Recyclable Single Polymer Floorcovering Article

Abstract

This invention relates to tufted floorcovering articles, including carpet tiles and broadloom carpet. In particular, this invention relates to tufted floorcovering articles made from the family of polymers known as polyester. Specifically, this invention relates to tufted carpet tile products made from polyester. The polyester carpet tiles meet commercial performance specifications and are fully end-of-life recyclable.

What is claimed is: 
     
         1 . A polyester floorcovering article comprised of:
 (a) polyester pile yarn;   (b) a spunbond nonwoven polyester primary backing layer;   (c) a first layer of polyester hot melt adhesive having a certain viscosity, wherein the hot melt adhesive is comprised of at least 50% recycled material;   (d) a second layer of polyester hot melt adhesive having a viscosity or molecular weight that is three to five times higher than the viscosity or molecular weight of layer “c;” and   (e) a polyester needlepunch nonwoven secondary backing layer.   
     
     
         2 . The floorcovering article of  claim 1 , wherein the article exhibits a solution intrinsic viscosity of greater than 0.50 dl/g when tested according to ASTM D4603 and an ash content of less than 0.25% when tested according to ASTM D5630. 
     
     
         3 . The floorcovering article of  claim 1 , wherein the article exhibits a Velcro Roller Fuzzing value of greater than 3 when tested according to ITTS 112. 
     
     
         4 . The floorcovering article of  claim 1 , wherein the article exhibits a Resistance to Delamination value of greater than 12 pounds when tested according to ASTM D3936. 
     
     
         5 . The floorcovering article of  claim 1 , wherein the article exhibits Aachen dimensional stability of less than +/−0.1% change when tested according to ISO 2551. 
     
     
         6 . A floorcovering article comprised of:
 (a) a layer of polyester yarn selected from the group consisting of loop pile, cut pile, or a combination of loop and cut pile;   (b) a layer of polyester primary backing layer selected from the group consisting of spunbond nonwoven, stitchbonded nonwoven, woven tape, and needlepunch nonwoven;   (c) a layer of polyester adhesive having a certain viscosity;   (d) a layer of polyester adhesive having viscosity at least two times greater than the viscosity of layer “c;” and   (e) a layer of polyester secondary backing layer in the weight range of 200 gsm to 850 gsm.   
     
     
         7 . The floorcovering article of  claim 6 , wherein the article exhibits a solution intrinsic viscosity of greater than 0.50 dl/g when tested according to ASTM D4603 and an ash content of less than 0.25% when tested according to ASTM D5630. 
     
     
         8 . The floorcovering article of  claim 6 , wherein the article exhibits a Velcro Roller Fuzzing value of greater than 3 when tested according to ITTS 112. 
     
     
         9 . The floorcovering article of  claim 6 , wherein the article exhibits a Resistance to Delamination value of greater than 12 pounds when tested according to ASTM D3936. 
     
     
         10 . The floorcovering article of  claim 6 , wherein the article exhibits Aachen dimensional stability of less than +/−0.1% change when tested according to ISO 2551. 
     
     
         11 . The floorcovering article of  claim 6 , wherein at least one of layers “c” and “d” is a hot melt adhesive. 
     
     
         12 . The floorcovering article of  claim 6 , wherein layers “c” and “d” are independently selected from aqueous material and film material. 
     
     
         13 . The floorcovering article of  claim 6 , wherein the viscosity of layer “d” is from 2 to 10 times greater than the viscosity of layer “c.” 
     
     
         14 . The floorcovering article of  claim 6 , wherein the viscosity of layer “d” is from 2 to 8 times greater than the viscosity of layer “c.” 
     
     
         15 . The floorcovering article of  claim 6 , wherein the viscosity of layer “d” is from 2 to 5 times greater than the viscosity of layer “c.” 
     
     
         16 . The floorcovering article of  claim 6 , wherein the viscosity of layer “d” is from 3 to 5 times greater than the viscosity of layer “c.” 
     
     
         17 . A polyester floorcovering article comprised of:
 (a) 100% polyester yarn with a weight range of 15-60 oz/yd 2 ;   (b) a polyester woven tape primary backing layer;   (c) a polyester adhesive layer having viscosity in the range from 2100 cps to 8500 cps; and   (d) a secondary backing layer comprised of polyester.   
     
     
         18 . The polyester floorcovering article of  claim 17 , wherein the secondary backing layer is selected from the group consisting of polyester spunbonded, stitchbonded, needlepunched, hydroentangled, carded and thermally bonded materials. 
     
     
         19 . The polyester floorcovering article of  claim 17 , wherein the adhesive layer is comprised of a material selected from film, dispersion, powder, or hot melt. 
     
     
         20 . A floor covering article comprised substantially of 100% polyester material, wherein the article contains an average post-consumer recycle content in the range from 70% to 100% by weight, and wherein the article is fully recyclable at the end-of-life.