RECYCLABLE SURFACE COVERING AND METHOD OF MANUFACTURING
A surface covering is provided, comprising a substrate with a flocking layer adhered to the substrate by an adhesive. The substrate is formed at least partially from granulated recycled rubber and a binding agent. In an exemplary embodiment, a design is applied to the flocking layer. A method of manufacturing the surface covering comprises the steps of producing a substrate formed at least partially from granulated recycled rubber and a binding agent, flocking the substrate with fibers of a selected base color to form a base covering, printing a transfer paper with a design and transferring the design from the transfer paper to fibers of the base covering.
1 . A surface covering, comprising:
a substrate formed at least partially from granulated recycled rubber and a binding agent;
a flocking layer adhered to the substrate with an adhesive to form a base covering and
a decorative design is applied to the base covering.
2 . The surface covering of claim 1 , wherein the binding agent is urethane.
3 . The surface covering of claim 1 , wherein the adhesive is an acrylic adhesive
4 . The surface covering of claim 1 , wherein the substrate is shaved from a cylindrical billet of granulated recycled rubber.
5 . The surface covering of claim 1 , wherein the substrate comprises granulated recycled rubber from recycled surface covering.
6 . The surface covering of claim 5 , wherein the substrate further comprises granulated recycled rubber from other sources.
7 . The surface covering of claim 5 , wherein the substrate further comprises a filler.
8 . The surface covering of claim 5 , wherein the substrate comprises at least 10 wt-% of reground rubber from recycled surface covering.
9 . The surface covering of claim 1 , wherein a decorative design is formed on the flocking layer.
10 . The surface covering of claim 9 , wherein the decorative design is formed using a dye sublimation process.
11 . The surface covering of claim 9 , wherein the decorative design comprises a picture.
12 . The surface covering of claim 9 , wherein the decorative design comprises a pattern.
13 . A method of manufacturing a recyclable surface covering comprising flocking adhered to a granulated recycled rubber substrate, comprising the steps of:
producing a substrate formed at least partially from granulated recycled rubber and a binding agent;
flocking the substrate with fibers of a selected base color to form a base covering;
printing a transfer paper with a design; and
transferring the design from the transfer paper to fibers of the base covering.
14 . The method of claim 13 wherein the base covering is warehoused prior to printing.
15 . The method of claim 14 wherein a number of transfer papers are printed and stored.
16 . The method of claim 15 wherein the base covering is produced in a first facility and then shipped to a distribution center for printing.
17 . The method of claim 16 wherein the transfer papers are stored at the distribution facility.