Floor covering composition containing renewable polymer
View Patent ↗A composition is described that includes at least one polyolefin, at least one thermoplastic bio-resin derived from starch or soy or both, and at least one compatibilizer having at least one polyolefin and at least one polar group. Surface coverings and floor coverings, such as laminated floor coverings, having the composition, are also described.
1. A composition for a surface covering or portion thereof comprising:
A) at least one ethylene propylene copolymer having a melt flow rate of from 0.5 to 15 g/10 min., obtainable by Ziegler Natta sequential polymerization, where the total content of copolymerized ethylene is from about 20 to about 60 wt %, having a melting point of from about 140° C. to about 160° C., a flexural modulus of from about 20 Mpa to about 500 Mpa and a density from 0.870 to 0.900 g/cm 3 ,
(B) at least one thermoplastic bio-resin derived from starch or soy or both, optionally having a softening temperature of about 125° C., and/or a melting temperature of about 156° C., and/or a density of about 1.12 to 1.3 g/cm 3 , and/or a melt flow rate of about 0.5 to about 2.0 g/10 min.,
(C) at least one compatibilizer made from functionalizing polyolefin with at least one polar group of carboxylic acid, maleic anhydride, acrylic acid, ethylene methacrylic acid, or methyl acrylate, where the polar group is present in the range of from about 0.1 to about 10 wt % of the polyolefin (based on the total weight of the composition), and the polyolefin having an isotactic index of from about 85% to about 95% and the functionalizing polyolefin having a melt flow rate range from about 100-450 g/10 min,
(D) at least one styrenic thermoplastic block copolymer of styrene/ethylene/butylene or styrene/ethylene/propylene where the polystyrene content in the block copolymer is from about 7 to about 30%, and the block copolymer having a melt flow rate of from 2.5 to 25 g/10 min.,
(E) at least one filler, and
(F) at least one dispersion agent made from isotactic polypropylene homopolymer by either free radical degradation in peroxide or an isotactic polypropylene homopolymer made by single site catalyst polymerization, having an isotactic index greater than 80 and a melt flow rate (melt flow rate) from about 1000 to about 2000 g/10 min., at 230° F. and 2.16 kg according to ASTM D1238, and, optionally, at least one hydrocarbon tackifier comprising a blend of an aliphatic hydrocarbon resin, an aromatic hydrocarbon polymer functionalized with fatty acid ester having a softening temperature at from about 103° C. to 113° C., and, optionally, at least one ethylene octene copolymer produced by single site catalyst polymerization and having a melt flow rate from about 3 to about 30 g/10 min., a melting temperature from about 60° C. to 90° C. and a density from about 0.860 to about 0.902 g/cm 3 , wherein the ethylene octene copolymer is optionally in part or a whole replacement of component (A).
2. The composition of claim 1 , wherein rate of heat release of the composition as measured by ASTM E1354 is from 200 to 340 kW/m 2 .
3. The composition of claim 1 , wherein smoke generation of the composition as measured by ASTM E1354 is from 250 to 350 m 2 /Kg.
4. The composition of claim 1 , wherein carbon mono-oxide yield of the composition as measured by ASTM E1354 is from 0.086 to 0.250.
5. The composition of claim 1 , wherein tear strength of the composition as measured by ASTM D1938-94 is greater than or equal to 8 lbf/in.
6. The composition of claim 1 , wherein the thermoplastic bio-resin derived from starch is produced from corn, wheat, potatoes, or grass.
7. The composition of claim 1 , wherein the thermoplastic bio-resin derived from starch is produced from non-genetically modified cornstarch.
8. The composition of claim 7 , wherein the thermoplastic bio-resin derived from non-genetically modified cornstarch comprises 65-95 w % plant starch, 1-15 w % reactive plasticizer.
9. The composition of claim 1 , wherein the thermoplastic bio-resin derived from starch has a melting temperature of about 300° F.-315° F.
10. The composition of claim 1 , wherein the thermoplastic bio-resin derived from starch has a softening temperature of about 250° F.-260° F.
11. The composition of claim 1 , wherein the first polyolefin comprises 3-10 carbon atoms.
12. The composition of claim 1 , further comprising a thermoplastic that is different from any thermoplastic present in said composition.
13. The composition of claim 1 , further comprising a flame retardant.
14. The composition of claim 1 , wherein said polar group is present in an amount of from about 0.5 wt % to about 5 wt %, based on the total weight of the composition.
15. The composition of claim 1 , wherein the hydrocarbon tackifier is present and comprises at least one aliphatic hydrocarbon resin, at least one aromatic hydrocarbon resin, and at least one fatty acid ester compound.
16. The composition of claim 1 , wherein the hydrocarbon tackifier is present in an amount of from about 0.1 wt % to about 5 wt %, based on the total weight of the composition.
17. The composition of claim 1 , wherein said dispersion agent is present in an amount of from about 0.1 wt % to about 5 wt %, based on the total weight of the composition.
18. The composition of claim 1 , wherein the filler comprises talc, mica, calcium carbonate, barite, kaolin, silica, glass, or any combination thereof.
19. The composition of claim 1 , wherein the filler is present in an amount of from about 50 wt % to about 90 wt %, based on the total weight of the composition.
20. The composition of claim 1 , further comprising at least one additive comprising a pigment, flame retardant, thermal stabilizer, antimicrobial, biocide, light stabilizer, antistatic, or any combination thereof.
21. The composition of claim 1 , wherein at least one component is a recycled material.
22. The composition of claim 21 , wherein the recycled material comprises polyolefin, polyethylene, polypropylene, ethylene propylene, olefin copolymers, carpet comprising an olefin backing with nylon faced yarn, carpet comprising olefin backing with olefin faced yarn, glass beads, fly ash, gypsum or any combination thereof.
23. A flooring covering comprising the composition of claim 1 .
24. The flooring covering of claim 23 , wherein the composition is in the form of multiple-colored and/or variable-sized chips.
25. The floor covering of claim 23 , wherein the floor covering is in the form of a sheet, a tile or a plank.
26. The floor covering of claim 24 , wherein the floor covering is in the form of a sheet, a tile or a plank.
27. A laminated surface covering comprising:
a backing layer comprising the composition of claim 1 , wherein the backing layer has a top surface and a bottom surface,
a décor layer having a top surface and a bottom surface, wherein the bottom surface of the décor layer is affixed to the top surface of the backing layer, and
at least one wear layer having a top surface and a bottom surface, wherein the bottom surface of the wear resistant layer is affixed to the top surface of the décor layer.
28. The laminated surface covering of claim 27 , wherein the at least one wear layer comprises an unsaturated functional acrylate and aluminum oxide particles.
29. The laminated surface covering of claim 27 , wherein the at least one wear layer is directly on the top surface of the décor layer and is cured by electron beam or radiation.
30. The laminated surface covering of claim 27 , wherein the décor layer comprises a gravure print, a digital print, a flexo print, a transfer print, a pad print, a stamping print, a decorative painting, or any combination thereof.
31. The laminated surface covering of claim 27 , wherein the décor layer comprises a substrate, and wherein the substrate comprises a plastic film and/or paper.
32. The laminated surface covering of claim 31 , wherein the plastic film comprises a non-poly vinyl chloride plastic film.
33. The laminated surface covering of claim 27 , wherein the bottom surface of the décor layer is affixed to the top surface of the backing layer by hot melt, moisture cure polyurethane glue.
34. The laminated surface covering of claim 28 , wherein the unsaturated functional acrylate comprises an epoxy oligomer, urethane oligomer, polyester oligomer, or any combination thereof.
35. The laminated surface covering of claim 27 , wherein the at least one wear layer comprises a reactive monomer, wherein the reactive monomer comprises a mono-functional diluent, a di-functional diluent, a multi-functional diluent, or any combination thereof.
36. The laminated surface covering of claim 27 , wherein the at least one wear layer comprises at least one surfactant, at least one defoaming agent, at least one abrasive resistant particle, or any combination thereof, and optionally at least one photoinitiator.
37. The laminated surface covering of claim 27 , further comprising at least one additional layer, wherein the additional layer comprises an olefin blend, a glass mat, a thermoplastic film, or any combination thereof.
38. A method of making the composition of claim 1 , comprising mixing components of the composition or extruding the composition in a twin screw, a single screw, a banbury mixer, an extruder with a slot die, or any combination thereof.
39. The composition of claim 1 , wherein said composition is halogen-free.
40. The floor covering comprising the composition of claim 39 .
41. A laminated surface covering comprising:
a backing layer comprising the composition of claim 39 , wherein the backing layer has a top surface and a bottom surface,
a décor layer having a top surface and a bottom surface, wherein the bottom surface of the décor layer is affixed to the top surface of the backing layer, and
at least one wear layer having a top surface and a bottom surface, wherein the bottom surface of the wear resistant layer is affixed to the top surface of the décor layer.