Production of backing component for carpet products

Abstract

Disclosed are plastic compositions for a carpet backing having from about 5 to about 25% by weight PVC resin, from about 5 to about 25% by weight plasticizer, and from about 50 to about 90% by weight filler. In a preferred embodiment, the plastic composition is about 15% by weight Geon-138, about 15% by weight di-isononyl phthalate, and about 70% by weight fly ash. Also disclosed are methods for forming backings for floorcoverings using the disclosed plastic compositions. In preferred embodiments, a plastic composition is applied through a slot-die directly to the underside of a carpet or alternatively onto a conveyor belt on top of which the carpet or floorcovering may be subsequently positioned.

1 - 20 . (canceled) 
   
   
       21 . A method for forming a floorcovering comprising:
 a. preparing a plastic composition by mixing from about 5 to about 25% by weight PVC resin, from about 5 to about 25% by weight plasticizer, and from about 50 to about 90% by weight filler; and   b. forming the plastic composition into a backing layer by feeding the plastic composition through a slot-die.   
   
   
       22 . The method of  claim 21 , wherein the plastic composition is prepared in a holding tank and pumped from the holding tank to the slot die through a gear pump. 
   
   
       23 . The method of  claim 21 , wherein:
 a. the plasticizer is selected from the group consisting of di-isononyl phthalate, di-isoheptyl phthalate, di-isoundecyl phthalate and combinations thereof; and   b. the filler is selected from the group consisting of fly ash, dirt, calcium carbonate and combinations thereof.   
   
   
       24 . The method of  claim 23 , wherein the plastic composition comprises about 15% by weight PVC resin, about 15% by weight di-isononyl phthalate, and about 70% by weight fly ash. 
   
   
       25 . The method of  claim 21 , wherein the backing layer exiting the slot-die is positioned directly onto a conveyor belt. 
   
   
       26 . The method of  claim 25 , further comprising positioning a face of the floorcovering above the backing layer. 
   
   
       27 . The method of  claim 26 , further comprising positioning a stabilizing layer between the backing layer and the face. 
   
   
       28 . The method of  claim 27 , wherein the floorcovering comprises carpet. 
   
   
       29 . The method of  claim 21 , wherein the backing layer exiting the slot-die is positioned on the underside of a face of the floorcovering. 
   
   
       30 . The method of  claim 29 , wherein the floorcovering comprises carpet.