Granted Patent B1

US 6,860,953 · App. 09/621,591 · Granted Mar 1, 2005

Assignee: Collins & Aikman Floorcoverings, Inc.

Abstract

Claims (68)

1. A process for manufacturing a backing material for a floor covering comprising the steps of:

chopping a mixture of waste polymeric material wherein the waste polymeric material has about 0.1 to 40 percent aliphatic polyamide material having a predetermined melting temperature;

granulating the chopped mixture into fragments that are smaller than the original size of the waste polymeric material;

densifying the granulated mixture into pelletized waste polymeric material;

mixing the waste polymeric material with a blowing agent having a predetermined decomposition temperature;

extruding the mixed waste polymeric material and blowing agent at a temperature less than the melting temperature of a majority of the aliphatic polyamide material and less than the decomposition temperature of the blowing agent to form an extrudate;

calendering the extrudate to form a backing sheet;

adhering the backing sheet to the floor covering; and

heating the backing sheet to a temperature above the decomposition temperature of the blowing agent, thereby causing the backing sheet to expand to form a cushioned backing layer.

2. A process for manufacturing a backing material for a floor covering comprising:

granulating a mixture of waste polymeric material including from about 0.1 to about 40 percent aliphatic polyamide material into a granulated mixture of fragments at least an order of magnitude smaller than the original size of the waste polymeric material;

densifying the granulated mixture of waste polymeric material;

mixing the waste polymeric material with a blowing agent having a predetermined decomposition temperature;

forming a sheet from the mixture of waste polymeric material and blowing agent;

adhering the sheet to a back surface of the floor covering; and

heating the sheet to a temperature above the decomposition temperature of the blowing agent, thereby causing the sheet to expand to form a cushioned backing layer,

wherein the step of forming a sheet is carried out at temperatures below the melting temperature of a majority of the aliphatic polyamide material and below the decomposition temperature of the blowing agent.

3. A process for manufacturing a backing material according to claim 2 wherein the step of forming a sheet includes extruding the waste polymeric material at a temperature less than the melting temperature of a majority of the aliphatic polyamide material and less than the decomposition temperature of the blowing agent.

4. A process for manufacturing a backing material according to claim 2 wherein the step of forming a sheet includes calendering the waste polymeric material.

5. A process for manufacturing a backing material according to claim 2 further comprising cryogenically grinding the waste polymeric material.

6. A process for manufacturing a backing material according to claim 2 wherein the step of densifying the waste polymeric material includes forming the waste polymeric material into pellets.

7. A process for manufacturing a backing material for a floor covering comprising:

cryogenically grinding a mixture of waste polymeric material including from about 0.1 to about 40 percent aliphatic polyamide material;

densifying the granulated mixture of waste polymeric material;

mixing the waste polymeric material with a blowing agent having a predetermined decomposition temperature;

extruding the waste polymeric material at a temperature less than the melting temperature of a majority of the aliphatic polyamide material and less than the decomposition temperature of the blowing agent;

calendering the extruded waste polymeric material to form a sheet;

adhering the sheet to a back surface of the floor covering; and

heating the sheet to a temperature above the decomposition temperature of the blowing agent, thereby causing the sheet to expand to form a cushioned backing layer.

8. A process for manufacturing a backing material for a floor covering comprising:

cryogenically grinding a mixture of waste polymeric material including from about 0.1 to about 40 percent aliphatic polyamide material to form a powder of waste polymeric material;

mixing the powder of waste polymeric material with a blowing agent having a predetermined decomposition temperature;

forming a sheet from the mixture of waste polymeric material and blowing agent;

adhering the sheet to a back surface of the floor covering; and

heating the sheet to a temperature above the decomposition temperature of the blowing agent, thereby causing the sheet to expand to form a cushioned backing layer,

wherein the step of forming a sheet is carried out at temperatures below the melting temperature of a majority of the aliphatic polyamide material and below the decomposition temperature of the blowing agent.

9. A process for manufacturing a backing material according to claim 8 wherein the step of forming a sheet includes extruding the mixture of waste polymeric material and blowing agent at a temperature less than the melting temperature of a majority of the aliphatic polyamide material and less than the decomposition temperature of the blowing agent.

10. A process for manufacturing a backing material according to claim 9 wherein the mixture of waste polymeric material and blowing agent is extruded through a sheet die.

11. A process for manufacturing a backing material according to claim 8 wherein the step of forming a sheet includes calendering the waste polymeric material.

12. A process for manufacturing a foamed backing material from waste polymeric material derived in part from recycled carpet the foamed backing material having a substantially uniform thickness, for a floor covering comprising:

granulating a mixture of waste polymeric material derived in part from recycled carpet including from about 0.1 to about 40 percent aliphatic polyamide material into a granulated mixture of fragments at least an order of magnitude smaller than the original size of the waste polymeric material;

densifying the granulated mixture of waste polymeric material;

mixing the waste polymeric material with a blowing agent having a predetermined decomposition temperature;

forming a sheet from the mixture of waste polymeric material and blowing agent;

heating the sheet to a temperature above the decomposition temperature of the blowing agent, thereby causing the sheet to expand to form a cushioned backing layer; and

adhering the cushioned backing layer to a back surface of the floor covering,

wherein the step of forming a sheet is carried out at temperatures below the melting temperature of a majority of the aliphatic polyamide material and below the decomposition temperature of the blowing agent.

13. A process for manufacturing a backing material according to claim 12 wherein the step of forming a sheet includes extruding the waste polymeric material at a temperature less than the melting temperature of a majority of the aliphatic polyamide material and less than the decomposition temperature of the blowing agent.

14. A process for manufacturing a backing material according to claim 12 wherein the step of forming a sheet includes calendering the waste polymeric material.

15. A process for manufacturing a backing material according to claim 12 further comprising cryogenically grinding the waste polymeric material.

16. A process for manufacturing a backing material according to claim 12 wherein the step of densifying the waste polymeric material includes forming the waste polymeric material into pellets.

17. A process for manufacturing a foamed backing material from waste polymeric material derived in part from recycled carpet, the foamed backing material having a substantially uniform thickness, for a floor covering comprising:

cryogenically grinding a mixture of waste polymeric material derived in part from recycled carpet including from about 0.1 to about 40 percent aliphatic polyamide material;

densifying the granulated mixture of waste polymeric material;

mixing the waste polymeric material with a blowing agent having a predetermined decomposition temperature;

extruding the waste polymeric material at a temperature less than the melting temperature of a majority of the aliphatic polyamide material and less than the decomposition temperature of the blowing agent;

calendering the extruded waste polymeric material to form a sheet;

heating the sheet to a temperature above the decomposition temperature of the blowing agent, thereby causing the sheet to expand to form a cushioned backing layer; and

adhering the cushioned backing layer to a back surface of the floor covering.

18. A process for manufacturing a foamed backing material from waste polymeric material derived in part from recycled carpet, the foamed backing material having a substantially uniform thickness, for a floor covering comprising:

cryogenically grinding a mixture of waste polymeric material derived in part from recycled carpet including from about 0.1 to about 40 percent aliphatic polyamide material to form a powder of waste polymeric material;

mixing the powder of waste polymeric material with a blowing agent having a predetermined decomposition temperature;

forming a sheet from the mixture of waste polymeric material and blowing agent; and

heating the sheet to a temperature above the decomposition temperature of the blowing agent, thereby causing the sheet to expand to form a cushioned backing,

wherein the step of forming a sheet is carried out at temperatures below the melting temperature of a majority of the aliphatic polyamide material and below the decomposition temperature of the blowing agent.

19. A process for manufacturing a backing material according to claim 18 wherein the step of forming a sheet includes extruding the mixture of waste polymeric material and blowing agent at a temperature less than the decomposition temperature of the blowing agent to form a sheet.

20. A process for manufacturing a backing material according to claim 19 wherein the mixture of waste polymeric material and blowing agent is extruded through a sheet die.

21. A process for manufacturing a backing material according to claim 18 wherein the step of forming a sheet includes calendering the waste polymeric material.

Assignments (9)

Continuity (3)