particles together in a partially compressed state to form a stable backing structure with the desired thickness and elasticity. In this regard, greater compression will result in a lower level of cushioning elasticity. Simultaneously, the outer composite layer 118" is bonded to the backing structure by the adhesive of the recycled bonding sheet and the applied adhesive 150'. After formation, the resulting structure is transported to Brick cutter 31', or if used in longer length segments or cut later, the resulting structure is wound on rollers (not shown). An optional lower layer (e.g., formed of a friction-increasing material layer) can be added upstream of the backing 152', after the belt 124', after the brick cutter 131', or at the time of packaging or winding of the product 110.

Of course, it is understood that any number or other embodiments of surface coverings may be employed depending on the intended use and performance requirements. By way of example only, a contemplated alternative structure is depicted in FIG. 5 , where parts corresponding to those previously described are labeled with like numerals within the 200 series. It will be appreciated that the surface covering 210 in FIG. 5 has substantially the same structure as the surface covering 10 of FIG. Composed backing sheet 252. In this construction, the backing sheet 252 is preferably held in place by an adhesive in the backing layer 214 that holds the particles together. However, other adhesive layers may be used if desired. It is contemplated that if the backing structure 214 is an in-situ formed particle and adhesive backing (e.g., ground material such as crumb foam, rubber, or cork), then the and the described process to form such a structure, if the backing structure is a preformed sheet (e.g., a preformed sheet of particles and binder, such as recycled adhesive foam, etc.), it can be obtained by the process described in Figure 2A or Figure 4A process to form this structure. In such a practice, one of the rolls feeding the stabilizing material and the reservoir in Figure 4 or Figure 4A (or one of the rolls feeding the recycled adhesive sheet material) is not operating.

Another contemplated surface covering structure 310 is depicted in FIG. 6 , where parts corresponding to those previously described are labeled with like numerals within the 300 series. In this construction, a stabilizing layer 342, such as woven or non-woven glass, is adhesively attached beneath the saturated exposed surface material 318 by an adhesive layer 350, such as hot melt polyurethane. It is conceivable that such a structure could be formed by the process depicted and described in Figure 4 if using ground materials such as crumb foam, rubber or cork, or by The process described in Figure 4A forms such a structure. In such a practice, the second accumulator (or the roll downstream feeding the recycled adhesive sheet) is not running at all. The resulting structure provides considerable internal dimensional stability and is particularly suitable for applications such as carpet tiles, floor tiles, stabilizing membranes and the like.

Yet another contemplated surface covering structure 410 is depicted in FIG. 7 , where components corresponding to those previously described are labeled with like numerals within the 400 series. In this construction, a particle/adhesive layer 440 of ground particles or a preformed sheet structure such as a recycled bonded foam sheet structure is adhesively joined to a saturated exposed surface material 418 by an adhesive layer 450 such as hot melt polyurethane. below. It is contemplated that such structures may be formed by the processes depicted or described in Figures 2, 4 or 4A. For example, such a structure can be formed by the process in Figure 4 if using an in-situ milled backing material such as crumb foam or cork, or by the process in Figure 4A if using a pre-formed, e.g. recycled bonded foam sheet. the process described. In such a practice, the roll supplying the recycled adhesive sheet and the second accumulator (or the roll downstream supplying the recycled adhesive sheet) are not running at all.

Yet another contemplated surface covering structure 510 is depicted in FIG. 8 , where components corresponding to those previously described are labeled with like numerals within the 500 series. It will be appreciated that this structure is a modification of that of FIG. 7 in that adhesive layer 550 is removed and adhesive layer 554 is placed between backing structure 514 and fibrous backing sheet 552 . It is contemplated that such structures may be formed by the processes depicted or described in Figures 2, 4 or 4A. For example, such a structure can be formed by slightly modifying the process depicted and described in Figure 4 if using an in situ milled backing material such as detritus foam or cork, or if using a preform such as recycled bonded foam sheet, such a structure can be formed by the process described in Figure 4A. In such a practice, the adhesive applicator is positioned upstream of the first reservoir (or first roll supplying recycled adhesive sheet material) to apply the adhesive on top of the fibrous backing layer 552 prior to bonding with the upper layer layer. The adhesive applicator handling the outer composite layer, the roll feeding the stabilizing material, and the second accumulator (or the downstream roll feeding the recycled adhesive sheet) were not running at all. Alternatively, the dispenser 120 in FIG. 4 could be replaced with a roll coater for applying the adhesive 554 to the backing 552 . Adhesive layer 554 helps bond backing 514 to, for example, polyester or polypropylene nonwoven or felt backing 552 . Optional additional layers 517 may be added.

Yet another contemplated surface covering structure 610 is depicted in FIG. 9 , where components corresponding to those previously described are labeled with like numerals within the 600 series. It will be appreciated that this structure is a modification of the structure in Figure 7 or Figure 8, wherein the adhesive layer 650 is disposed between the surface layer 618 and the backing 640, and the adhesive layer 654 is disposed between the backing layer 640 and the fibrous backing sheet 652 between. It is contemplated that such structures may be formed by the processes depicted or described in Figures 2, 4 or 4A. For example, if using an in situ milled backing material such as crumb foam or cork, such a structure can be formed by slightly modifying the process depicted and described in Figure 4, if using preformed sheets of e.g. recycled bonded foam , then such a structure can be formed through the process described in FIG. 4A. In such a practice, the adhesive applicator is positioned upstream of the first reservoir (or first roll feeding the recycled adhesive sheet) to coat the top of the fibrous backing layer 652 prior to bonding with the upper layer. Adhesive layer. The roll feeding the stabilizing material and the second accumulator (or the downstream roll feeding the recycled adhesive sheet) were not running at all. Alternatively, the dispenser 120 in FIG. 4 could be replaced with a roll coater for applying the adhesive 654 to the backing 652 . The structure 610 of FIG. 9 is particularly suitable for use as a backing layer 640 of a preformed sheet, such as particles and binder.

Yet another contemplated surface covering structure 710 is depicted in FIG. 10 , where components corresponding to those previously described are labeled with like numerals within the 700 series. It will be appreciated that this structure is a modification of the structure of Figure 6, wherein the scrim layer 757 [such as polyester, polypropylene, glass, etc. 742 adjoining. It is conceivable that such a structure could be formed by the process depicted and described in Figure 4 if using an in situ ground backing material such as crumb foam or cork, and an adhesive, or if using, for example, recycled A preformed sheet of bonded foam can then be used to form such a structure by the process described in Figure 4A. In such a practice, the scrim feed roll is located upstream of the roll that feeds the stabilizing material, and the second accumulator (or downstream roll that feeds the recycled bonded sheet material) is not operating. The resulting structure provides considerable internal dimensional stability and is particularly suitable for use in items such as carpet tiles, floor tiles, modular products, and the like. For example, the scrim 757 can counteract any shrinkage in the surface material 712, thereby providing a flat or slightly domed product. The additional stabilizing layer 757 can help to remove or remove the textile backing 752, use a lighter face fabric 712, use less composition 716 or 717, provide a more durable printable product, and the like.

Yet another contemplated surface covering structure 810 is depicted in FIG. 11 , wherein components corresponding to those previously described are labeled with like numerals within the 800 series. It will be appreciated that this structure is a modification of the structure of Figure 3 in that there are no additional layers between the outer composite layer 818 and the bottom layer. It is conceivable that such a structure could be formed by the process depicted and described in Figure 4 if using an in situ milled backing material such as crumb foam or cork and adhesive, or if using e.g. recycled adhesive foam Such a structure can be formed by the process described in Figure 4A. In such a practice, the adhesive applicator handling the outer composite layer is preferably not running at all. The use of other adhesives in the backing 814 may facilitate removal of other adhesive layers.

It will be appreciated that, if desired, in any of the described embodiments, one or more additional adhesive layers, such as hot melt polyurethane, polyester, polyamide and/or the like, may be interposed between any of the layers. substance.

Thus, by way of example, it may be between a backing sheet and an adjacent backing layer and/or between an underlying backing layer and a stabilizing layer (if employed) and/or between a stabilizing layer (if employed) and an overlying A layer of adhesive is added between the backing layers (if present). Likewise, it is contemplated that in any of the depicted and/or described embodiments, structures may be formed with or without a fibrous backing sheet. Also, more adhesive can be applied to the surface of any preformed product sheet, such as a recycled adhesive foam preform. Furthermore, one or more additional top layers (17) or one or more bottom layers (15) may or may not be added to the particular structure.

A contemplated benefit of at least some embodiments or structures is the ability to incorporate large percentages of recycled, renewable, recyclable, natural, bio-based, biodegradable or other environmentally friendly or reliable materials such as , waste such as recycled weatherstripping, recycled rugs, recycled tires, used carpets, used flooring, recycled surface coverings, processing waste, final pre-consumer recycling, final post-consumer recycling, and/or the like. Likewise, renewable resources such as cork or wood can be used alone or with recycled materials. By way of example only, recycled fill materials such as surface coverings, face materials, backing materials, carpet and/or the like may be ground (or densified, crushed, shredded, pulverized, high shear mixed, cryogenically ground crushed, ground, and/or similarly processed), then blended with rubber particles (and/or cork particles) and binder before being deposited in the desired layer relationship. In such a process, the ground material does not melt, but instead forms an elastic matrix component, which forms the backing. Thus, since the individual rubber particles (and/or cork particles) are not fused, relatively high levels of waste carpet, old flooring, etc. can be added without negatively affecting elasticity.

Another contemplated benefit of at least some embodiments or structures is that the lay fabric employed in the outer composite layer constitutes a relatively small percentage of the weight of the final structure. This weight percentage is generally less than about 25%, preferably about 10% or less. Thus, the surface covering product of the present invention can itself be ground up and recycled as new backing material multiple times without contamination by unsuitable fiber components. In a specific example, the particle binder mixture is comprised of one third cork particles, one third rubber particles, and one third recycled surface covering particles. The one-third ratio may be based on weight or volume. Binders such as MDI or MDE bind three different types of particles together.

As previously indicated, one envisaged use of the present structure is in the form of surface covering tiles or mats, such as floor tiles, floor mats and the like. An exemplary floor tile product 900 is depicted in FIGS. 12 and 13 having a decorative exposed surface 975 bounded by an outer composite layer comprising a decorative textile layer as previously described and covering a particle backing 914 . Of course, it will be appreciated that only a single layer of particulate backing 914 is shown for simplicity, and that any of the described backing constructions could likewise be used, if desired. The tile 900 may also include an optional cover layer 977 , a textural decoration 979 such as embossing, and a friction increasing layer 980 . Also, while square tiles are described, it is contemplated that other geometries such as interlocking wedges, corrugations, etc. could be used.

It is also envisioned that the material forming the backing structure may itself be used to provide a portion of the aesthetically pleasing exposed surface. By way of illustration, in Figures 14 and 15, a surface covering tile or mat structure 1000 is depicted having a decorative exposed surface 1075 bounded by an outer composite layer comprising a decorative textile layer as previously described and The particle backing 1014 is covered. As shown, a portion of the particle backing 1014 extends beyond the outer composite layer, thereby defining a decorative border. Such a structure can be used to assist the tiles to form an apparently seamless pavement when placed on a surface, since all edges have a matched and consistent appearance.

Likewise, the tile 1000 may also include optional cover layers 1077 , textured decorations 1079 such as embossing, and friction-enhancing layers 1080 .

The material forming the backing structure can also be used to provide a portion of the aesthetically pleasing revealing surface by using a relatively open woven or knitted structure, including a net or mesh scrim, so that the backing is visible through the revealing surface fabric. These open fabrics can be used alone or with outward facing borders, and the bottom surface of any of the structures, structures or products described herein can also have textured decorations such as embossing to increase surface friction and the like.

According to at least one possible embodiment, the structure formed by the textile surface and at least one backing of the agglomerated adjoining particle layer is cured, cut into adobes, coloured, printed or dyed, and the surface is then coated with a film or film-forming composition, and cure to form a clear transparent or at least translucent film. The textile surface, backing and/or film may be textured, embossed, etc. before, during or after colouring, printing or dyeing.

Printing or dyeing bricks or modular blanks to match is simpler and easier, as opposed to printing or dyeing them in broad format and then cutting them. Backed floor tiles with a light or white textile surface suitable for staining, printing, dyeing, etc. (textile surface, particle/adhesive backing, with or without additional stabilizing layer, adhesive layer, textile backing linings, friction-enhancing backings, and/or similar layers) may be used for coloring, dyeing, printing, texturing, treating, embossing, thereby forming thereon with relative precision (e.g. placing a square adobe on a jig) such as images, patterns or graphics, thereby making for example floors with images, graphics or patterns which, in the installation of floor tiles, will match adjacent images, graphics or patterns of adjacent floor tiles. In this way, a large image, graphic or pattern can be divided into multiple parts, each part on a separate tile. Alternatively, a brick pattern intended to match at least some elements of an adjacent brick pattern may be realized in an exact fit, thereby providing a very pleasing seamless appearance to the overall installation.

Similarly, a brick or module having a textile exposed surface impregnated with a protective coating and a particle/binder backing can be cured and then processed by, for example, a sublimation process (e.g., dye-sublimation printing, ink-sublimation printing, ink-jet printing). Sublimation printing, etc.) pigmented, printed, dyed and/or similarly processed in which dyes, inks, images, patterns, figures etc. are printed on the surface of the textile through a protective film so that through the transparent or translucent protective film e.g. images are visible , color, pattern or graphics, etc. Typically performed on polyester, polymer or coated polymer surfaces.

For example, at high temperatures, solid dyes in sublimation printing can be converted to gas without becoming liquid. The high temperature also opens up the pores in the polymer film or fabric and allows gas to enter. When the item is removed from heat, the temperature drops, the polymer pores close and the others revert to a solid state and become part of the polymer film or fabric. When done correctly, it will not wash off or fade unless the solid fibers or coating are damaged.

Most inkjet sublimation is done on a white material (substrate). The reason for this is that the ink is actually transparent when sublimated, requiring a white background to show it through. White is an ideal background because it does not clash with colour. In fact, the white background enhances the colors.

According to at least selected embodiments, a white textile, a white coated textile or a white coating or film is used as a white substrate or background beneath a clear or transparent polymer coating or film such as a polyester coating, the clear or Transparent polymer coatings or films are used for sublimation printing of images, patterns or graphics on surface coverings.

Likewise, one or more other clear coats, films or wear layers may be added over the polyester or other polymeric coating or film.

According to at least selected embodiments, a layer composed of a single polymer or polymer type may form a surface covering to facilitate recycling. For example, the surface covering may be formed entirely of polyolefin or entirely of polyamide components.

According to at least one embodiment, the surface and/or backing of the surface covering meets or exceeds, for example, flammability, smoke emission, toxicity, soil protection, antimicrobial, odor, VOC, smoke density, pill test, Lightfastness, Blooming, Static, Dimensional Stability, Aachen Test, Dye Fastness, Durability, Office Chair Caster Test, Surface Weight, Height, Flex, Size, Warp, Curl, Bend, Deviation, Skew , height change, three-dimensional structure change, stain resistance, stain resistance, stain resistance, cleanability, commercial rating, user rating, cushioning, elasticity, drape, sewability, appearance retention, compression, compression set, recycled content, Industry standards for recyclable content, renewable material content, etc., and other industry standards, environmental standards, test ratings, and/or similar standards. For example, floor covering industry standards and/or specifications, more specifically commercial flooring standards, residential flooring standards, industrial flooring standards (e.g. hospital, educational and/or government standards), restaurant flooring standards, retail flooring standards and/or similar standard.

According to at least one embodiment, it is preferred that the particles and/or debris in the particle/binder backing structure or layer be about 6 mm or smaller (powder or granules).

The particle/adhesive backing of at least one embodiment cures at a pressure of about 100 psi (pounds per square inch) or less, preferably 50 psi or less, more preferably 25 psi or less, most preferably 10 psi or less. A low pressure cured particle/adhesive backing having interstices between the chips (particles) and containing chips primarily in the range of about 2 mm to about 6 mm in size provides lateral grip on smooth, even carpet surfaces. Lateral grip keeps surface coverings like floors from shifting or shifting. Floor tiles with lateral grip tend to stay in place even after installations without full adhesive, releasable adhesives, double-sided tape, or even after free-standing or adhesive-free installations .

The pellets/adhesive-backed pellets or scrap of at least some embodiments can be selected from recycled, recyclable, renewable, waste, by-product, refurbished, and/or virgin materials.

It is preferred to use recycled, recyclable and/or renewable materials where possible. For example, recycled surface coverings, recycled flooring, recycled foam, recycled rubber, recycled cork, cork, wood, and combinations thereof are preferred. Recycled flooring such as recycled carpet, recycled carpet tile, recycled carpet waste, recycled carpet, recycled trim waste, recycled carpet manufacturing waste, etc. can be processed to produce particles or chips smaller than about 20 mm, preferably Less than about 15 mm, more preferably less than about 10 mm, most preferably less than about 6 mm (powder or granulate). While post-consumer recyclate may be preferred, post-industrial recyclate, renewable, recyclable, natural, bio-based, degradable bio-based, and other environmentally friendly or reliable materials may also be used.

According to at least one selected embodiment, the present invention may relate to surface coverings, such as floor coverings, wall coverings, furniture coverings, etc., having a textile or fabric exposed surface, a decorative layer or face and an optional backing. The textile exposed surface, layer or face is selectively impregnated, covered and/or coated, or includes a protective coating composition or an abrasive surface, such as a transparent resin or polymeric material. In at least one exemplary embodiment, the textile exposed surface is in overlying relationship with a backing that consists of or includes agglomerated contiguous particle components. In at least another exemplary embodiment, the textile exposed surface is in covering relationship with a backing that is comprised of or includes a foam cushion. In another exemplary embodiment, the textile exposed surface is in covering relationship with a backing that is a blend or combination of particles and foam. Specifically, but not exclusively, at least some embodiments of the present invention relate to surface coverings, such as floor coverings, including but not limited to carpets, carpet tiles, floors, floor tiles, rugs, carpet tiles, strips Carpets, rugs, floor mats, stable broadloom, floor tiles, rolls and more. Surface coverings may include tufted, viscoeled, knitted, woven, nonwoven, needle punched, flocked, etc. textile or fabric exposed surfaces, surface materials, decorative textile layers, and the like. The textile layer can be impregnated, covered and/or coated with a film or film-forming composition that is desirably transparent or translucent when cured. Alternatively or additionally, the veil or fibers may include one or more coatings or layers, such as transparent, translucent and/or colored coatings or layers. For example, the face yarn may comprise a core yarn or core fiber or filament or core material coated with one or more coatings, sheaths, sheaths, layers, wear layers, films, and the like. It is also desirable that the film or film-forming composition or one or more coatings or layers be abrasion resistant, stain resistant, stain resistant, aesthetically pleasing, fusible, and/or the like. In one embodiment, the textile surface may be disposed in overlying relationship on an elastic and/or flexible backing composed of agglomerated clumps of particles, examples of which are irregular particles such as new, recycled, recyclable renewable, natural, bio-based, biodegradable and/or other environmentally friendly or reliable materials such as recycled flooring, foam, rubber and/or cork. The textile surface and the particulate backing are usually bonded together in contiguous relationship. Optional adhesive layers, adhesive films, stabilizing layers, textile backings and/or the like may be disposed on, in or below the particulate backing. Materials or coatings that increase friction, adhesion, or aid in fit may be added to the particle backing and/or to the underside of the particle backing. For example, the particle backing can include voids to increase lateral grip, reduce slippage, and the like. Alternatively or additionally, a textile or fabric backing with a friction increasing coating may be affixed under the particle backing, under the foam backing or under a particle and foam hybrid or combination backing. Methods of manufacture and recycling of these surface coverings are also provided.

According to at least one embodiment, the present invention may relate to surface coverings, such as floor coverings, wall coverings, furniture coverings, etc., having a coated yarn textile exposed surface or face and an optional backing. The coated yarn textile exposed surface or face is selectively impregnated, covered, coated, or includes a protective coating composition or abrasive surface, such as at least one transparent resin or polymeric material. In at least one exemplary embodiment, the coated yarn textile exposed surface is in overlying relationship with a backing that consists of or includes agglomerated contiguous particle components. In at least another exemplary embodiment, the coated yarn textile exposed surface is in covering relationship with a backing that is comprised of or includes a foam cushion. In another exemplary embodiment, the textile exposed surface is in covering relationship with a backing that is a blend or combination of particles and foam. The textile surface and the particulate backing are usually bonded together in contiguous relationship. Optional adhesive films or layers, stabilizing layers, textile backings and/or the like may be disposed on, in or below the particulate backing. Materials or coatings that increase friction, adhesion, or aid in fit may be added to the backing and/or to the underside of the backing. For example, the particle backing can include voids to increase lateral grip, reduce slippage, and the like. Alternatively or additionally, a felt backing with a friction increasing coating, material, pattern, etc. may be added under the particle backing or under the foam backing. The coated veil may be a coated natural and/or synthetic fiber or filament or material yarn, such as monofilament or multifiber (spun yarn or Filament) extruded yarn coated with a clear colorless polymer wear layer or film such as high density polypropylene on said clear colorless, white or colored polyolefin or PVC polymeric material. Methods of manufacture and recycling of these surface coverings are also provided.

Referring to Figures 16 to 20 of the drawings, and according to at least some selected embodiments, the veil, fiber, filament, material, etc. is shown as a coated yarn in any configuration or variation thereof such as Figures 1 to 15 or Figures 22 to 28 Thread, fiber, silk, material, etc. Referring again to FIG. 16 , an exemplary coated yarn 1100 includes a core yarn 1102 , a first coating 1104 and a second coating 1106 . For example, core yarn 1102 is coated with a first polymer or resin 1104 (such as colored PVC or polyolefin) and then coated with a second polymer or resin 1106 (such as clear polyester, polyolefin, acrylic, or polyurethane). natural and/or synthetic yarns (such as white polyester or polypropylene).

Referring again to FIGS. 17A and 17B , another exemplary coated yarn 1200 includes a core yarn 1202 and a coating 1204 . For example, the core yarn is a natural and/or synthetic yarn (eg, colored polyester or polyolefin) coated with a polymer or resin 1204 (eg, colored polyester, polyolefin, acrylic, or polyurethane). It is preferred that the colored yarn is a brightly colored yarn, such as a flat polyester yarn, because the coating will tarnish the yarn.

Referring again to FIG. 18 , an exemplary coated yarn, fiber, filament, or material 1300 includes a core yarn, core fiber, core filament, or core material 1302 and a coating 1304 . For example, the core 1302 is a natural and/or synthetic yarn, fiber, filament or material (e.g., clear, white or colored polyester) coated with a polymer or resin 1304 (e.g., clear polyester, polyolefin, acrylic, polyurethane, etc.) , polypropylene or optical fibers, filaments or materials).

Referring again to FIG. 19 , an exemplary coated yarn, fiber or filament 1400 includes a core yarn, core fiber or filament 1402 and a coating 1404 . For example, the core yarn, core fiber, or core filament 1402 is a natural and/or synthetic yarn, fiber, coated with a polymer or resin 1404, such as white, colored, or clear polyester, polyolefin, acrylic, PVC, or polyurethane. or filaments (eg white or colored tri-lobal fibers or filaments of polyamide, polyester or polyolefin).

Referring again to FIG. 20, an exemplary coated yarn 1500 similar to coated yarn 1100 of FIG. The third coating 1510 on. For example, core yarns 1502, 1508 are each coated with a polymer or resin 1504, 1510 (such as colored PVC or polyolefin) and then coated with a second polymer or resin 1506 (such as clear polyester, polyolefin, acrylic, or polyurethane). Coated natural and/or synthetic yarns (eg white polyester or polyolefin).

Thus, a coated face yarn, fiber, filament, material, etc. may have one or more single or multiple core yarns, core fibers, core filaments or core materials and one or more layers of coating, etc. For example, the core size is about 150 to 5,000 denier, preferably about 500 to 2500 denier, and the single coated yarn size is about 1,000 to 10,000 denier or greater, preferably about 2,000 to 8,000 denier denier, and the double-coated yarn size is about 2,000 to 20,000 denier or greater, preferably about 3,000 to 18,000 denier.

Referring to Figures 21A to 21D of the accompanying drawings, at least selected embodiments of veils, face fibers, face threads, etc. may have different cross-sectional shapes (transverse shapes), for example, split fibers (split fibers) 1600 (semicircular, Fig. 21A), slit film fibers or ribbons 1700 (rectangular, Fig. 21B), oval 1800 (Fig. 21C), or circular 1900 (Fig. 21D). Even though selected shapes are shown, other known shapes of yarns, fibers, filaments, or materials are contemplated. Likewise, yarns may be deformed, twisted, swollen, etc. Additionally, the fibers may be staple or filaments, continuous filaments, monofilaments, and the like.

Referring to Figure 22 of the drawings, in which parts corresponding to those previously described are designated by like numerals within the series 2000, a woven surface covering structure or product 2010 includes a woven surface material 2018 which includes adhesive or pre-coated Yarn 2012 adhered to layer 2050 of recycled adhesive foam layer 2014. Additionally, backing material 2052 is adhered or bonded to the bottom of foam layer 2014 by, for example, flame lamination or in-situ molding. Recycled bonded foam backing structures are described in the following references: e.g., U.S. Patent Application Nos. 09/721,871 and 09/993,158 (U.S. Application Publication No. US 2002/0132085) and 10/209,050 (U.S. Application Publication No. US 2004/0022991) and British Patent GB 2369294 to Higgins et al., the above reference is hereby incorporated by reference as if fully set forth herein. Optional additional upper or lower layers 2017 and 2015 may be added.

Referring to FIG. 23 , where parts corresponding to those previously described are numbered like numbers within the sequence 2100, for another potentially preferred embodiment, a surface covering 2110 comprises a woven or knitted textile or fabric surface 2118 , the textile or fabric surface has yarns or fibers 2112 held in place by a precoat or adhesive 2150, said yarns or fibers 2112 are bonded to an adhesive or primer layer 2160, which in turn, 2160 is bonded to a stabilizing layer 2142 Together, the stabilization layer 2142 is bonded to the foam layer 2114, and the foam layer 2114 is bonded to the backing 2152. Precoat 2150 may be, for example, latex or a hot melt or polyurethane-based adhesive. Primer layer 2160 may be a hot melt adhesive. The pre-coat and primer layer can be integrated. Layer 2142 is preferably a nonwoven glass mat, layer 2114 is preferably polyurethane foam, and layer 2152 may be a nonwoven polyester and/or polypropylene mat. Optional upper or lower layers 2117 and 2115 may be added.

These new or filled foam backing structures are described, for example, in US Patent Nos. 5,545,276; 5,948,500; 6,203,881 and 6,468,623, each of which is incorporated herein by reference.

Referring to FIG. 24 , where parts corresponding to those previously described are numbered like numbers within the sequence 2200, a surface covering 2210 includes a tufted textile or fabric surface 2218 having yarns tufted through a primary backing 2262. The threads or fibers 2212 are secured with a precoat or adhesive 2150 which is bonded to an adhesive or primer layer 2260 which in turn is bonded 2260 to a stabilizing layer 2142 which is bonded to a foam layer 2214 , the foam layer 2214 is bonded to the backing 2152 . Precoat 2150 may be, for example, latex or a hot melt or polyurethane-based adhesive. Primer layer 2160 may be a hot melt adhesive. The pre-coat and primer layer can be integrated. Layer 2142 is preferably a nonwoven glass mat, layer 2214 is preferably polyurethane foam, and layer 2152 may be a nonwoven polyester and/or polypropylene mat. Optional upper or lower layers 2217 and 2215 may be added, or alternatively or additionally, yarn 2212 may be coated with layer 2217 prior to tufting. While a single layer loop pile is shown, multiple layers, fancy, cut pile, loop and/or cut pile loop piles are also contemplated.

Referring again to Figures 22 to 24, the surface of each structure or composite may be coated with one or more protective layers. In a preferred embodiment, the face yarn is a fully polyolefin-coated yarn (polyolefin core yarn, polyolefin coating) that is woven and then thermally bonded (or fused), and a clear coating such as high-density polyolefin or polyolefin A clear wear layer of ester or acrylic can be added to the coated yarn. An exemplary clear coat material is Surlyn polymer from DuPont. It is preferred to manufacture the coated yarn by extrusion coating.

Referring to FIG. 25 , wherein parts corresponding to those previously described are designated by like numerals within the sequence 2300, as another possibly preferred embodiment, a surface covering 2310 comprises a cut pile textile or fabric surface 2318, the A cut pile textile or fabric surface 2318 has yarns or fibers 2312 in tufts passed through a primary backing 2362 and secured with a pre-coat or adhesive 2350 bonded to an adhesive or primer layer 2360, in turn , 2360 is bonded to stabilization layer 2342 , stabilization layer 2342 is bonded to foam layer 2314 , and foam layer 2314 is bonded to backing 2352 . Precoat 2350 may be, for example, latex or a hot melt or polyurethane-based adhesive. Primer layer 2360 may be a hot melt adhesive. The pre-coat and primer layer can be integrated. Layer 2342 is preferably a nonwoven glass mat, layer 2314 is preferably polyurethane foam, and layer 2352 may be a nonwoven polyester and/or polypropylene mat. Optional upper or lower layers 2317 and 2315 may be added.

Referring to FIG. 26 , wherein parts corresponding to those previously described are designated by like numerals within the sequence 2400, as another possibly preferred embodiment, a surface covering 2410 comprises a tufted textile or fabric surface 2418, the The tufted textile or fabric surface 2418 has yarns or fibers 2412 in tufts passed through a primary backing 2462 and secured with a pre-coat or adhesive 2450 bonded to an adhesive or primer layer 2460, in turn , 2460 is bonded to stabilization layer 2442 , stabilization layer 2442 is bonded to foam layer 2414 , and foam layer 2414 is bonded to backing 2452 . Precoat 2450 may be, for example, latex or a hot melt or polyurethane-based adhesive. Primer layer 2460 may be a hot melt adhesive. The pre-coat and primer layer can be integrated. Layer 2442 is preferably a nonwoven glass mat, layer 2414 is preferably polyurethane foam, and layer 2452 may be a nonwoven polyester and/or polypropylene mat. Optional upper or lower layers 2417 and 2415 may be added.

Referring to FIG. 27 , in which parts corresponding to those previously described are designated by like numerals within the sequence 2500, a nonwoven surface covering structure or product 2510 includes a nonwoven surface material 2518 comprising an adhesive or precoat 2550 with The yarn 2512 bonded to the bonding foam layer 2514 is regenerated. Additionally, the backing material 2552 is adhered or bonded to the bottom of the foam layer 2514 by, for example, flame lamination or in-situ forming, regenerated bonded foam backing structures as described in the following references: e.g., U.S. Patent Application Serial No. 09/721,871 and 09/993,158 (U.S. Application Publication No. US 2002/0132085) and 10/209,050 (U.S. Application Publication No. US2004/0022991) and British Patent GB 2369294 to Higgins et al., the above references are hereby incorporated by reference as if at This is exactly the same as stated. Optional additional upper or lower layers 2517 and 2515 may be added.

Referring to FIG. 28 , in which parts corresponding to those previously described are designated by like numerals within the sequence 2600 , a needled or needled surface covering structure or product 2610 includes a needled surface material 2618 which includes a needled surface material 2618 Included is yarn 2612 bonded to recycled adhesive foam layer 26514 by adhesive or precoat 2650. In addition, the backing material 2652 is adhered or bonded to the bottom of the foam layer 2614 by, for example, flame lamination or in-situ forming, regenerated bonded foam backing structures as described in the following references: e.g., U.S. Patent Application Serial No. 09/721,871 and 09/993,158 (U.S. Application Publication No. US 2002/0132085) and 10/209,050 (U.S. Application Publication No. US 2004/0022991) and British Patent GB2369294 to Higgins et al., which references are hereby incorporated by reference , as fully described here. Optional additional upper or lower layers 2617 and 2615 may be added.

Preferred yarns for weaving coated yarn surface materials, depending on selected features or embodiments, are brightly colored, flat, monofilament polyester yarns coated with HDPP containing 4% oxide to improve Abrasion resistance, HDPP has been cross-linked and the fabric is thermally bonded to prevent yarn slippage.

According to at least one specific embodiment, the backing is formed from a three-layer composite of a flame-laminated or adhesive-bonded composite of a glass layer, a buffer layer, and a felt backing layer. The buffer layer can be a particle/binder layer, a foam layer, a foam/particle layer, and the like. Preferably the composite backing can be bonded to the decorative surface with a pre-coat or layer of an adhesive such as hot melt, latex, polyurethane or the like. Hot melt precoats are preferred.

It is preferable to use a precision coating device such as a LACOM coater to precisely measure the optimum pre-coat or adhesive layer to laminate the backing to the decorative surface, thereby achieving the desired tuft lock, lamination strength, flexibility and/or of a similar nature. Hot melt or polyurethane adhesives are preferred.

According to at least selected embodiments, the backing below the decorative surface is a thin, dense, flexible, elastic backing layer bonded to the decorative surface, with or without a stabilizing layer in between. Heavy fillers are preferred because they produce dense backings. Magnetic or magnetizable fillers are also available as an option.

In at least selected embodiments, it is preferred that the monofilaments of the coated yarn are colored and the coating is clear. Coatings can keep yarns from getting dirty, add luster or serve as a continuous sheet of protective film. The yarn can be multifilament, but during extrusion, the bulk material will be drawn from the yarn, so there is little advantage to using multifilament. The filaments can be monochromatic or multicolored integrally, and can be of various sizes or cross-sectional shapes. Recycled yarns with a variety of controllable colors are preferred.

According to another backing example, the polymeric foam forming composition can be used to make a high recycled carpet content backing or a high recycled carpet content high density pad. This can be accomplished by dispersing particles or chips of recycled carpet into the polyurethane foam glue and then mixing the chips into the liquid foam either by mechanical agitation or simply by rotating the glue mixture. Alternatively, the chips can be dosed into the liquid foam as the foam is piped through a static mixer. Such a process would benefit from less air entering the liquid foam making the foam a better adhesive. Small pieces such as recycled carpet, recycled carpet tile, recycled surface coverings, recycled trimming waste, recycled polyurethane foam, recycled EPDM, recycled tire rubber, recycled flooring, recycled plastic, recycled glass, and/or the like can be in the process The result is a more economical and higher recycled content backing in backing and cushion foams. In one example, 25% by weight chips are added to 75% by weight liquid foam. A weight or volume ratio of chips/foam of 25/75 is preferred.

While at least some aspects, features, or implementations have been depicted and described with respect to certain potentially preferred implementations and practices, it is to be understood that the depicted and described implementations and practices are illustrative only, and that the invention is not intended to Not limited to this. Rather, it is well contemplated that modifications and variations of the invention will become apparent to those skilled in the art from reading the foregoing description and/or practice of the invention. Accordingly, the present invention is to cover at least all such modifications and variations, and to embrace its broad scope, embodiments, examples, etc., within the full scope of the following claims and their equivalents.

The words "comprising" and "having/comprising" used herein, for example, when referring to the present invention are used to specify the presence of, for example, certain features, integers, steps or components, but do not exclude the additional presence of one or more other Features, integers, steps, components and groups thereof and/or the like.

It is to be appreciated that certain features, aspects, implementations, examples, etc., which are, for clarity, described in separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features, aspects, implementations, examples that are, for brevity, described in the context of a single embodiment, may also be provided independently or in any suitable subgroup.

Claims (14)

1. surface covering; it comprise defined with covering relation be arranged on the single or multiple lift backing appear the surface external composite layer; wherein said external composite layer comprises decorative textile product or tissue layer; described decorative textile product or tissue layer optionally soak into, cover with diaphragm or film-forming composition and apply at least a, and wherein said backing optionally comprises conglomeration particulate mass, foam, foam and particle, felt or its combination that is bonded together with syntople.

2. surface covering as claimed in claim 1, it further comprises the fiber backing sheet that is arranged on the described backing bottom side portion.

3. surface covering as claimed in claim 1, wherein said surface covering is a floor tile.

4. surface covering as claimed in claim 1, wherein said decorative textile product layer are at least a in woven, knitting, non-woven, acupuncture, tufting and the flocked fabric.

5. surface covering as claimed in claim 1, wherein said fabric is formed by coated yarns.

6. surface covering as claimed in claim 1, wherein said decorative textile product layer comprises one deck upside protectiveness wearing layer or film at least.

7. surface covering as claimed in claim 1, wherein said backing are flexible and/or flexible.

8. surface covering as claimed in claim 1, the wherein said surface that appears is arranged on the multilayer backing with covering relation.

9. surface covering as claimed in claim 1, it further comprises one deck stabilized zone at least.

10. surface covering as claimed in claim 1, wherein said backing are at least a in particle backing and the foam-back.

11. a manufacturing has the method for the surface covering of coated yarns textile surface and backing, said method comprising the steps of: for example the particle of rubber and/or foam and/or granulated cork and so on mixes mutually with adhesive or foam, and optionally adds one or more fillers, reagent or compound; With described particle/binder or particle/foam mixture deposit stratification; The textile surface material that optionally applies, covers or soak into is placed on the illuvium, forms sandwich construction; Suppress described sandwich construction, make described adhesive or foam curing with for example heat simultaneously, thereby make the bonding formation backing of described particle and described adhesive or foam, described backing optionally comprises the space between compressed granulate, and wherein said textile surface material and the described backing that optionally applies is bonding.

12. method as claimed in claim 11, the wherein said textile surface material that optionally applies at least a through in stamp or the dyeing at least before or after it is coated.

13. method as claimed in claim 12, the wherein said textile surface material that optionally applies is a sublimation (transfer) printing.

14. method as claimed in claim 11 is wherein added one or more layers additional wearing layer on the described textile surface material that optionally applies.

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