High-strength, low-cost, recyclable backing for fabrics and method for making same

Abstract

A backing material is made of low-density and/or high-density polyethylene(s) and/or a flexibilizer to provide high-strength, low-cost, and recyclable backing material for fabrics. The backing material can incorporate polypropylene(s), additional flexibilizers, fillers, flame-retardants, anti-microbials, odor minimizers/eliminators, scent, and protectants for further desired properties.

1 - 44 . (canceled)  
   
   
       45 . A composition comprising a blend of: 
 a flexibilizer; and    a low density polyethylene having a melt index greater than about 1,000.    
   
   
       46 . The composition  claim 45 , wherein said blend is a melt blend.  
   
   
       47 . The composition of  claim 45 , wherein said low density polyethylene has at least one of the properties of a number average molecular weight less than about 10,000, a weight average molecular weight less than about 35,000, or a specific gravity less than or equal to 0.92.  
   
   
       48 . The composition of  claim 45 , wherein said low density polyethylene has a specific gravity less than or equal to 0.92.  
   
   
       49 . The composition of  claim 45 , wherein said flexibilizer comprises at least one of a thermoplastic elastomer, a thermoplastic rubber, a contained geometry catalyzed low-density polyethylene, ethylene methylacrylate, ethylene vinyl acetate and ethylene butyl modified polyethylene.  
   
   
       50 . The composition of  claim 45  further comprising at least one filler.  
   
   
       51 . The composition of  claim 50 , wherein said at least one filler comprises at least one of magnesium hydroxide, Portland cement, calcium carbonate and calcium oxide.  
   
   
       52 . The composition of  claim 45  further comprising a dispersant.  
   
   
       53 . The composition of  claim 52 , wherein said dispersant is magnesium stearate or calcium stearate.  
   
   
       54 . The composition of  claim 45 , wherein said composition is in the form of blocks, billets or pellets.  
   
   
       55 . A method comprising forming a blend of a flexibilizer and a low density polyethylene having a melt index greater than about 1,000.  
   
   
       56 . The method of  claim 55 , wherein said blend is formed by melting said flexibilizer and said low density polyethylene.  
   
   
       57 . The method  claim 56 , wherein said melting is performed by extruding said flexibilizer and said low density polyethylene.  
   
   
       58 . The method of  claim 55 , wherein said low density polyethylene has at least one of the properties of a number average molecular weight less than about 10,000, a weight average molecular weight less than about 35,000, or a specific gravity less than 0.92.  
   
   
       59 . The method of  claim 55 , wherein said low density polyethylene has a specific gravity less than 0.92.  
   
   
       60 . The method of  claim 55 , wherein said flexibilizer comprises at least one of a thermoplastic elastomer, a thermoplastic rubber, a contained geometry catalyzed low-density polyethylene, ethylene methylacrylate, ethylene vinyl acetate and ethylene butyl modified polyethylene.  
   
   
       61 . The method of  claim 55 , wherein said blend further comprises at least one filler.  
   
   
       62 . The method of  claim 61 , wherein said at least one filler comprises at least one of magnesium hydroxide, Portland cement, calcium carbonate and calcium oxide.  
   
   
       63 . The method of  claim 55 , wherein said blend further comprises a dispersant.  
   
   
       64 . The method of  claim 63 , wherein said dispersant is magnesium stearate or calcium stearate.  
   
   
       65 . The method of  claim 55  further comprising forming said blend into blocks, billets or pellets.  
   
   
       66 . The method of  claim 65  further comprising extruding said blocks, billets or pellets of said blend to form a layer.  
   
   
       67 . A method comprising: 
 melting blocks, billets or pellets of a composition comprising a flexibilizer and a low density polyethylene having a melt index greater than about 1,000 to form a blend;    preheating a substrate; and    applying said blend to said preheated substrate.    
   
   
       68 . The method of  claim 67 , wherein said substrate is a textile material.  
   
   
       69 . The method of  claim 67 , wherein said substrate is a carpet.  
   
   
       70 . The method of  claim 67 , wherein said substrate is a carpet tile.  
   
   
       71 . The method of  claim 67 , wherein said composition is melted and blended in an extruder.