CA2349052A1 - Floor covering with moisture and plasticizer barrier layer - Google Patents
Floor covering with moisture and plasticizer barrier layer Download PDFInfo
- Publication number
- CA2349052A1 CA2349052A1 CA 2349052 CA2349052A CA2349052A1 CA 2349052 A1 CA2349052 A1 CA 2349052A1 CA 2349052 CA2349052 CA 2349052 CA 2349052 A CA2349052 A CA 2349052A CA 2349052 A1 CA2349052 A1 CA 2349052A1
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- CA
- Canada
- Prior art keywords
- layer
- floor covering
- barrier
- backing layer
- copolymers
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 230000004888 barrier function Effects 0.000 title claims abstract description 143
- 239000004014 plasticizer Substances 0.000 title claims abstract description 77
- 239000010410 layer Substances 0.000 claims abstract description 300
- 229920000642 polymer Polymers 0.000 claims abstract description 57
- 239000012790 adhesive layer Substances 0.000 claims abstract description 40
- 230000005012 migration Effects 0.000 claims abstract description 39
- 238000013508 migration Methods 0.000 claims abstract description 39
- 239000000758 substrate Substances 0.000 claims abstract description 39
- 239000000470 constituent Substances 0.000 claims abstract description 32
- 239000000853 adhesive Substances 0.000 claims abstract description 27
- 230000001070 adhesive effect Effects 0.000 claims abstract description 27
- 239000000203 mixture Substances 0.000 claims abstract description 22
- 239000011342 resin composition Substances 0.000 claims description 42
- 229920001577 copolymer Polymers 0.000 claims description 34
- 239000004753 textile Substances 0.000 claims description 27
- -1 ethylene, propylene, isobutylene Chemical group 0.000 claims description 26
- 239000000835 fiber Substances 0.000 claims description 25
- 230000002401 inhibitory effect Effects 0.000 claims description 17
- 229920003051 synthetic elastomer Polymers 0.000 claims description 16
- 239000005061 synthetic rubber Substances 0.000 claims description 16
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 claims description 14
- 239000000839 emulsion Substances 0.000 claims description 14
- 229920000728 polyester Polymers 0.000 claims description 14
- 239000000463 material Substances 0.000 claims description 12
- WNLRTRBMVRJNCN-UHFFFAOYSA-L adipate(2-) Chemical compound [O-]C(=O)CCCCC([O-])=O WNLRTRBMVRJNCN-UHFFFAOYSA-L 0.000 claims description 10
- 229920003052 natural elastomer Polymers 0.000 claims description 10
- 229920001194 natural rubber Polymers 0.000 claims description 10
- 229920000098 polyolefin Polymers 0.000 claims description 10
- 229920002635 polyurethane Polymers 0.000 claims description 10
- 239000004814 polyurethane Substances 0.000 claims description 10
- 229920002689 polyvinyl acetate Polymers 0.000 claims description 10
- 244000043261 Hevea brasiliensis Species 0.000 claims description 9
- 125000005591 trimellitate group Chemical group 0.000 claims description 9
- 229920002554 vinyl polymer Polymers 0.000 claims description 9
- PPBRXRYQALVLMV-UHFFFAOYSA-N Styrene Chemical compound C=CC1=CC=CC=C1 PPBRXRYQALVLMV-UHFFFAOYSA-N 0.000 claims description 8
- XTXRWKRVRITETP-UHFFFAOYSA-N Vinyl acetate Chemical compound CC(=O)OC=C XTXRWKRVRITETP-UHFFFAOYSA-N 0.000 claims description 8
- 229920001903 high density polyethylene Polymers 0.000 claims description 8
- 239000004700 high-density polyethylene Substances 0.000 claims description 8
- 229920001684 low density polyethylene Polymers 0.000 claims description 8
- 239000004702 low-density polyethylene Substances 0.000 claims description 8
- 229920001707 polybutylene terephthalate Polymers 0.000 claims description 8
- 229920000139 polyethylene terephthalate Polymers 0.000 claims description 8
- 239000005020 polyethylene terephthalate Substances 0.000 claims description 8
- 229920002215 polytrimethylene terephthalate Polymers 0.000 claims description 8
- SMZOUWXMTYCWNB-UHFFFAOYSA-N 2-(2-methoxy-5-methylphenyl)ethanamine Chemical compound COC1=CC=C(C)C=C1CCN SMZOUWXMTYCWNB-UHFFFAOYSA-N 0.000 claims description 7
- 239000004952 Polyamide Substances 0.000 claims description 7
- 229920002367 Polyisobutene Polymers 0.000 claims description 7
- 229920006397 acrylic thermoplastic Polymers 0.000 claims description 7
- 229920001893 acrylonitrile styrene Polymers 0.000 claims description 7
- 229920003232 aliphatic polyester Polymers 0.000 claims description 7
- 125000003118 aryl group Chemical group 0.000 claims description 7
- 229920001400 block copolymer Polymers 0.000 claims description 7
- XNGIFLGASWRNHJ-UHFFFAOYSA-L phthalate(2-) Chemical compound [O-]C(=O)C1=CC=CC=C1C([O-])=O XNGIFLGASWRNHJ-UHFFFAOYSA-L 0.000 claims description 7
- 229920003229 poly(methyl methacrylate) Polymers 0.000 claims description 7
- 229920002647 polyamide Polymers 0.000 claims description 7
- SCUZVMOVTVSBLE-UHFFFAOYSA-N prop-2-enenitrile;styrene Chemical compound C=CC#N.C=CC1=CC=CC=C1 SCUZVMOVTVSBLE-UHFFFAOYSA-N 0.000 claims description 7
- ISXSCDLOGDJUNJ-UHFFFAOYSA-N tert-butyl prop-2-enoate Chemical compound CC(C)(C)OC(=O)C=C ISXSCDLOGDJUNJ-UHFFFAOYSA-N 0.000 claims description 7
- NIXOWILDQLNWCW-UHFFFAOYSA-N 2-Propenoic acid Natural products OC(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 claims description 6
- 229920003145 methacrylic acid copolymer Polymers 0.000 claims description 6
- 239000000178 monomer Substances 0.000 claims description 5
- BZHJMEDXRYGGRV-UHFFFAOYSA-N Vinyl chloride Chemical compound ClC=C BZHJMEDXRYGGRV-UHFFFAOYSA-N 0.000 claims description 4
- KRKNYBCHXYNGOX-UHFFFAOYSA-K Citrate Chemical compound [O-]C(=O)CC(O)(CC([O-])=O)C([O-])=O KRKNYBCHXYNGOX-UHFFFAOYSA-K 0.000 claims description 3
- 239000010426 asphalt Substances 0.000 claims description 3
- 229920000747 poly(lactic acid) Polymers 0.000 claims description 3
- 239000004626 polylactic acid Substances 0.000 claims description 3
- 239000011118 polyvinyl acetate Substances 0.000 claims description 3
- 229920000915 polyvinyl chloride Polymers 0.000 claims description 3
- 239000004800 polyvinyl chloride Substances 0.000 claims description 3
- 235000012424 soybean oil Nutrition 0.000 claims description 3
- 239000003549 soybean oil Substances 0.000 claims description 3
- 239000000945 filler Substances 0.000 claims description 2
- 125000005498 phthalate group Chemical group 0.000 claims 2
- 235000013312 flour Nutrition 0.000 claims 1
- 230000003993 interaction Effects 0.000 abstract description 4
- 230000015556 catabolic process Effects 0.000 abstract description 3
- 238000006731 degradation reaction Methods 0.000 abstract description 3
- 239000000047 product Substances 0.000 description 6
- 238000009434 installation Methods 0.000 description 5
- 239000000126 substance Substances 0.000 description 5
- 239000004820 Pressure-sensitive adhesive Substances 0.000 description 3
- 238000010276 construction Methods 0.000 description 3
- 230000001627 detrimental effect Effects 0.000 description 3
- 238000000034 method Methods 0.000 description 3
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 2
- 230000002745 absorbent Effects 0.000 description 2
- 239000002250 absorbent Substances 0.000 description 2
- 230000006978 adaptation Effects 0.000 description 2
- 239000012943 hotmelt Substances 0.000 description 2
- 230000007246 mechanism Effects 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 239000002861 polymer material Substances 0.000 description 2
- 230000005855 radiation Effects 0.000 description 2
- 238000007127 saponification reaction Methods 0.000 description 2
- 230000035939 shock Effects 0.000 description 2
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 description 2
- 239000002759 woven fabric Substances 0.000 description 2
- QTBSBXVTEAMEQO-UHFFFAOYSA-M Acetate Chemical compound CC([O-])=O QTBSBXVTEAMEQO-UHFFFAOYSA-M 0.000 description 1
- 241000272470 Circus Species 0.000 description 1
- 239000004908 Emulsion polymer Substances 0.000 description 1
- CERQOIWHTDAKMF-UHFFFAOYSA-N Methacrylic acid Chemical compound CC(=C)C(O)=O CERQOIWHTDAKMF-UHFFFAOYSA-N 0.000 description 1
- 239000006057 Non-nutritive feed additive Substances 0.000 description 1
- 239000004743 Polypropylene Substances 0.000 description 1
- 150000001242 acetic acid derivatives Chemical class 0.000 description 1
- 238000007605 air drying Methods 0.000 description 1
- 150000001298 alcohols Chemical class 0.000 description 1
- 150000001338 aliphatic hydrocarbons Chemical class 0.000 description 1
- 150000004945 aromatic hydrocarbons Chemical class 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 239000007795 chemical reaction product Substances 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 235000014113 dietary fatty acids Nutrition 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 239000004744 fabric Substances 0.000 description 1
- 229930195729 fatty acid Natural products 0.000 description 1
- 239000000194 fatty acid Substances 0.000 description 1
- 150000004665 fatty acids Chemical class 0.000 description 1
- 239000011256 inorganic filler Substances 0.000 description 1
- 229910003475 inorganic filler Inorganic materials 0.000 description 1
- 229920000092 linear low density polyethylene Polymers 0.000 description 1
- 239000004707 linear low-density polyethylene Substances 0.000 description 1
- 239000012766 organic filler Substances 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 229920001155 polypropylene Polymers 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 229920001169 thermoplastic Polymers 0.000 description 1
- 239000004416 thermosoftening plastic Substances 0.000 description 1
- 238000004804 winding Methods 0.000 description 1
- 230000037303 wrinkles Effects 0.000 description 1
Landscapes
- Laminated Bodies (AREA)
Abstract
A floor covering having a backing layer formed from a polymer composition includes a barrier layer formulated and configured to inhibit the migration of moisture from a substrate into the backing layer and to inhibit the migration of backing layer constituents out of the backing layer. The barrier layer also inhibits migration of backing layer constituents into an adhesive layer attached beneath the backing layer, thereby preventing degradation of the adhesive's effectiveness due to interaction with these constituents. The barrier layer also prevents contact between plasticizers used in the backing layer and moisture within or on the surface of the floor to which the carpet is adhered.
Description
BP #11920-14 BERESKIN & PARR CANADA
Title: FLOOR COVERING WITH MOISTURE AND PLASTICIZER
BARRIER LAYER
Inventor s : HAMMEL, Wallace J.;
EVANS, Paul D. Jr.;
RANDALL, Brian S
FLOOR COVERING WITH MOISTURE AND PLASTICIZER
BARR~R LAYER
Background Of The Invention Carpet having a shock absorbent resinous thermoplastic backing layer is commonly applied to hard Moor surfaces. The shock absorbent backing layer may be a secondary backing underlying a primary backing to which textile fibers are secured, as in a tufted carpet, or it may be a backing layer adhered to the backside of a fabric of warp_and weft yarns, as in <i waven carpet.
Carpets having such backing layers are subject to several detrimental effects due to the migration of moisture into the backing layer or due to the migration of certain constituents out of the backing layer. The detrimental effects due to moisture include dimensional instability of the backing layer which can cause the carpet to warp or wrinkle and chemical interaction of the moisture with backing layer components that can changf: the physical characteristics of the backing layer or produce undesirable reaction products. A particular concern is the interaction of moisture with plasticizers in the backing layer because of the potential for a saponification reaction. Such a reaction produces an organic alcohol with a low vapor pressure, which allows th.e alcohol to pass into the atmosphere, thereby producing a negative effect on air quality in the vicinity of the carpet.
Migration of backing layer constituents out of the backing layer can also result in a change in the physical characteristics of the backing layer. Of particular concern is the migration of plasticizc:rs aut of the backing layer, which can render the backing layer stiff and inflexible. If an adhesive layer is applied to the back of the carpet, migration of plasticizers from the backing layer into the adhesive layer can degrade 2~ the effectiveness of the adheaive. Migration of plasticizers out of the backing layer may also present the possibility of interaction with moisture in the substrate that has not itself' migrated into the backing layer.
Summary Of The Invention T'uf3ed carpet products typically have a resin composition locking layer that locks the textile fibers to the primary backing. A secondary backing is then adhered to the locking layer. Woven carpet products have a woven textile layer to which a resin composition locking; layer is applied. A backing layer is then adhered to the resin composition locking; layer. In both types of carpet, moisture from the outer face side of the carpet may be substantially prevented from reaching the secondary backing layer (or the backing; layer in the case of woven carpets) by the resin composition layer. There is, however, no corresponding mechanism for preventing; moisture from the substrate side of the carpet from reaching the backing layer. Further, there is no mechanism for preventing backing material constituents from migrating out of the backing layer into lower layers of the carpet or into the substrate.
Accordingly, there is a need for a carpet product wherein migration of moisture into a backing layer of the carpet and migration of backing layer constituents out of a backing layer of the carpet are substantially inhibited.
It is therefore an oibjective of the present invention to provide a floor covering;
having; a harrier layer that inhibits the migration of moisture from a substrate into a backing layer of the floor covering.
It is also an objective of the present invention to provide a floor covering having a barrier layer that inhibits the migration of backing layer constituents from a backing; layer of the floor covering.
It is a further objective of the present invention to provide a floor covering barrier layer that inhibits the migration ofplasticizers from the backing layer to an adhesive layer or to a substrate.
It is yet another objective of the present invention to provide a floor covering with a barrier layer that is. compatible with presently used materials for carpet backing and adhesives.
It is still another objective of the present invention to provide a floor covering with a thin, flexible barrier layer that does not significantly affect the storage and installation of the floor covering.
To these ends, a floor covering for mounting to a substrate according to the present invention comprises textile fibers defining an upper surface and a resin composition layer adhered to at least a portion of the textile fibers. A
backing layer is adhered to the resin composition layer. The backing layer has an upper surface adjacent the resin composition layer and a lower surface. A barrier layer is adhered to the lower surface of the backing layer, the barrier layer having an upper barrier surface adjacent the backing layer and a lower barrier surface. The barrier layer is effective for substantially inhibiting migration of moisture from the substrate into the backing layer.
The barrier layer of a floor covering according to the present invention is preferably effective for substantially inhibiting migration of backing layer _constituents from the backing layer to the substrate. Such backing layer constituents may include a plasticizes. A plasticizes in a backing layer of a floor covering according to the present invention may be selected from the group consisting of phthalate plasticizers, adipate plasticizers and trimellitate plasticizers. A
plasticizes -, may also be selected from 'the group consisting of polymeric plasticizers, secondary plasticizers, citrate plastici:aers and epoxidized soybean oil.
The backing layer constituents of a floor covering according to the present invention may include a polymer composition including a polymer derived from at least one monomer selected from the group consisting of ethylene, propylene, isobutylene, styrene, vinyl .acetate and vinyl chloride. Further, the backing layer constituents may include a polymer composition including a polymer selected from the group consisting of bitumen, polyurethane, polyvinyl chloride, polylactic acid, polyolefins, polyvinyl acetate, and polyethylene-vinyl acetate. The backing 1~0 constituents may include a polymer composition derived from the group consisting of synthetic nibbers and natural rubbers. The backing layer may further include at least - ..........."_.
one filler material The barrier layer of a floor covering according to the present invention is preferably effective for substantially preventing substrate moisture from making contact with the backing layer constituents.
A floor covering according to the present invention may further comprise an adhesive layer attached to the lower barrier surface, the adhesive layer having an upper adhesive surface adjacent the lower barrier surface and a lower adhesive surface. The barrier layer o:Fthis floor covering is effective for substantially inhibiting migration of backing layer constituents from the backing layer to the adhesive layer.
~ release cover is preferably releasably attached to the lower adhesive surface.
The barrier layer of a floor covering according to the present invention may be ' ~ formed from polymers selected from the group consisting of acrylics, copolymers of acrylic acid, copolymers of methacrylic acid, acrylic-styrene copolymers, acrylonitrile-styrene copolyrners, vinyl polymers including but not limited to polyvinyl acetates and vinylidene chloride-acrylonitrile copolymers, and combinations thereof. Ln addition, the barrier layer may be formed from polymers selected from the group consisting of polyurethanes, copolymers derived from aromatic polyester urethane emulsions, copolymers derived from aliphatic polyester S urethane emulsions, and combinations thereof. The barrier layer may also be formed from polymers selected from the group consisting of natural rubber, synthetic rubbers, block copolymers of synthetic rubbers, polyolefins including but not limited to polyisobutylene, low density polyethylene, and high density polyethylene, and combinations thereof. The: barrier layer may also be formed from polymers selected from the group consisting of polyamides, polyesters including but not limited to polyethylene terephthalate, polytrimethylene terephthalate, polybutylene terephthalate, and combinations thereof. ' A floor covering according to the present invention may further comprise a primary backing to which the textile fibers are attached, the textile fibers extending 1 ~ outward from the primary backing to define a tufted carpet face. The backing layer of this floor covering is adherE:d to the primary backing by the resin composition layer.
Alternatively, the textile fibers of a floor covering according to the present invention may be formed into interwoven warp and weft yarns. The backing layer of this floor covering is adhered by the resin composition layer to the interwoven warp and weft yarns.
In an illustrative embodiment of the present invention, a floor covering for mounting to a substrate comprises textile fibers defining an upper surface and a resin composition layer adhered to at least a portion of the textile fibers. A
backing layer adhered to the resin composition layer is formed from a polymer composition including a plasticizer and has an upper surface adjacent the resin composition layer and a lower surface. The floor covering further comprises a barrier layer adhered to the lower surface of the backing layer. The barrier layer has an upper barrier surface adjacent the backing layer and a lower barrier surface and is effective for substantially inhibiting migration of the plasticizer from the backing layer to the substrate.
In another illustrative embodiment of the present invention, a floor covering for mounting to a substratf; comprises textile fibers defining an upper surface and a resin composition layer adhered to at least a portion of the textile fibers. A
backing layer adhered to the resin composition layer is formed from a polymer composition including a plasticizer selected from the group consisting of phthalate plasticizers, adipate plasticizers and trirnellitate plasticizers. The backing layer has an upper surface adjacent the resin composition layer and a lower surface. The floor covering further comprises a barrier layer adhered to the lower surface of the backing layer.
The barrier layer has an upper barrier surface adjacent the backing layer and a lower l 5 barrier surface. An adhesive Layer is attached to the lower barrier surface and has an upper adhesive surface adjacent the lower barrier surface and a lower barrier surface.
The barrier layer is effectivE: for substantially preventing substrate moisture from making contact with the plasticizer.
In yet another illustrative embodiment of the present invention, a floor covering for mounting to a substrate comprises a primary backing layer with textile f tiers attached to the primary backing and extending outward therefrom to define a tufted carpet face. The floor covering further comprises a resin composition layer adhered to the primary backing and at least a portion of the textile fibers. A
secondary backing layer is adhered to the resin composition layer. The secondary backing layer is formed from, a polymer composition including a plasticizer selected from the group consisting ofphthalate plasticizers, adipate plasticizers and trimellitate plasticizers, and has an upper surface adjacent the resin composition layer and a lower surface. A barrier layer is adhered to the lower surface of the secondary backing layer, the barrier layer having an upper barrier surface adjacent the secondary backing layer and a lower barrier surface. An adhesive layer is attached to the lower barrier surface, the adhesive layer having an upper adhesive surface adjacent the lower barrier surface and a lower adhesive surface. The barrier layer is effective for substantially inhibiting migration of the plasticizer from the secondary backing layer to the adhesive layer and for substantially preventing substrate moisture from making contact with the plasticizf:r.
In still another illustrative embodiment ofthe present invention, a floor covering for mounting to a substrate comprises interwoven warp and weft yarns formed from textile fibers and defining a face surface. A resin composition layer is adhered to at least a portion of the interwoven warp and weft yarns and a backing layer is adhered to the resin composition layer. The backing layer is formed from a polymer composition including a plasticizer selected from the group consisting of phthalate plasticizers, adipate plasticizers and trimellitate plasticizers, and has an upper surface adjacent the resin composition layer and a lower surface. The floor covering further comprises a barrier layer adhered to the lower surface of the backing layer, the barrier layer having an upper barrier surface adjacent the backing layer and a lower barrier surface. A:n adhesive layer is attached to the lower barrier surface, the adhesive layer having an upper adhesive surface adjacent the lower barrier surface and a lower adhesive surface. The barrier layer is effective for substantially inhibiting migration of the plasticizes from the backing layer to the adhesive layer and for substantially preventing substrate moisture from making contact with the plasticizes.
CA 02349052 2001-05-29 , -Brief Description of the Drawings Figure 1 is a cross-sectional view of a floor covering according to an exemplary embodiment of the present invention; and Figure 2 is a cross-sectional view of a floor covering according to another exemplary embodiment of the present invention Description of the Preferred Embodiments The present invention is directed to a carpet product having a resin composition backing layer and a barrier layer for inhibiting the migration of moisture into the backing layer and the migration of backing layer constituents out of the backing layer. The carpet product may be of any suitable construction including tufted, woven and fusion-bonded carpets with backing layers susceptible to the detrimental effects of moisture. According to the present invention, the barrier layer is positioned between the backing layer and the subfloor to which the carpet is to be mounted. In particular, the barrier layer is placed between the backing layer and an 1 ~ adhesive layer formed on th.e underside of the carpet for adhering the carpet to the subfloor.
Turning now to the drawings, a carpet product 10 according to the present invention may be of tufted construction as shown in Figure 1. The carpet 10 includes a primary backing 12 to which tuft yarns 14 are attached to form the face surface 16 of the carpet. The tuft yarns 14 are attached so that a portion of the yarns 14 extend through and beneath the primary backing 12. A resin composition pre-coat layer 18 is applied to the backside of the primary backing 12 and to the lower portion of the tuft yarns 14 attached thereto. T'he pre-coat layer 18 serves to lock the tuft yarns 14 to the primary backing 12 and to adhere a secondary backing layer 20 to the primary backing 12. A barrier layer 22 formed of a material resistant to the migration of - backing layer constituents and moisture is adhered to the lower side of the secondary backing layer 20. A pressure-sensitive adhesive layer 24 having a releasable cover 26 is attached to the lower side of the barrier layer 22.
The secondary backing layer 20 may be formed from any resinous composition. Typically, the secondary backing layer 20 is formed from a polymer composition that may inchude polymers derived from at least one monomer from the group consisting of ethylene, propylene, isobutylene, styrene, vinyl acetate and vinyl chloride. The polymer composition may alternatively or in combination include a polymer selected from the group including but not limited to natural and synthetic rubbers, bitumen, polyurethane, polypropylene, polyvinyl chloride, polylactic acid, polyolefins, polyvinyl acetate and polyethylene-vinyl acetate. The backing layer 20 can be neat or blended resin and can also be loaded with organic or inorganic fillers.
The backing layer :?0 may incorporate a plasticizer for imparting flexibility to 1 ~ the backing layer 20. Any suitable plasticizer may be used including but not limited to general phthalate plasticizers, adipate plasticizers, trimellitate plasticizers, polymeric plasticizers, secondary plasticizers, citrate plasticizers and epoxidized soybean oil (ESO).
The barrier layer 2'.? is formed on the underside of the secondary backing layer 20 specifically to provide a barrier against moisture and against the migration of the constituents of the secondary backing layer 20 from the secondary backing layer 20 to the adhesive layer 24 or to a substrate supporting the carpet 10. The barrier layer 22 also acts as a barrier against the migration of chemicals from the substrate into the backing layer 20.
The barrier layer 2:2 is formed from a polymer composition selected for its effectiveness in inhibiting the migration of chemicals, for its capability as a moisture barrier and for its resistance to degradation over time. The chemicals against which the barrier is effective inchade such typical backing layer constituents as polymers, plasticizers, and processinf; aids. The barrier layer 22 is effective against polymers including but not limited to acrylics, copolymers of acrylic and/or methacrylic acid, polyurethanes, copolymers derived from aromatic polyester urethane emulsions or aliphatic polyester urethane emulsions, natural rubber, synthetic rubbers, block copolymers of synthetic rubbers, vinyl polymers including but not limited to vinyl IO acetates and polyvinyl acetates, polyisobutylene, polyolefins such as low density polyethylene (LDPE) and High density polyethylene (HDPE), polyamides, polyester polymers such as polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT) and polybutylene terephthalate (PBT), acrylic-styrene copolymers, acrylonitrile-styrene copolymers, vinylidene chloride-acrylonitrile copolymers, and combination thereof.
The barrier layer 22 is an effective migration barrier for the typical backing layer plasticizers discussed above and against processing aids and other constituents including but not limited to aliphatic hydrocarbons, fatty acids, residual monomers, alcohols and aromatic hydrocarbons.
The barrier layer material must be compatible with the adhesive used to form the adhesive: layer 24 and must form a good bond with both the adhesive layer 24 and the secondary backing layer 20. In particular, the bonds between the barrier layer 22 and the adhesive and secondary backing layers 20, 24 should be stronger than the bond between the adhesive layer 24 and the substrate. This assures that the barrier 2~ layer 22 and. the adhesive layer 24 will remain adhered to the carpet when the carpet is removed from the substrate for relocation or replacement. The barrier layer 22 should also be flexible to allow for processing and handling of the carpet 10.
The minimum thickness of the barrier layer 22 is determined by the relative effectiveness of the selected polymer material at inhibiting migration of moisture and backing layer constituents. A typical thickness may be between about 0.1 mils and about 10 mils depending o~n the composition of the barrier layer 22.
The barrier layer 2:2 can be applied by a number of different methods known to those skilled in the art. The specific method is usually dependent on the polymer material used. Emulsion polymers and solvent-based polymer systems are usually applied by knife and blade coaters, air knife coaters, bar coaters, roll coaters, reverse roll coaters, gravure coaters and other systems known to one skilled in the art. . Other polymers may require hot melt application. Hot melt application techniques include, but are not limited to, slot orifice coaters, roll coaters, and extrusion coaters. Some polymers may be applied by spraying the polymer on the lower surface of the secondary backing layer 20.
The barrier layer 2~'. may be cured by ultra-violet radiation, infrared radiation, hot air convection, heated plates, steam or air drying depending on the thickness of the layer and the type of polymer used.
The adhesive layer 24 may be formed from any pressure-sensitive adhesive having a high shear strength for preventing slippage between the carpet 10 and the ,underlying floor. The adhesive layer 24 preferably has a low tensile strength to facilitate removal and replacement of the carpet 10 by permitting peeling of the carpet 10 from the floor. A release cover 26 is releasably secured to the adhesive layer 24 to protect and maintain the tackiness of the adhesive prior to installation. To minimize wrinkling of the release cover 26 during winding onto a roll, the release cover 26 is . - CA 02349052 2001-05-29 preferably formed of a flexible, high stretch plastic material such as a linear low density polyethylene. Significantly, because of the effectiveness of the barrier layer 22 in preventing plasticizers and other backing layer constituents from reaching the adhesive layer 24, the adhesive material need not be selected for its resistance to degradation from such materials.
The carpet 10 is flexible and can easily be rolled for storage and handling.
The barrier layer 22 applieal between the secondary backing layer 20 and the adhesive layer 24 is thin and flexible and does not significantly affect the handling and installation of the carpet 10. The barrier layer 22, however, will substantially inhibit the migration of plasticizers and other materials from the secondary backing layer 20 or other carpet components to the adhesive layer 24 during storage and after installation In addition, once the carpet 10 is installed on a substrate, the barrier layer 22 prevents moisture from the substrate surface or from within the substrate from reaching the secondary backing layer 20. The barrier layer 22 also prevents any plasticizers from migrating out of the backing layer after installation, thereby substantially preventing the occurrence of saponification due to contact with substrate moisture.
As noted above, the barrier layer of the present invention may be used in any type of carpet construction. As shown in Figure 2, a woven carpet 50 according to the present invention may have a surface face 56 presented by a woven fabric 51 formed by warp and weft~yarns ~'?, 54. A resin composition layer 58 is used to coat the underside of the woven fabric 51 and penetrate the interstices of the warp and weft yarns ~2, ~4. A backing layer 60 formed of a resinous composition similar to that of the secondary backing layer 20 of the tufted carpet 10 is adhered to the lower surface of the resin composition layer 58. A barrier layer 62 formed of a material resistant to the migration of backing layer constituents and moisture is adhered to the lower side of the backing layer 60. ,a pressure-sensitive adhesive layer 24 having a releasable cover 26 is attached to the lower side of the barrier layer 22.
The constituents of t:he backing layer 60 may be selected from the materials described above for the secondary backing layer 20 of the tufted carpet 10.
The barrier layer 62 is similar to the barrier layer 22 of the tufted carpet 10 and acts to inhibit migration of the backing layer constituents from the backing layer 60.
The barrier layer 62 also preventa moisture within or on the surface of a substrate from making contact with the backing layer 60 or the backing layer constituents.
It will be readily understood by those persons skilled in the art that the present invention is susceptible to broad utility and application. Many embodiments and adaptations of the present invention other than those herein described, as well as many variations, modifications and equivalent arrangement, will be apparent from or reasonably suggested by the present invention and the foregoing description without departing from the substance or scope of the present invention.
Accordingly, while the present invention has been described in detail in relation to its preferred embodiment, it is to be understood that this disclosure is only illustrative and exemplary ofthe present invention and is made merely for purposes of providing a full and enablins; disclosure of the invention. The foregoing disclosure is not intended to be construed to limit the present invention or otherwise exclude any other embodiments, adaptations, variations, modifications or equivalent arrangements, the present invention being limited only by the claims and the equivalents thereof.
Title: FLOOR COVERING WITH MOISTURE AND PLASTICIZER
BARRIER LAYER
Inventor s : HAMMEL, Wallace J.;
EVANS, Paul D. Jr.;
RANDALL, Brian S
FLOOR COVERING WITH MOISTURE AND PLASTICIZER
BARR~R LAYER
Background Of The Invention Carpet having a shock absorbent resinous thermoplastic backing layer is commonly applied to hard Moor surfaces. The shock absorbent backing layer may be a secondary backing underlying a primary backing to which textile fibers are secured, as in a tufted carpet, or it may be a backing layer adhered to the backside of a fabric of warp_and weft yarns, as in <i waven carpet.
Carpets having such backing layers are subject to several detrimental effects due to the migration of moisture into the backing layer or due to the migration of certain constituents out of the backing layer. The detrimental effects due to moisture include dimensional instability of the backing layer which can cause the carpet to warp or wrinkle and chemical interaction of the moisture with backing layer components that can changf: the physical characteristics of the backing layer or produce undesirable reaction products. A particular concern is the interaction of moisture with plasticizers in the backing layer because of the potential for a saponification reaction. Such a reaction produces an organic alcohol with a low vapor pressure, which allows th.e alcohol to pass into the atmosphere, thereby producing a negative effect on air quality in the vicinity of the carpet.
Migration of backing layer constituents out of the backing layer can also result in a change in the physical characteristics of the backing layer. Of particular concern is the migration of plasticizc:rs aut of the backing layer, which can render the backing layer stiff and inflexible. If an adhesive layer is applied to the back of the carpet, migration of plasticizers from the backing layer into the adhesive layer can degrade 2~ the effectiveness of the adheaive. Migration of plasticizers out of the backing layer may also present the possibility of interaction with moisture in the substrate that has not itself' migrated into the backing layer.
Summary Of The Invention T'uf3ed carpet products typically have a resin composition locking layer that locks the textile fibers to the primary backing. A secondary backing is then adhered to the locking layer. Woven carpet products have a woven textile layer to which a resin composition locking; layer is applied. A backing layer is then adhered to the resin composition locking; layer. In both types of carpet, moisture from the outer face side of the carpet may be substantially prevented from reaching the secondary backing layer (or the backing; layer in the case of woven carpets) by the resin composition layer. There is, however, no corresponding mechanism for preventing; moisture from the substrate side of the carpet from reaching the backing layer. Further, there is no mechanism for preventing backing material constituents from migrating out of the backing layer into lower layers of the carpet or into the substrate.
Accordingly, there is a need for a carpet product wherein migration of moisture into a backing layer of the carpet and migration of backing layer constituents out of a backing layer of the carpet are substantially inhibited.
It is therefore an oibjective of the present invention to provide a floor covering;
having; a harrier layer that inhibits the migration of moisture from a substrate into a backing layer of the floor covering.
It is also an objective of the present invention to provide a floor covering having a barrier layer that inhibits the migration of backing layer constituents from a backing; layer of the floor covering.
It is a further objective of the present invention to provide a floor covering barrier layer that inhibits the migration ofplasticizers from the backing layer to an adhesive layer or to a substrate.
It is yet another objective of the present invention to provide a floor covering with a barrier layer that is. compatible with presently used materials for carpet backing and adhesives.
It is still another objective of the present invention to provide a floor covering with a thin, flexible barrier layer that does not significantly affect the storage and installation of the floor covering.
To these ends, a floor covering for mounting to a substrate according to the present invention comprises textile fibers defining an upper surface and a resin composition layer adhered to at least a portion of the textile fibers. A
backing layer is adhered to the resin composition layer. The backing layer has an upper surface adjacent the resin composition layer and a lower surface. A barrier layer is adhered to the lower surface of the backing layer, the barrier layer having an upper barrier surface adjacent the backing layer and a lower barrier surface. The barrier layer is effective for substantially inhibiting migration of moisture from the substrate into the backing layer.
The barrier layer of a floor covering according to the present invention is preferably effective for substantially inhibiting migration of backing layer _constituents from the backing layer to the substrate. Such backing layer constituents may include a plasticizes. A plasticizes in a backing layer of a floor covering according to the present invention may be selected from the group consisting of phthalate plasticizers, adipate plasticizers and trimellitate plasticizers. A
plasticizes -, may also be selected from 'the group consisting of polymeric plasticizers, secondary plasticizers, citrate plastici:aers and epoxidized soybean oil.
The backing layer constituents of a floor covering according to the present invention may include a polymer composition including a polymer derived from at least one monomer selected from the group consisting of ethylene, propylene, isobutylene, styrene, vinyl .acetate and vinyl chloride. Further, the backing layer constituents may include a polymer composition including a polymer selected from the group consisting of bitumen, polyurethane, polyvinyl chloride, polylactic acid, polyolefins, polyvinyl acetate, and polyethylene-vinyl acetate. The backing 1~0 constituents may include a polymer composition derived from the group consisting of synthetic nibbers and natural rubbers. The backing layer may further include at least - ..........."_.
one filler material The barrier layer of a floor covering according to the present invention is preferably effective for substantially preventing substrate moisture from making contact with the backing layer constituents.
A floor covering according to the present invention may further comprise an adhesive layer attached to the lower barrier surface, the adhesive layer having an upper adhesive surface adjacent the lower barrier surface and a lower adhesive surface. The barrier layer o:Fthis floor covering is effective for substantially inhibiting migration of backing layer constituents from the backing layer to the adhesive layer.
~ release cover is preferably releasably attached to the lower adhesive surface.
The barrier layer of a floor covering according to the present invention may be ' ~ formed from polymers selected from the group consisting of acrylics, copolymers of acrylic acid, copolymers of methacrylic acid, acrylic-styrene copolymers, acrylonitrile-styrene copolyrners, vinyl polymers including but not limited to polyvinyl acetates and vinylidene chloride-acrylonitrile copolymers, and combinations thereof. Ln addition, the barrier layer may be formed from polymers selected from the group consisting of polyurethanes, copolymers derived from aromatic polyester urethane emulsions, copolymers derived from aliphatic polyester S urethane emulsions, and combinations thereof. The barrier layer may also be formed from polymers selected from the group consisting of natural rubber, synthetic rubbers, block copolymers of synthetic rubbers, polyolefins including but not limited to polyisobutylene, low density polyethylene, and high density polyethylene, and combinations thereof. The: barrier layer may also be formed from polymers selected from the group consisting of polyamides, polyesters including but not limited to polyethylene terephthalate, polytrimethylene terephthalate, polybutylene terephthalate, and combinations thereof. ' A floor covering according to the present invention may further comprise a primary backing to which the textile fibers are attached, the textile fibers extending 1 ~ outward from the primary backing to define a tufted carpet face. The backing layer of this floor covering is adherE:d to the primary backing by the resin composition layer.
Alternatively, the textile fibers of a floor covering according to the present invention may be formed into interwoven warp and weft yarns. The backing layer of this floor covering is adhered by the resin composition layer to the interwoven warp and weft yarns.
In an illustrative embodiment of the present invention, a floor covering for mounting to a substrate comprises textile fibers defining an upper surface and a resin composition layer adhered to at least a portion of the textile fibers. A
backing layer adhered to the resin composition layer is formed from a polymer composition including a plasticizer and has an upper surface adjacent the resin composition layer and a lower surface. The floor covering further comprises a barrier layer adhered to the lower surface of the backing layer. The barrier layer has an upper barrier surface adjacent the backing layer and a lower barrier surface and is effective for substantially inhibiting migration of the plasticizer from the backing layer to the substrate.
In another illustrative embodiment of the present invention, a floor covering for mounting to a substratf; comprises textile fibers defining an upper surface and a resin composition layer adhered to at least a portion of the textile fibers. A
backing layer adhered to the resin composition layer is formed from a polymer composition including a plasticizer selected from the group consisting of phthalate plasticizers, adipate plasticizers and trirnellitate plasticizers. The backing layer has an upper surface adjacent the resin composition layer and a lower surface. The floor covering further comprises a barrier layer adhered to the lower surface of the backing layer.
The barrier layer has an upper barrier surface adjacent the backing layer and a lower l 5 barrier surface. An adhesive Layer is attached to the lower barrier surface and has an upper adhesive surface adjacent the lower barrier surface and a lower barrier surface.
The barrier layer is effectivE: for substantially preventing substrate moisture from making contact with the plasticizer.
In yet another illustrative embodiment of the present invention, a floor covering for mounting to a substrate comprises a primary backing layer with textile f tiers attached to the primary backing and extending outward therefrom to define a tufted carpet face. The floor covering further comprises a resin composition layer adhered to the primary backing and at least a portion of the textile fibers. A
secondary backing layer is adhered to the resin composition layer. The secondary backing layer is formed from, a polymer composition including a plasticizer selected from the group consisting ofphthalate plasticizers, adipate plasticizers and trimellitate plasticizers, and has an upper surface adjacent the resin composition layer and a lower surface. A barrier layer is adhered to the lower surface of the secondary backing layer, the barrier layer having an upper barrier surface adjacent the secondary backing layer and a lower barrier surface. An adhesive layer is attached to the lower barrier surface, the adhesive layer having an upper adhesive surface adjacent the lower barrier surface and a lower adhesive surface. The barrier layer is effective for substantially inhibiting migration of the plasticizer from the secondary backing layer to the adhesive layer and for substantially preventing substrate moisture from making contact with the plasticizf:r.
In still another illustrative embodiment ofthe present invention, a floor covering for mounting to a substrate comprises interwoven warp and weft yarns formed from textile fibers and defining a face surface. A resin composition layer is adhered to at least a portion of the interwoven warp and weft yarns and a backing layer is adhered to the resin composition layer. The backing layer is formed from a polymer composition including a plasticizer selected from the group consisting of phthalate plasticizers, adipate plasticizers and trimellitate plasticizers, and has an upper surface adjacent the resin composition layer and a lower surface. The floor covering further comprises a barrier layer adhered to the lower surface of the backing layer, the barrier layer having an upper barrier surface adjacent the backing layer and a lower barrier surface. A:n adhesive layer is attached to the lower barrier surface, the adhesive layer having an upper adhesive surface adjacent the lower barrier surface and a lower adhesive surface. The barrier layer is effective for substantially inhibiting migration of the plasticizes from the backing layer to the adhesive layer and for substantially preventing substrate moisture from making contact with the plasticizes.
CA 02349052 2001-05-29 , -Brief Description of the Drawings Figure 1 is a cross-sectional view of a floor covering according to an exemplary embodiment of the present invention; and Figure 2 is a cross-sectional view of a floor covering according to another exemplary embodiment of the present invention Description of the Preferred Embodiments The present invention is directed to a carpet product having a resin composition backing layer and a barrier layer for inhibiting the migration of moisture into the backing layer and the migration of backing layer constituents out of the backing layer. The carpet product may be of any suitable construction including tufted, woven and fusion-bonded carpets with backing layers susceptible to the detrimental effects of moisture. According to the present invention, the barrier layer is positioned between the backing layer and the subfloor to which the carpet is to be mounted. In particular, the barrier layer is placed between the backing layer and an 1 ~ adhesive layer formed on th.e underside of the carpet for adhering the carpet to the subfloor.
Turning now to the drawings, a carpet product 10 according to the present invention may be of tufted construction as shown in Figure 1. The carpet 10 includes a primary backing 12 to which tuft yarns 14 are attached to form the face surface 16 of the carpet. The tuft yarns 14 are attached so that a portion of the yarns 14 extend through and beneath the primary backing 12. A resin composition pre-coat layer 18 is applied to the backside of the primary backing 12 and to the lower portion of the tuft yarns 14 attached thereto. T'he pre-coat layer 18 serves to lock the tuft yarns 14 to the primary backing 12 and to adhere a secondary backing layer 20 to the primary backing 12. A barrier layer 22 formed of a material resistant to the migration of - backing layer constituents and moisture is adhered to the lower side of the secondary backing layer 20. A pressure-sensitive adhesive layer 24 having a releasable cover 26 is attached to the lower side of the barrier layer 22.
The secondary backing layer 20 may be formed from any resinous composition. Typically, the secondary backing layer 20 is formed from a polymer composition that may inchude polymers derived from at least one monomer from the group consisting of ethylene, propylene, isobutylene, styrene, vinyl acetate and vinyl chloride. The polymer composition may alternatively or in combination include a polymer selected from the group including but not limited to natural and synthetic rubbers, bitumen, polyurethane, polypropylene, polyvinyl chloride, polylactic acid, polyolefins, polyvinyl acetate and polyethylene-vinyl acetate. The backing layer 20 can be neat or blended resin and can also be loaded with organic or inorganic fillers.
The backing layer :?0 may incorporate a plasticizer for imparting flexibility to 1 ~ the backing layer 20. Any suitable plasticizer may be used including but not limited to general phthalate plasticizers, adipate plasticizers, trimellitate plasticizers, polymeric plasticizers, secondary plasticizers, citrate plasticizers and epoxidized soybean oil (ESO).
The barrier layer 2'.? is formed on the underside of the secondary backing layer 20 specifically to provide a barrier against moisture and against the migration of the constituents of the secondary backing layer 20 from the secondary backing layer 20 to the adhesive layer 24 or to a substrate supporting the carpet 10. The barrier layer 22 also acts as a barrier against the migration of chemicals from the substrate into the backing layer 20.
The barrier layer 2:2 is formed from a polymer composition selected for its effectiveness in inhibiting the migration of chemicals, for its capability as a moisture barrier and for its resistance to degradation over time. The chemicals against which the barrier is effective inchade such typical backing layer constituents as polymers, plasticizers, and processinf; aids. The barrier layer 22 is effective against polymers including but not limited to acrylics, copolymers of acrylic and/or methacrylic acid, polyurethanes, copolymers derived from aromatic polyester urethane emulsions or aliphatic polyester urethane emulsions, natural rubber, synthetic rubbers, block copolymers of synthetic rubbers, vinyl polymers including but not limited to vinyl IO acetates and polyvinyl acetates, polyisobutylene, polyolefins such as low density polyethylene (LDPE) and High density polyethylene (HDPE), polyamides, polyester polymers such as polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT) and polybutylene terephthalate (PBT), acrylic-styrene copolymers, acrylonitrile-styrene copolymers, vinylidene chloride-acrylonitrile copolymers, and combination thereof.
The barrier layer 22 is an effective migration barrier for the typical backing layer plasticizers discussed above and against processing aids and other constituents including but not limited to aliphatic hydrocarbons, fatty acids, residual monomers, alcohols and aromatic hydrocarbons.
The barrier layer material must be compatible with the adhesive used to form the adhesive: layer 24 and must form a good bond with both the adhesive layer 24 and the secondary backing layer 20. In particular, the bonds between the barrier layer 22 and the adhesive and secondary backing layers 20, 24 should be stronger than the bond between the adhesive layer 24 and the substrate. This assures that the barrier 2~ layer 22 and. the adhesive layer 24 will remain adhered to the carpet when the carpet is removed from the substrate for relocation or replacement. The barrier layer 22 should also be flexible to allow for processing and handling of the carpet 10.
The minimum thickness of the barrier layer 22 is determined by the relative effectiveness of the selected polymer material at inhibiting migration of moisture and backing layer constituents. A typical thickness may be between about 0.1 mils and about 10 mils depending o~n the composition of the barrier layer 22.
The barrier layer 2:2 can be applied by a number of different methods known to those skilled in the art. The specific method is usually dependent on the polymer material used. Emulsion polymers and solvent-based polymer systems are usually applied by knife and blade coaters, air knife coaters, bar coaters, roll coaters, reverse roll coaters, gravure coaters and other systems known to one skilled in the art. . Other polymers may require hot melt application. Hot melt application techniques include, but are not limited to, slot orifice coaters, roll coaters, and extrusion coaters. Some polymers may be applied by spraying the polymer on the lower surface of the secondary backing layer 20.
The barrier layer 2~'. may be cured by ultra-violet radiation, infrared radiation, hot air convection, heated plates, steam or air drying depending on the thickness of the layer and the type of polymer used.
The adhesive layer 24 may be formed from any pressure-sensitive adhesive having a high shear strength for preventing slippage between the carpet 10 and the ,underlying floor. The adhesive layer 24 preferably has a low tensile strength to facilitate removal and replacement of the carpet 10 by permitting peeling of the carpet 10 from the floor. A release cover 26 is releasably secured to the adhesive layer 24 to protect and maintain the tackiness of the adhesive prior to installation. To minimize wrinkling of the release cover 26 during winding onto a roll, the release cover 26 is . - CA 02349052 2001-05-29 preferably formed of a flexible, high stretch plastic material such as a linear low density polyethylene. Significantly, because of the effectiveness of the barrier layer 22 in preventing plasticizers and other backing layer constituents from reaching the adhesive layer 24, the adhesive material need not be selected for its resistance to degradation from such materials.
The carpet 10 is flexible and can easily be rolled for storage and handling.
The barrier layer 22 applieal between the secondary backing layer 20 and the adhesive layer 24 is thin and flexible and does not significantly affect the handling and installation of the carpet 10. The barrier layer 22, however, will substantially inhibit the migration of plasticizers and other materials from the secondary backing layer 20 or other carpet components to the adhesive layer 24 during storage and after installation In addition, once the carpet 10 is installed on a substrate, the barrier layer 22 prevents moisture from the substrate surface or from within the substrate from reaching the secondary backing layer 20. The barrier layer 22 also prevents any plasticizers from migrating out of the backing layer after installation, thereby substantially preventing the occurrence of saponification due to contact with substrate moisture.
As noted above, the barrier layer of the present invention may be used in any type of carpet construction. As shown in Figure 2, a woven carpet 50 according to the present invention may have a surface face 56 presented by a woven fabric 51 formed by warp and weft~yarns ~'?, 54. A resin composition layer 58 is used to coat the underside of the woven fabric 51 and penetrate the interstices of the warp and weft yarns ~2, ~4. A backing layer 60 formed of a resinous composition similar to that of the secondary backing layer 20 of the tufted carpet 10 is adhered to the lower surface of the resin composition layer 58. A barrier layer 62 formed of a material resistant to the migration of backing layer constituents and moisture is adhered to the lower side of the backing layer 60. ,a pressure-sensitive adhesive layer 24 having a releasable cover 26 is attached to the lower side of the barrier layer 22.
The constituents of t:he backing layer 60 may be selected from the materials described above for the secondary backing layer 20 of the tufted carpet 10.
The barrier layer 62 is similar to the barrier layer 22 of the tufted carpet 10 and acts to inhibit migration of the backing layer constituents from the backing layer 60.
The barrier layer 62 also preventa moisture within or on the surface of a substrate from making contact with the backing layer 60 or the backing layer constituents.
It will be readily understood by those persons skilled in the art that the present invention is susceptible to broad utility and application. Many embodiments and adaptations of the present invention other than those herein described, as well as many variations, modifications and equivalent arrangement, will be apparent from or reasonably suggested by the present invention and the foregoing description without departing from the substance or scope of the present invention.
Accordingly, while the present invention has been described in detail in relation to its preferred embodiment, it is to be understood that this disclosure is only illustrative and exemplary ofthe present invention and is made merely for purposes of providing a full and enablins; disclosure of the invention. The foregoing disclosure is not intended to be construed to limit the present invention or otherwise exclude any other embodiments, adaptations, variations, modifications or equivalent arrangements, the present invention being limited only by the claims and the equivalents thereof.
Claims (43)
1. A floor covering for mounting to a substrate, the floor covering comprising:
textile fibers defining an upper surface;
a resin composition layer adhered to at least a portion of the textile fibers;
a backing layer adhered to the resin composition layer, the backing layer having an upper surface adjacent the resin composition layer and a lower surface; and a barrier layer adhered to the lower surface of the backing layer, the barrier layer having an upper barrier surface adjacent the backing layer and a lower barrier surface, the barrier layer being effective for substantially inhibiting migration of moisture from the substrate into the backing layer.
textile fibers defining an upper surface;
a resin composition layer adhered to at least a portion of the textile fibers;
a backing layer adhered to the resin composition layer, the backing layer having an upper surface adjacent the resin composition layer and a lower surface; and a barrier layer adhered to the lower surface of the backing layer, the barrier layer having an upper barrier surface adjacent the backing layer and a lower barrier surface, the barrier layer being effective for substantially inhibiting migration of moisture from the substrate into the backing layer.
2. A floor covering according to claim 1 wherein the barrier layer is effective for substantially inhibiting migration of backing layer constituents from the backing layer to the substrate.
3. A floor covering according to claim 2 wherein the backing layer constituents include a plasticizer.
4. A floor covering according to claim 3 wherein the plasticizer is selected from the group consisting of phthalate plasticizers, adipate plasticizers and trimellitate plasticizers.
5. A floor covering according to claim 3 wherein the plasticizer is selected from the group consisting of polymeric plasticizers, secondary plasticizers, citrate plasticizers and epoxidized soybean oil.
6. A floor covering according to claim 3 wherein the backing layer constituents include a polymer composition derived from at least one monomer selected from the group consisting of ethylene, propylene, isobutylene, styrene, vinyl acetate and vinyl chloride
7. A floor covering according to claim 3 wherein the backing layer constituents include a polymer composition including a polymer selected from the group consisting of bitumen, polyurethane, polyvinyl chloride, polylactic acid, polyolefins, polyvinyl acetate and polyethylene-vinyl acetate.
8. A floor covering according to claim 3 wherein the backing layer constituents include a polymer composition derived from the group consisting of synthetic rubbers and natural rubbers.
9. A floor covering according to claim 3 wherein the barrier layer is effective for substantially preventing substrate moisture from making contact with the plasticizer.
10. A floor covering according to claim 1 further comprising an adhesive layer attached to the lower barrier surface, the adhesive layer having an upper adhesive surface adjacent the lower barrier surface and a lower adhesive surface, wherein the barrier layer is effective for substantially inhibiting migration of backing layer constituents from the backing layer to the adhesive layer.
11. A floor covering according to claim 10 further comprising a release cover releasably attached to the lower adhesive surface.
12. A floor covering according to claim 1 wherein the backing layer includes at least one filler material.
13. A floor covering according to claim 1 wherein the barrier layer is formed from polymers selected from the group consisting of acrylics, copolymers of acrylic acid, copolymers of methacrylic acid, acrylic-styrene copolymers, acrylonitrile-styrene copolymers, vinyl polymers, vinyl acetates, polyvinyl acetates, vinylidene chloride-acrylonitrile copolymers, and combinations thereof.
14. A floor covering according to claim 1 wherein the barrier layer is formed from polymers selected from the group consisting of polyurethanes, copolymers derived from aromatic polyester urethane emulsions, copolymers derived from aliphatic polyester urethane emulsions, and combinations thereof.
15. A floor covering according to claim 1 wherein the barrier layer is formed from polymers selected from the group consisting of natural rubber, synthetic rubbers, block copolymers of synthetic rubbers, polyolefins, polyisobutylene, low density polyethylene, high density polyethylene, and combinations thereof.
16. A floor covering according to claim 1 wherein the barrier layer is formed from polymers selected from the group consisting of polyamides, polyesters, polyethylene terephthalate, polytrimethylene terephthalate, polybutylene terephthalate, and combinations thereof.
17. A floor covering according to claim 1 further comprising a primary backing to which the textile fibers are attached, the textile fibers extending outward from the primary backing to define a tufted carpet face, and wherein the backing layer is adhered to the primary backing by the resin composition layer.
18. A floor covering according to claim 1 wherein the textile fibers are formed into interwoven warp and weft yarns and the backing layer is adhered to the interwoven warp and weft yarns by the resin composition layer.
19. A floor covering for mounting to a substrate, the floor covering comprising:
textile fibers defining an upper surface;
a resin composition layer adhered to at least a portion of the textile fibers;
a backing layer adhered to the resin composition layer, the backing layer being formed from a polymer composition including a plasticizer and having an upper surface adjacent the resin composition layer and a lower surface;
and a barrier layer adhered to the lower surface of the backing layer, the barrier layer having an upper barrier surface adjacent the backing layer and a lower barrier surface;
wherein the barrier layer is effective for substantially inhibiting migration of the plasticizer from the backing layer to the substrate.
textile fibers defining an upper surface;
a resin composition layer adhered to at least a portion of the textile fibers;
a backing layer adhered to the resin composition layer, the backing layer being formed from a polymer composition including a plasticizer and having an upper surface adjacent the resin composition layer and a lower surface;
and a barrier layer adhered to the lower surface of the backing layer, the barrier layer having an upper barrier surface adjacent the backing layer and a lower barrier surface;
wherein the barrier layer is effective for substantially inhibiting migration of the plasticizer from the backing layer to the substrate.
20. A floor covering according to claim 19 wherein the plasticizer is selected from the group consisting of phthalate plasticizers, adipate plasticizers and trimellitate plasticizers.
21. A floor covering according to claim 19 wherein the polymer composition includes a polymer derived from at least one monomer selected from the group consisting of ethylene, propylene, isobutylene, styrene, vinyl acetate and vinyl chloride.
22. A floor covering according to claim 19 wherein the barrier layer is formed from polymers selected from the group consisting of acrylics, copolymers of acrylic acid, copolymers of methacrylic acid, acrylic-styrene copolymers, acrylonitrile-styrene copolymers, vinyl polymers, vinyl acetates, polyvinyl acetates, vinylidene chloride-acrylonitrile copolymers, and combinations thereof.
23. A floor covering according to claim 19 wherein the barrier layer is formed from polymers selected from the group consisting of polyurethanes, copolymers derived from aromatic polyester urethane emulsions, copolymers derived from aliphatic polyester urethane emulsions, and combinations thereof.
24. A floor covering according to claim 19 wherein the barrier layer is formed from polymers selected from the group consisting of natural rubber, synthetic rubbers, block copolymers of synthetic rubbers, polyolefins, polyisobutylene, low density polyethylene, high density polyethylene, and combinations thereof.
25. A floor covering according to claim 19 wherein the barrier layer is formed from polymers selected from the group consisting of polyamides, polyesters, polyethylene terephthalate, polytrimethylene terephthalate, polybutylene terephthalate, and combinations thereof.
26. A floor covering according to claim 19 wherein the barrier layer is effective for substantially preventing substrate moisture from making contact with the plasticizer.
27. A floor covering according to claim 19 further comprising an adhesive layer attached to the lower barrier surface, the adhesive layer having an upper adhesive surface adjacent the lower barrier surface and a lower adhesive surface, wherein the barrier layer is effective for substantially inhibiting migration of the plasticizer from the backing layer to the adhesive layer.
28. A floor covering according to claim 27 further comprising a release cover releasably attached to the lower adhesive surface.
29. A floor covering for mounting to a substrate, the floor covering comprising:
textile fibers defining an upper surface;
a resin composition layer adhered to at least a portion of the textile fibers;
a backing layer adhered to the resin composition layer, the backing layer being formed from a polymer composition including a plasticizer selected from the group consisting of phthalate plasticizers, adipate plasticizers and trimellitate plasticizers, and having an upper surface adjacent the resin composition layer and a lower surface;
a barrier layer adhered to the lower surface of the backing layer, the barrier layer having an upper barrier surface adjacent the backing layer and a lower barrier surface; and an adhesive layer attached to the lower barrier surface, the adhesive layer having an upper adhesive surface adjacent the lower barrier surface and a lower adhesive surface, wherein the barrier layer is effective for substantially inhibiting migration of the plasticizer from the backing layer to the adhesive layer and for substantially preventing substrate moisture from making contact with the plasticizer.
textile fibers defining an upper surface;
a resin composition layer adhered to at least a portion of the textile fibers;
a backing layer adhered to the resin composition layer, the backing layer being formed from a polymer composition including a plasticizer selected from the group consisting of phthalate plasticizers, adipate plasticizers and trimellitate plasticizers, and having an upper surface adjacent the resin composition layer and a lower surface;
a barrier layer adhered to the lower surface of the backing layer, the barrier layer having an upper barrier surface adjacent the backing layer and a lower barrier surface; and an adhesive layer attached to the lower barrier surface, the adhesive layer having an upper adhesive surface adjacent the lower barrier surface and a lower adhesive surface, wherein the barrier layer is effective for substantially inhibiting migration of the plasticizer from the backing layer to the adhesive layer and for substantially preventing substrate moisture from making contact with the plasticizer.
30. A floor covering according to claim 29 wherein the barrier layer is formed from polymers selected from the group consisting of acrylics, copolymers of acrylic acid, copolymers of methacrylic acid, acrylic-styrene copolymers, acrylonitrile-styrene copolymers, vinyl polymers, vinyl acetates, polyvinyl acetates, vinylidene chloride-acrylonitrile copolymers, and combinations thereof.
31. A flour covering according to claim 29 wherein the barrier layer is formed from polymers selected from the group consisting of polyurethanes, copolymers derived from aromatic polyester urethane emulsions, copolymers derived from aliphatic polyester urethane emulsions, and combinations thereof.
32. A floor covering according to claim 29 wherein the barrier layer is formed from polymers selected from the group consisting of natural rubber, synthetic rubbers, block copolymers of synthetic rubbers, polyolefins, polyisobutylene, low density polyethylene, high density polyethylene, and combinations thereof.
33. A floor covering according to claim 29 wherein the barrier layer is formed from polymers selected from the group consisting of polyamides, polyesters, polyethylene terephthalate, polytrimethylene terephthalate, polybutylene terephthalate, and combinations thereof.
34. A floor covering for mounting to a substrate, the floor covering comprising:
a primary backing layer;
textile fibers attached to the primary backing and extending outward therefrom to define a tufted carpet face;
a resin composition layer adhered to the primary backing and at least a portion of the textile fibers;
a secondary backing layer adhered to the resin composition layer, the secondary backing layer being formed from a polymer composition including a plasticizer selected from the group consisting of phthalate plasticizers, adipate plasticizers and trimellitate plasticizers, and having an upper surface adjacent the resin composition layer and a lower surface;
a barrier layer adhered to the lower surface of the secondary backing layer, the barrier layer having an upper barrier surface adjacent the secondary backing layer and a lower barrier surface; and an adhesive layer attached to the lower barrier surface, the adhesive layer having an upper adhesive surface adjacent the lower barrier surface and a lower adhesive surface, wherein the barrier layer is effective for substantially inhibiting migration of the plasticizer from the secondary backing layer to the adhesive layer and for substantially preventing substrate moisture from making contact with the plasticizer.
a primary backing layer;
textile fibers attached to the primary backing and extending outward therefrom to define a tufted carpet face;
a resin composition layer adhered to the primary backing and at least a portion of the textile fibers;
a secondary backing layer adhered to the resin composition layer, the secondary backing layer being formed from a polymer composition including a plasticizer selected from the group consisting of phthalate plasticizers, adipate plasticizers and trimellitate plasticizers, and having an upper surface adjacent the resin composition layer and a lower surface;
a barrier layer adhered to the lower surface of the secondary backing layer, the barrier layer having an upper barrier surface adjacent the secondary backing layer and a lower barrier surface; and an adhesive layer attached to the lower barrier surface, the adhesive layer having an upper adhesive surface adjacent the lower barrier surface and a lower adhesive surface, wherein the barrier layer is effective for substantially inhibiting migration of the plasticizer from the secondary backing layer to the adhesive layer and for substantially preventing substrate moisture from making contact with the plasticizer.
35. A floor covering according to claim 34 wherein the barrier layer is formed from polymers selected from the group consisting of acrylics, copolymers of acrylic acid, copolymers of methacrylic acid, acrylic-styrene copolymers, acrylonitrile-styrene copolymers, vinyl polymers, vinyl acetates, polyvinyl acetates, vinylidene chloride-acrylonitrile copolymers, and combinations thereof.
36. A floor covering according to claim 34 wherein the barrier layer is formed from polymers selected from the group consisting of polyurethanes, copolymers derived from aromatic polyester urethane emulsions, copolymers derived from aliphatic polyester urethane emulsions, and combinations thereof.
37. A floor covering according to claim 34 wherein the barrier layer is formed from polymers selected from the group consisting of natural rubber, synthetic rubbers, block copolymers of synthetic rubbers, polyolefins, polyisobutylene, low density polyethylene, high density polyethylene, and combinations thereof.
38. A floor covering according to claim 34 wherein the barrier layer is formed from polymers selected from the group consisting of polyamides, polyesters, polyethylene terephthalate, polytrimethylene terephthalate, polybutylene terephthalate, and combinations thereof.
39. A floor covering for mounting to a substrate, the floor covering comprising:
interwoven warp and weft yarns formed from textile fibers and defining a face surface;
a resin composition layer adhered to at least a portion of the interwoven warp and weft yarns;
a backing layer adhered to the resin composition layer, the backing layer being formed from a polymer composition including a plasticizer selected from the group consisting of phthalate plasticizers, adipate plasticizers and trimellitate plasticizers, and having an upper surface adjacent the resin composition layer and a lower surface;
a barrier layer adhered to the lower surface of the backing layer, the barrier layer having an upper barrier surface adjacent the backing layer and a lower barrier surface; and an adhesive layer attached to the lower barrier surface, the adhesive layer having an upper adhesive surface adjacent the lower barrier surface and a lower adhesive surface, wherein the barrier layer is effective for substantially inhibiting migration of the plasticizer from the backing layer to the adhesive layer and for substantially preventing substrate moisture from making contact with the plasticizer.
interwoven warp and weft yarns formed from textile fibers and defining a face surface;
a resin composition layer adhered to at least a portion of the interwoven warp and weft yarns;
a backing layer adhered to the resin composition layer, the backing layer being formed from a polymer composition including a plasticizer selected from the group consisting of phthalate plasticizers, adipate plasticizers and trimellitate plasticizers, and having an upper surface adjacent the resin composition layer and a lower surface;
a barrier layer adhered to the lower surface of the backing layer, the barrier layer having an upper barrier surface adjacent the backing layer and a lower barrier surface; and an adhesive layer attached to the lower barrier surface, the adhesive layer having an upper adhesive surface adjacent the lower barrier surface and a lower adhesive surface, wherein the barrier layer is effective for substantially inhibiting migration of the plasticizer from the backing layer to the adhesive layer and for substantially preventing substrate moisture from making contact with the plasticizer.
40. A floor covering according to claim 39 wherein the barrier layer is formed from polymers selected from the group consisting of acrylics, copolymers of acrylic acid, copolymers of methacrylic acid, acrylic-styrene copolymers, acrylonitrile-styrene copolymers, vinyl polymers, vinyl acetates, polyvinyl acetates, vinylidene chloride-acrylonitrile copolymers, and combinations thereof.
41. A floor covering according to claim 39 wherein the barrier layer is formed from polymers selected from the group consisting of polyurethanes, copolymers derived from aromatic polyester urethane emulsions, copolymers derived from aliphatic polyester urethane emulsions, and combinations thereof.
42. A floor covering according to claim 39 wherein the barrier layer is formed from polymers selected from the group consisting of natural rubber, synthetic rubbers, block copolymers of synthetic rubbers, polyolefins, polyisobutylene, low density polyethylene, high density polyethylene, and combinations thereof.
43. A floor covering according to claim 39 wherein the barrier layer is formed from polymers selected from the group consisting of polyamides, polyesters, polyethylene terephthalate, polytrimethylene terephthalate, polybutylene terephthalate, and combinations thereof.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US63740800A | 2000-08-11 | 2000-08-11 | |
| US09/637,408 | 2000-08-11 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2349052A1 true CA2349052A1 (en) | 2002-02-11 |
Family
ID=24555793
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2349052 Abandoned CA2349052A1 (en) | 2000-08-11 | 2001-05-29 | Floor covering with moisture and plasticizer barrier layer |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2349052A1 (en) |
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2010142325A1 (en) * | 2009-06-09 | 2010-12-16 | Tarkett G.D.L. S.A. | Multilayer surface coating with barrier layer |
| WO2012049003A3 (en) * | 2010-10-12 | 2012-06-07 | Tarkett Gdl | Process for the production of a pvc- based surface covering having a top coating layer |
| CN104246060A (en) * | 2012-04-24 | 2014-12-24 | 纳幕尔杜邦公司 | Compositions comprising poly(trimethylene terephthalate) and thermoplastic polyolefin and processes using the compositions |
| EP2955013A1 (en) | 2014-04-16 | 2015-12-16 | Copaco N.V. | Dimensional stable flooring materials and its intermediates |
-
2001
- 2001-05-29 CA CA 2349052 patent/CA2349052A1/en not_active Abandoned
Cited By (11)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2010142325A1 (en) * | 2009-06-09 | 2010-12-16 | Tarkett G.D.L. S.A. | Multilayer surface coating with barrier layer |
| CN102459431A (en) * | 2009-06-09 | 2012-05-16 | 塔克特Gdl股份有限公司 | Multilayer surface coating with barrier layer |
| CN102459431B (en) * | 2009-06-09 | 2013-08-28 | 塔克特Gdl股份有限公司 | Multilayer surface coating with barrier layer |
| RU2516109C2 (en) * | 2009-06-09 | 2014-05-20 | Таркетт Г.Д.Л. С.А. | Sandwiched surface coat with barrier ply |
| US8795827B2 (en) | 2009-06-09 | 2014-08-05 | Tarkett G.D.L. S.A. | Multilayer surface covering with barrier layer |
| AU2009347572B2 (en) * | 2009-06-09 | 2014-10-30 | Tarkett G.D.L. S.A. | Multilayer surface coating with barrier layer |
| WO2012049003A3 (en) * | 2010-10-12 | 2012-06-07 | Tarkett Gdl | Process for the production of a pvc- based surface covering having a top coating layer |
| US9103129B2 (en) | 2010-10-12 | 2015-08-11 | Tarkett Gdl | Process for the production of a surface covering having a barrier layer |
| RU2573901C2 (en) * | 2010-10-12 | 2016-01-27 | Таркетт Гдл | Method for obtaining surface coating, which has protective layer |
| CN104246060A (en) * | 2012-04-24 | 2014-12-24 | 纳幕尔杜邦公司 | Compositions comprising poly(trimethylene terephthalate) and thermoplastic polyolefin and processes using the compositions |
| EP2955013A1 (en) | 2014-04-16 | 2015-12-16 | Copaco N.V. | Dimensional stable flooring materials and its intermediates |
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