FLOOR COVERING FORMED FROM A RENEWABLE RESOURCE DERIVATIVE

CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of U.S. Application No. 60/728,537, filed October 20, 2005, and U.S. Application No. 60/731,189, filed October 28, 2005, each of which is incorporated by reference herein it its entirety.

BACKGROUND Most commercially available carpets and carpet backings are formed from materials derived from fossil fuels. For example, the wear surface often is made from an abrasion resistant and highly resilient fiber formed from nylon 6 or nylon 6,6 fibers, polypropylene, or polyester. Likewise, typical caipet backings are made from polymers derived from petroleum. Examples of polymers used to form carpet backings include, but are not limited to, styrene- butadiene rubber, VAE, polyvinyl chloride, polyurethane, bitumen, polyethylene, and so forth.

As the population of the world grows and as standards of living increase, the world energy demand will continue to rise. As such, there is an increasing need for products derived from renewable resources.

Although there has been some interest in developing such products, the difficulties associated with transforming the raw materials into a useful, effective end product have limited the use of renewable resource derivatives in many products. For example, GB 1260615 teaches the use of certain cellulose based polymers as a foamed carpet backing. However, the reference does not teach or suggest a process for doing so. Thus, there remains a need for products formed from one or more materials derived at least partially from renewable resources and processes for forming such products and materials.

SUMMARY

The present invention is directed generally to various floor coverings, components used in floor coverings, and methods of making such floor coverings and components. In one aspect, a floor covering comprises a plurality of floor covering components, where at least one of the plurality of floor covering components comprises a renewable resource derivative. In one variation, the renewable resource derivative is a rapidly renewable resource derivative, the plurality of floor covering components includes a first floor covering component comprising plurality of fibers, the first component comprises the rapidly renewable resource derivative, and the rapidly renewable resource comprises polylactic acid. In one particular example, the first floor covering component comprises at least about 25 wt % polylactic acid. In another example, the first floor covering component comprises at least about 50 wt % polylactic acid. In another variation, the plurality of floor covering components includes a backing, the backing comprises the renewable resource derivative, and the renewable resource derivative comprises a cellulose derivative. In one example, the backing comprises at least about 25 wt % cellulose derivative. In another example, the backing comprises at least about 50 wt % cellulose derivative.

In other variations, the floor covering of the invention comprises less than about 50 wt % fossil fuel derivative, less than about 25 wt % fossil fuel derivative, less than about 10 wt % fossil fuel derivative, or is substantially free of fossil fuel derivative. In another aspect of the invention, a floor covering includes a plurality of fibers comprising a first renewable resource derivative, a precoat layer securing the plurality of fibers to a primary backing, and a secondary backing substantially overlying the precoat layer. The precoat layer comprises a second renewable resource derivative, and the secondary backing comprises a third

renewable resource derivative. In one variation, the first renewable resource derivative comprises an animal hair or fiber. In another variation, the first renewable resource derivative comprises a rapidly renewable resource derivative. In yet another variation, the rapidly renewable resource derivative comprises polylactic acid. In still another variation, each of the second renewable resource derivative and the third renewable resource derivative independently comprise a cellulose derivative selected from the group consisting of ethyl cellulose, hydroxymethyl cellulose, nitrocellulose, cellulose acetate, cellulose acetate butyrate, cellulose acetate propionate, and any combination thereof.

In still another aspect of the invention, a backing for a carpet comprises a renewable resource derivative in an amount of from about 25 wt % to about 100 wt % of the backing. In one variation of this aspect, the renewable resource derivative comprises a cellulose derivative, for example, ethyl cellulose, hydroxymethyl cellulose, nitrocellulose, cellulose acetate, cellulose acetate butyrate, cellulose acetate propionate, or any combination thereof. In one particular example, the cellulose derivative comprises about 33 wt % of the backing.

Other features, aspects, and embodiments will be apparent from the following description and accompanying figures.

BRIEF DESCRIPTION OF THE DRAWINGS

The description refers to the accompanying drawings, some of which are schematic, in which like reference characters refer to like parts throughout the several views, and in which:

FIG. 1 depicts an exemplary tufted carpet that may be used in accordance with various aspects of the invention; and

FIG. 2 schematically depicts an exemplary process for forming a carpet in accordance with various aspects of the invention.

DETAILED DESCRIPTION

The present invention relates generally to various carpets, carpet tiles, and other floor coverings (sometimes collectively referred to as "floor coverings"), components or layers of materials used to form carpets, carpet tiles, and other floor coverings, for example, carpet fibers or yarns, carpet backings, reinforcement layers, other layers, and any combination thereof (generally referred to as "floor covering components"), and methods of forming such floor coverings and floor covering components. Although tufted carpet is described in detail herein, it will be understood that the various aspects of the invention have broad utility with numerous types of floor coverings including, but not limited to, tufted carpets, woven carpets, tufted carpet tiles, woven carpet tiles, nonwoven flooring products, rugs, and flooring tiles.

In one aspect, the floor covering or floor covering component is formed or derived at least partially, substantially, or entirely from at least one renewable resource. As used herein, the term "renewable resource" refers to a material that is capable of being restored or replenished naturally within a period of about 200 years. For simplicity, and not limitation, the term "renewable resource" shall refer to one renewable resource or more than one renewable resource. Examples of renewable resources include, but are not limited to, timber-based products. A material derived from a renewable resource shall be referred to herein as a "renewable resource derivative" or as "renewable resource derivatives," either of which shall be construed to include one renewable resource derivative or more than one renewable resource derivative, such that a floor covering or floor covering component comprising a renewable resource derivative will be understood as being formed from one or more renewable resource derivatives.

In some examples, the renewable resource may comprise a rapidly renewable resource. As used herein, the term "rapidly renewable resource"

refers to a material that is capable of being restored or replenished naturally within a period of about two years. For simplicity, and not limitation, the term "rapidly renewable resource" shall refer to the use of one rapidly renewable resource or more than one rapidly renewable resource. Examples of rapidly renewable resources include, but are not limited to, grain-based feed stocks such as corn. A material derived from a rapidly renewable resource may be referred to herein as a "rapidly renewable resource derivative" or as "rapidly renewable resource derivatives," either of which shall be construed to include one rapidly renewable resource derivative or more than one rapidly renewable resource derivative, such that a floor covering or floor covering component comprising a rapidly renewable resource derivative will be understood as being formed from one or more rapidly renewable resource derivatives.

Alternatively or additionally, the renewable resource may comprise a modified renewable resource. It will be understood that some materials that are derived from a renewable resource or rapidly renewable resource, for example, polymers or other chemicals or chemical compositions, may be modified chemically to alter the performance and/or processing characteristics thereof. Where the renewable resource or rapidly renewable resource serves as the primary starting or end material, or forms the backbone of a resulting polymer, the material is referred to herein as a "modified renewable resource." For simplicity, and not limitation, the term "modified renewable resource" shall refer to the use of one modified renewable resource or more than one modified renewable resource. Examples of modified renewable resources include, but are not limited to, polymers derived from renewable resources, and renewable resources treated with additives or coatings to enhance performance or processing.

A material derived from a modified renewable resource may be referred to herein as a "modified renewable resource derivative" or as "modified renewable resource derivatives," either of which shall be construed to include

one modified renewable resource derivative or more than one modified renewable resource derivative, such that a floor covering or floor covering component comprising a modified renewable resource derivative will be understood as being formed from one or more modified renewable resource derivatives.

Alternatively or additionally still, the renewable resource may comprise a plentiful resource. As used herein, a "plentiful resource" or "plentiful material" refers to a material, for example, a mineral, that is present in nature in such great quantities that the material is not renewed intentionally. For simplicity, and not limitation, the term "plentiful resource" shall refer to the use of one plentiful resource or more man one plentiful resource. A material derived from a plentiful resource may be referred to herein as a "plentiful resource derivative" or as "plentiful resource derivatives," either of which shall be construed to include one plentiful resource derivative or more than one plentiful resource derivative, such that a floor covering or floor covering component comprising a plentiful resource derivative will be understood as being formed from one or more plentiful resource derivatives.

While the various materials have differing rates of renewal, for purposes of simplicity, and not limitation, the term "renewable resource derivative" shall be used hereinafter to refer to derivatives of renewable resources, rapidly renewable resources, modified renewable resources, plentiful resources, or any combination thereof unless specified otherwise.

In contrast, as used herein, a "nonrenewable resource" is a material that cannot be restored or replenished naturally within a period of about 200 years. For simplicity, and not limitation, the term "nonrenewable resource" shall refer to the use of one nonrenewable resource or more than one nonrenewable resource. A material derived from a nonrenewable resource shall be referred to herein as a "nonrenewable resource derivative" or as "nonrenewable resource derivatives," either of which shall be construed to include one nonrenewable

resource derivative or more than one nonrenewable resource derivative, such that a floor covering or floor covering component comprising a nonrenewable resource derivative will be understood as being formed from one or more nonrenewable resource derivatives. Examples of nonrenewable resources include, but are not limited to, fossil fuels. A material derived from a fossil fuel shall be referred to herein as a "fossil fuel derivative" or as "fossil fuel derivatives," either of which shall be construed to include one fossil fuel derivative or more than one fossil fuel derivative, such that a floor covering or floor covering component comprising a fossil fuel derivative will be understood as being formed from one or more fossil fuel derivatives.

Any of the various floor coverings or floor covering components of the invention may be formed from various renewable resource derivatives, various nonrenewable resource derivatives, or any combination of renewable resource derivatives and nonrenewable resource derivatives. In some particular examples, the renewable resource derivative may be a rapidly renewable resource derivative, a modified renewable resource derivative, a plentiful resource derivative, or any combination thereof. It will be understood that while various amounts, percentages, and ranges of various materials are provided herein, that such amounts, percentages, and ranges are provided as examples only. Numerous other amounts, percentages, and ranges are contemplated hereby.

Any of the various materials used in accordance with the invention may be virgin materials, recycled materials, or any combination thereof. For example, any of the various floor covering components or floor coverings may be formed at least partially from recycled carpets or backings or from other floor coverings. Likewise, any of the various components formed according to the invention may be recycled and used in carpets, backings, or other floor coverings.

In each of various examples, the floor covering or floor covering component independently may comprise 0 wt % renewable resource derivative, less than about 5 wt % renewable resource derivative, at least about 5 wt % renewable resource derivative, at least about 10 wt % renewable resource derivative, at least about 15 wt % renewable resource derivative, at least about 20 wt % renewable resource derivative, at least about 25 wt % renewable resource derivative, at least about 30 wt % renewable resource derivative, at least about 35 wt % renewable resource derivative, at least about 40 wt % renewable resource derivative, at least about 45 wt % renewable resource derivative, at least about 50 wt % renewable resource derivative, at least about 55 wt % renewable resource derivative, at least about 60 wt % renewable resource derivative, at least about 65 wt % renewable resource derivative, at least about 70 wt % renewable resource derivative, at least about 75 wt % renewable resource derivative, at least about 80 wt % renewable resource derivative, at least about 85 wt % renewable resource derivative, at least about 90 wt % renewable resource derivative, at least about 95 wt % renewable resource derivative, greater than about 99 wt % renewable resource derivative, or 100 wt % renewable resource derivative.

In each of various other examples, the floor covering or floor covering component independently may comprise from 0 wt % renewable resource derivative to about 25 wt % renewable resource derivative, from about 25 wt % to about 40 wt % renewable resource derivative, about 30 wt % to about 50 wt %, renewable resource derivative about 45 wt % to about 60 wt % renewable resource derivative, from about 50 wt % to about 75 wt % renewable resource derivative, about 60 wt % to about 80 wt % renewable resource derivative, from about 70 wt % to about 90 wt % renewable resource derivative, or from about 80 wt % to 100 wt % renewable resource derivative.

Likewise, in each of various examples, the floor covering or floor covering component independently may comprise 0 wt % nonrenewable

resource derivative, less than about 5 wt % nonrenewable resource derivative, at least about 5 wt % nonrenewable resource derivative, at least about 10 wt % nonrenewable resource derivative, at least about 15 wt % nonrenewable resource derivative, at least about 20 wt % nonrenewable resource derivative, at least about 25 wt % nonrenewable resource derivative, at least about 30 wt % nonrenewable resource derivative, at least about 35 wt % nonrenewable resource derivative, at least about 40 wt % nonrenewable resource derivative, at least about 45 wt % nonrenewable resource derivative, at least about 50 wt % nonrenewable resource derivative, at least about 55 wt % nonrenewable resource derivative, at least about 60 wt % nonrenewable resource derivative, at least about 65 wt % nonrenewable resource derivative, at least about 70 wt % nonrenewable resource derivative, at least about 75 wt % nonrenewable resource derivative, at least about 80 wt % nonrenewable resource derivative, at least about 85 wt % nonrenewable resource derivative, at least about 90 wt % nonrenewable resource derivative, at least about 95 wt % nonrenewable resource derivative, greater than about 99 wt % nonrenewable resource derivative, or 100 wt % nonrenewable resource derivative.

In each of various other examples, the floor covering or floor covering component independently may comprise from 0 wt % nonrenewable resource derivative to about 25 wt %, from about 25 wt % to about 40 wt % nonrenewable resource derivative, about 30 wt % to about 50 wt % nonrenewable resource derivative, about 45 wt % to about 60 wt % nonrenewable resource derivative, from about 50 wt % to about 75 wt % nonrenewable resource derivative, about 60 wt % to about 80 wt % nonrenewable resource derivative, from about 70 wt % to about 90 wt % nonrenewable resource derivative, or from about 80 wt % to 100 wt % renewable resource derivative.

More particularly, in each of various additional examples, the floor covering or floor covering component independently may be substantially free

of fossil fuel derivative, may comprise less than about 5 wt % fossil fuel derivative, less than about 10 wt % fossil fuel derivative, less than about 15 wt % fossil fuel derivative, less than about 20 wt % fossil fuel derivative, less than about 25 wt % fossil fuel derivative, less than about 30 wt % fossil fuel derivative, less than about 35 wt % fossil fuel derivative, less than about 40 wt % fossil fuel derivative, less than about 45 wt % fossil fuel derivative, less than about 50 wt % fossil fuel derivative, less than about 55 wt % fossil fuel derivative, less than about 60 wt % fossil fuel derivative, less than about 65 wt % fossil fuel derivative, less than about 70 wt % fossil fuel derivative, less than about 75 wt % fossil fuel derivative, less than about 80 wt % fossil fuel derivative, less than about 85 wt % fossil fuel derivative, less than about 90 wt % fossil fuel derivative, less than about 95 wt % fossil fuel derivative, less than about 99 wt % fossil fuel derivative, or may comprise 100 wt % fossil fuel derivative. The present invention may be understood further by referring to the figures. It also will be understood that various components used to form the numerous floor covering or floor covering components of the invention may be interchanged. Thus, while only certain combinations are illustrated herein, numerous other combinations and configurations are contemplated hereby. The individual components or layers of a typical floor covering, for example, a carpet, are well known to those of skill in the art and are described only briefly herein. Turning to FIG. 1, a floor covering, for example, a carpet 100 may include a plurality of fibers, optionally formed into yarns. The pile yarns 102 may be cut to form cut pile tufts as illustrated in FIG. I ₅ may be left in uncut loops (not shown), may be cut partially or "tip sheared" (not shown), or any combination thereof. Moreover, the carpet may include both high and low loops, each of which may be cut fully, cut partially, uncut, or any combination thereof.

The fibers may be formed from any suitable material, and in one aspect, the fibers are formed or derived at least partially, substantially, or entirely from a renewable resource, a nonrenewable resource, or any combination thereof in any suitable proportions. Thus, in each of various examples, the fibers may comprise 0 wt % renewable resource derivative, less than about 5 wt % renewable resource derivative, at least about 5 wt % renewable resource derivative, at least about 10 wt % renewable resource derivative, at least about 15 wt % renewable resource derivative, at least about 20 wt % renewable resource derivative, at least about 25 wt % renewable resource derivative, at least about 30 wt % renewable resource derivative, at least about 35 wt % renewable resource derivative, at least about 40 wt % renewable resource derivative, at least about 45 wt % renewable resource derivative, at least about 50 wt % renewable resource derivative, at least about 55 wt % renewable resource derivative, at least about 60 wt % renewable resource derivative, at least about 65 wt % renewable resource derivative, at least about 70 wt % renewable resource derivative, at least about 75 wt % renewable resource derivative, at least about 80 wt % renewable resource derivative, at least about 85 wt % renewable resource derivative, at least about 90 wt % renewable resource derivative, at least about 95 wt % renewable resource derivative, greater than about 99 wt % renewable resource derivative, or 100 wt % renewable resource derivative.

In each of various other examples, the fibers may comprise from 0 wt % renewable resource derivative to about 25 wt % renewable resource derivative, from about 25 wt % to about 40 wt % renewable resource derivative, about 30 wt % to about 50 wt %, renewable resource derivative about 45 wt % to about 60 wt % renewable resource derivative, from about 50 wt % to about 75 wt % renewable resource derivative, about 60 wt % to about 80 wt % renewable resource derivative, from about 70 wt % to about 90 wt % renewable resource derivative, or from about 80 wt % to 100 wt % renewable resource derivative.

In each of still other examples, the fibers may comprise 0 wt % nonrenewable resource derivative, less than about 5 wt % nonrenewable resource derivative, at least about 5 wt % nonrenewable resource derivative, at least about 10 wt % nonrenewable resource derivative, at least about 15 wt % nonrenewable resource derivative, at least about 20 wt % nonrenewable resource derivative, at least about 25 wt % nonrenewable resource derivative, at least about 30 wt % nonrenewable resource derivative, at least about 35 wt % nonrenewable resource derivative, at least about 40 wt % nonrenewable resource derivative, at least about 45 wt % nonrenewable resource derivative, at least about 50 wt % nonrenewable resource derivative, at least about 55 wt % nonrenewable resource derivative, at least about 60 wt % nonrenewable resource derivative, at least about 65 wt % nonrenewable resource derivative, at least about 70 wt % nonrenewable resource derivative, at least about 75 wt % nonrenewable resource derivative, at least about 80 wt % nonrenewable resource derivative, at least about 85 wt % nonrenewable resource derivative, at least about 90 wt % nonrenewable resource derivative, at least about 95 wt % nonrenewable resource derivative, greater than about 99 wt % nonrenewable resource derivative, or 100 wt % nonrenewable resource derivative.

In each of yet other examples, the fibers may comprise from 0 wt % nonrenewable resource derivative to about 25 wt % nonrenewable resource derivative, from about 25 wt % to about 40 wt % nonrenewable resource derivative, about 30 wt % to about 50 wt %, nonrenewable resource derivative about 45 wt % to about 60 wt % nonrenewable resource derivative, from about 50 wt % to about 75 wt % nonrenewable resource derivative, about 60 wt % to about 80 wt % nonrenewable resource derivative, from about 70 wt % to about 90 wt % nonrenewable resource derivative, or from about 80 wt % to 100 wt % renewable resource derivative.

More particularly, in each of various additional examples, the fibers may ^¬ be substantially free of fossil fuel derivative, may comprise less than about 5 wt

% fossil fuel derivative, less than about 10 wt % fossil fuel derivative, less than about 15 wt % fossil fuel derivative, less than about 20 wt % fossil fuel derivative, less than about 25 wt % fossil fuel derivative, less than about 30 wt % fossil fuel derivative, less than about 35 wt % fossil fuel derivative, less than about 40 wt % fossil fuel derivative, less than about 45 wt % fossil fuel derivative, less than about 50 wt % fossil fuel derivative, less than about 55 wt % fossil fuel derivative, less than about 60 wt % fossil fuel derivative, less than about 65 wt % fossil fuel derivative, less than about 70 wt % fossil fuel derivative, less than about 75 wt % fossil fuel derivative, less than about 80 wt % fossil fuel derivative, less than about 85 wt % fossil fuel derivative, less than about 90 wt % fossil fuel derivative, less than about 95 wt % fossil fuel derivative, less than about 99 wt % fossil fuel derivative, or may comprise 100 wt % fossil fuel derivative.

Examples of materials derived from a renewable resource that may be suitable for use with the invention include, but are not limited to, animal hairs, such as wool or hog hair, or other natural fibers. As another example, polylactic acid (PLA) polymer, made from monomers generated through corn sugar fermentation, may be used to make fibers for use in a floor covering or floor covering component. One example of a PLA fiber is available commercially from NatureWorks LLC under the trade name INGEO™. Examples of materials derived from a nonrenewable resource that may be suitable for use with the invention include, but are not limited to polyester, polypropylene, nylon 6, nylon 6,6, or any combination thereof.

Returning to FIG. 1, the fibers foπned into yarns 102 may be looped through a primary backing 104. The primary backing may be formed using a variety of techniques and thus may have a variety of forms. For example, the primary backing may be a woven material formed from, for example, a plurality of polymeric yarns, tapes, split films, or any combination thereof. As another example, the primary backing may be a nonwoven material or fabric

formed from a plurality of thermoplastic fibers or continuous filaments joined together by mechanical or thermal means. Fiber distribution can be earned out via spunbonding, meltblowing, wet laying, or air laying techniques and consolidation can take place via thermal bonding, needling, hydroentangling, and/or adhesive techniques. One or more polymeric materials may be used to form the primary backing, whether woven, nonwoven, or a combination thereof. In the case of two or more polymeric materials, the polymers may be independent (e.g. separate fibers, films, layers, etc. of homopolymer) or conjugate (e.g. bicomponent fibers such as sheath/core, side by side, islands in the sea, etc.).

The primary backing may be formed from any suitable material, and in one aspect, the primary backing is formed or derived at least partially, substantially, or entirely from a renewable resource, a nonrenewable resource, or any combination thereof in any suitable proportions. In each of various examples, the primary backing may comprise 0 wt % renewable resource derivative, less than about 5 wt % renewable resource derivative, at least about 5 wt % renewable resource derivative, at least about 10 wt % renewable resource derivative, at least about 15 wt % renewable resource derivative, at least about 20 wt % renewable resource derivative, at least about 25 wt % renewable resource derivative, at least about 30 wt % renewable resource derivative, at least about 35 wt % renewable resource derivative, at least about 40 wt % renewable resource derivative, at least about 45 wt % renewable resource derivative, at least about 50 wt % renewable resource derivative, at least about 55 wt % renewable resource derivative, at least about 60 wt % renewable resource derivative, at least about 65 wt % renewable resource derivative, at least about 70 wt % renewable resource derivative, at least about 75 wt % renewable resource derivative, at least about 80 wt % renewable resource derivative, at least about 85 wt % renewable resource derivative, at least about 90 wt % renewable resource derivative, at

least about 95 wt % renewable resource derivative, greater than about 99 wt % renewable resource derivative, or 100 wt % renewable resource derivative.

In each of various other examples, the primary backing may comprise from 0 wt % renewable resource derivative to about 25 wt % renewable resource derivative, from about 25 wt % to about 40 wt % renewable resource derivative, about 30 wt % to about 50 wt %, renewable resource derivative about 45 wt % to about 60 wt % renewable resource derivative, from about 50 wt % to about 75 wt % renewable resource derivative, about 60 wt % to about 80 wt % renewable resource derivative, from about 70 wt % to about 90 wt % renewable resource derivative, or from about 80 wt % to 100 wt % renewable resource derivative.

Likewise, in each of various examples, the primary backing may comprise 0 wt % nonrenewable resource derivative, less than about 5 wt % nonrenewable resource derivative, at least about 5 wt % nonrenewable resource derivative, at least about 10 wt % nonrenewable resource derivative, at least about 15 wt % nonrenewable resource derivative, at least about 20 wt % nonrenewable resource derivative, at least about 25 wt % nonrenewable resource derivative, at least about 30 wt % nonrenewable resource derivative, at least about 35 wt % nonrenewable resource derivative, at least about 40 wt % nonrenewable resource derivative, at least about 45 wt % nonrenewable resource derivative, at least about 50 wt % nonrenewable resource derivative, at least about 55 wt % nonrenewable resource derivative, at least about 60 wt % nonrenewable resource derivative, at least about 65 wt % nonrenewable resource derivative, at least about 70 wt % nonrenewable resource derivative, at least about 75 wt % nonrenewable resource derivative, at least about 80 wt % nonrenewable resource derivative, at least about 85 wt % nonrenewable resource derivative, at least about 90 wt % nonrenewable resource derivative, at least about 95 wt % nonrenewable resource derivative, greater than about 99

wt % nonrenewable resource derivative, or 100 wt % nonrenewable resource derivative.

In each of various other examples, the primary backing may comprise from 0 wt % nonrenewable resource derivative to about 25 wt % nonrenewable resource derivative, from about 25 wt % to about 40 wt % nonrenewable resource derivative, about 30 wt % to about 50 wt %, nonrenewable resource derivative about 45 wt % to about 60 wt % nonrenewable resource derivative, from about 50 wt % to about 75 wt % nonrenewable resource derivative, about 60 wt % to about 80 wt % nonrenewable resource derivative, from about 70 wt % to about 90 wt % nonrenewable resource derivative, or from about 80 wt % to 100 wt % nonrenewable resource derivative.

More particularly, in each of various additional examples, the primary backing may be substantially free of fossil fuel derivative, may comprise less than about 5 wt % fossil fuel derivative, less than about 10 wt % fossil fuel derivative, less than about 15 wt % fossil fuel derivative, less than about 20 wt % fossil fuel derivative, less than about 25 wt % fossil fuel derivative, less than about 30 wt % fossil fuel derivative, less than about 35 wt % fossil fuel derivative, less than about 40 wt % fossil fuel derivative, less than about 45 wt % fossil fuel derivative, less than about 50 wt % fossil fuel derivative, less than about 55 wt % fossil fuel derivative, less than about 60 wt % fossil fuel derivative, less than about 65 wt % fossil fuel derivative, less than about 70 wt % fossil fuel derivative, less than about 75 wt % fossil fuel derivative, less than about 80 wt % fossil fuel derivative, less than about 85 wt % fossil fuel derivative, less than about 90 wt % fossil fuel derivative, less than about 95 wt % fossil fuel derivative, less than about 99 wt % fossil fuel derivative, or may comprise 100 wt % fossil fuel derivative.

Examples of materials derived from a renewable resource that may be suitable for use in a primary backing include, but are not limited to, animal hair, PLA, or any combination thereof. One example of a PLA primary

backing is available from Unitika Ltd. (Japan) under the trade name Terramac®. Examples of materials derived from a nonrenewable resource include, but are not limited to, polypropylene, polyethylene, nylon, polyester, or any combination thereof. Returning to FIG. 1, a precoat layer 106 may be used to secure the pile yarns 102 on or within the primary backing 104. The precoat layer generally may be present in an amount of from about 5 to about 40 wt % based on the weight of the carpet (dry/dry basis). In one aspect, the precoat layer is present in an amount of from about 10 wt % to about 35 wt % based on the weight of the carpet (dry/dry basis). In another aspect, the precoat layer is present in an amount of from about 15 wt % to about 30 wt % based on the weight of the carpet (dry/dry basis). In yet another aspect, the precoat layer is present in an amount of from about 20 wt % to about 25 wt % based on the weight of the carpet (dry/dry basis). The precoat layer may be formed from any suitable material, and in one aspect, the precoat layer is formed or derived at least partially, substantially, or entirely from a renewable resource, a nonrenewable resource, or any combination thereof in any suitable proportions.

Thus, in each of various examples, the precoat layer may comprise 0 wt % renewable resource derivative, less than about 5 wt % renewable resource derivative, at least about 5 wt % renewable resource derivative, at least about 10 wt % renewable resource derivative, at least about 15 wt % renewable resource derivative, at least about 20 wt % renewable resource derivative, at least about 25 wt % renewable resource derivative, at least about 30 wt % renewable resource derivative, at least about 35 wt % renewable resource derivative, at least about 40 wt % renewable resource derivative, at least about 45 wt % renewable resource derivative, at least about 50 wt % renewable resource derivative, at least about 55 wt % renewable resource derivative, at least about 60 wt % renewable resource derivative, at least about 65 wt %

renewable resource derivative, at least about 70 wt % renewable resource derivative, at least about 75 wt % renewable resource derivative, at least about 80 wt % renewable resource derivative, at least about 85 wt % renewable resource derivative, at least about 90 wt % renewable resource derivative, at least about 95 wt % renewable resource derivative, greater than about 99 wt % renewable resource derivative, or 100 wt % renewable resource derivative.

In each of various other examples, the precoat layer may comprise from 0 wt % renewable resource derivative to about 25 wt % renewable resource derivative, from about 25 wt % to about 40 wt % renewable resource derivative, about 30 wt % to about 50 wt %, renewable resource derivative about 45 wt % to about 60 wt % renewable resource derivative, from about 50 wt % to about 75 wt % renewable resource derivative, about 60 wt % to about 80 wt % renewable resource derivative, from about 70 wt % to about 90 wt % renewable resource derivative, or from about 80 wt % to 100 wt % renewable resource derivative.

Likewise, in each of various examples, the precoat layer may comprise 0 wt % nonrenewable resource derivative, less than about 5 wt % nonrenewable resource derivative, at least about 5 wt % nonrenewable resource derivative, at least about 10 wt % nonrenewable resource derivative, at least about 15 wt % nonrenewable resource derivative, at least about 20 wt % nonrenewable resource derivative, at least about 25 wt % nonrenewable resource derivative, at least about 30 wt % nonrenewable resource derivative, at least about 35 wt % nonrenewable resource derivative, at least about 40 wt % nonrenewable resource derivative, at least about 45 wt % nonrenewable resource derivative, at least about 50 wt % nonrenewable resource derivative, at least about 55 wt % nonrenewable resource derivative, at least about 60 wt % nonrenewable resource derivative, at least about 65 wt % nonrenewable resource derivative, at least about 70 wt % nonrenewable resource derivative, at least about 75 wt % nonrenewable resource derivative, at least about 80 wt % nonrenewable

resource derivative, at least about 85 wt % nonrenewable resource derivative, at least about 90 wt % nonrenewable resource derivative, at least about 95 wt % nonrenewable resource derivative, greater than about 99 wt % nonrenewable resource derivative, or 100 wt % nonrenewable resource derivative. In each of various other examples, the precoat layer may comprise from

0 wt % nonrenewable resource derivative to about 25 wt % nonrenewable resource derivative, from about 25 wt % to about 40 wt % nonrenewable resource derivative, about 30 wt % to about 50 wt %, nonrenewable resource derivative about 45 wt % to about 60 wt % nonrenewable resource derivative, from about 50 wt % to about 75 wt % nonrenewable resource derivative, about 60 wt % to about 80 wt % nonrenewable resource derivative, from about 70 wt % to about 90 wt % nonrenewable resource derivative, or from about 80 wt % to 100 wt % nonrenewable resource derivative.

More particularly, in each of various additional examples, the precoat layer may be substantially free of fossil fuel derivative, may comprise less than about 5 wt % fossil fuel derivative, less than about 10 wt % fossil fuel derivative, less than about 15 wt % fossil fuel derivative, less than about 20 wt % fossil fuel derivative, less than about 25 wt % fossil fuel derivative, less than about 30 wt % fossil fuel derivative, less than about 35 wt % fossil fuel derivative, less than about 40 wt % fossil fuel derivative, less than about 45 wt % fossil fuel derivative, less than about 50 wt % fossil fuel derivative, less than about 55 wt % fossil fuel derivative, less than about 60 wt % fossil fuel derivative, less than about 65 wt % fossil fuel derivative, less than about 70 wt % fossil fuel derivative, less than about 75 wt % fossil fuel derivative, less than about 80 wt % fossil fuel derivative, less than about 85 wt % fossil fuel derivative, less than about 90 wt % fossil fuel derivative, less than about 95 wt % fossil fuel derivative, less than about 99 wt % fossil fuel derivative, or may comprise 100 wt % fossil fuel derivative.

Examples of materials derived from a renewable resource that may be suitable for use in the precoat layer include, but are not limited to, various cellulose-based polymers or materials (collectively "cellulose derivative" or "cellulose derivatives"), for example, ethyl cellulose, hydroxymethyl cellulose, nitrocellulose, cellulose acetate, cellulose acetate butyrate, cellulose acetate propionate, other cellulose derivatives, and any combination thereof. One particular example of ethyl cellulose is Ethocel® ethyl cellulose, commercially available from Dow Chemical Company (Midland, Michigan). Examples of materials derived from a nonrenewable resource that may be suitable for use in the precoat layer include, but are not limited to, ethylene/vinyl acetate copolymer, polyvinyl butyral, polyurethane, polyvinyl chloride, a tackified polyolefin, or any combination thereof. One example of polyurethane that may be suitable for use with the present invention is DOW 605.01, commercially available from Dow Chemical Company (Midland, Michigan). Still viewing FIG. 1, the floor covering 100 may include a secondary backing 110. In this example, the secondary backing is a foam having open cells 112. However, the secondary backing may be a flexible or semi-flexible non-foam layer.

The secondary backing may be formed from any suitable material, and in one aspect, the secondary backing layer is formed or derived at least partially, substantially, or entirely from a renewable resource, a nonrenewable resource, or any combination thereof in any suitable proportions.

In each of various examples, the secondary backing may comprise 0 wt % renewable resource derivative, less than about 5 wt % renewable resource derivative, at least about 5 wt % renewable resource derivative, at least about 10 wt % renewable resource derivative, at least about 15 wt % renewable resource derivative, at least about 20 wt % renewable resource derivative, at least about 25 wt % renewable resource derivative, at least about 30 wt % renewable resource derivative, at least about 35 wt % renewable resource

derivative, at least about 40 wt % renewable resource derivative, at least about 45 wt % renewable resource derivative, at least about 50 wt % renewable resource derivative, at least about 55 wt % renewable resource derivative, at least about 60 wt % renewable resource derivative, at least about 65 wt % renewable resource derivative, at least about 70 wt % renewable resource derivative, at least about 75 wt % renewable resource derivative, at least about 80 wt % renewable resource derivative, at least about 85 wt % renewable resource derivative, at least about 90 wt % renewable resource derivative, at least about 95 wt % renewable resource derivative, greater than about 99 wt % renewable resource derivative, or 100 wt % renewable resource derivative.

In each of various other examples, the secondary backing may comprise from 0 wt % renewable resource derivative to about 25 wt % renewable resource derivative, from about 25 wt % to about 40 wt % renewable resource derivative, about 30 wt % to about 50 wt %, renewable resource derivative about 45 wt % to about 60 wt % renewable resource derivative, from about 50 wt % to about 75 wt % renewable resource derivative, about 60 wt % to about 80 wt % renewable resource derivative, from about 70 wt % to about 90 wt % renewable resource derivative, or from about 80 wt % to 100 wt % renewable resource derivative. Likewise, in each of various examples, the secondary backing may comprise 0 wt % nonrenewable resource derivative, less than about 5 wt % nonrenewable resource derivative, at least about 5 wt % nonrenewable resource derivative, at least about 10 wt % nonrenewable resource derivative, at least about 15 wt % nonrenewable resource derivative, at least about 20 wt % nonrenewable resource derivative, at least about 25 wt % nonrenewable resource derivative, at least about 30 wt % nonrenewable resource derivative, at least about 35 wt % nonrenewable resource derivative, at least about 40 wt % nonrenewable resource derivative, at least about 45 wt % nonrenewable resource derivative, at least about 50 wt % nonrenewable resource derivative,

at least about 55 wt % nonrenewable resource derivative, at least about 60 wt % nonrenewable resource derivative, at least about 65 wt % nonrenewable resource derivative, at least about 70 wt % nonrenewable resource derivative, at least about 75 wt % nonrenewable resource derivative, at least about 80 wt % nonrenewable resource derivative, at least about 85 wt % nonrenewable resource derivative, at least about 90 wt % nonrenewable resource derivative, at least about 95 wt % nonrenewable resource derivative, greater than about 99 wt % nonrenewable resource derivative, or 100 wt % nonrenewable resource derivative. In each of various other examples, the secondary backing may comprise from 0 wt % nonrenewable resource derivative to about 25 wt % nonrenewable resource derivative, from about 25 wt % to about 40 wt % nonrenewable resource derivative, about 30 wt % to about 50 wt %, nonrenewable resource derivative about 45 wt % to about 60 wt % nonrenewable resource derivative, from about 50 wt % to about 75 wt % nonrenewable resource derivative, about 60 wt % to about 80 wt % nonrenewable resource derivative, from about 70 wt % to about 90 wt % nonrenewable resource derivative, or from about 80 wt % to 100 wt % nonrenewable resource derivative.

More particularly, in each of various additional examples, the secondary backing may be substantially free of fossil fuel derivative, may comprise less than about 5 wt % fossil fuel derivative, less than about 10 wt % fossil fuel derivative, less than about 15 wt % fossil fuel derivative, less than about 20 wt % fossil fuel derivative, less than about 25 wt % fossil fuel derivative, less than about 30 wt % fossil fuel derivative, less than about 35 wt % fossil fuel derivative, less than about 40 wt % fossil fuel derivative, less than about 45 wt % fossil fuel derivative, less than about 50 wt % fossil fuel derivative, less than about 55 wt % fossil fuel derivative, less than about 60 wt % fossil fuel derivative, less than about 65 wt % fossil fuel derivative, less than about 70 wt % fossil fuel derivative, less than about 75 wt % fossil fuel derivative, less than

about 80 wt % fossil fuel derivative, less than about 85 wt % fossil fuel derivative, less than about 90 wt % fossil fuel derivative, less than about 95 wt % fossil fuel derivative, less than about 99 wt % fossil fuel derivative, or may comprise 100 wt % fossil fuel derivative. Examples of materials derived from a renewable resource that may be suitable for use in the secondary backing include, but are not limited to, various cellulose derivatives, such as those described above. For example, the secondary backing may be formed from an ethyl cellulose, such as Ethocel® ethyl cellulose, commercially available from Dow Chemical Company (Midland, Michigan). Examples of materials derived from a nonrenewable resource that may be suitable for use in the secondary backing include, but are not limited to, ethylene/vinyl acetate copolymer, polyvinyl butyral, polyurethane, polyvinyl chloride, a tackified polyolefin, or any combination thereof. One example of polyurethane that may be suitable for use with the present invention is DOW 605.01, commercially available from Dow Chemical Company (Midland, Michigan).

Various additives may be included in the composition used to form the secondary backing or other floor covering components. Examples of such additives include, but are not limited to, extenders or fillers, blowing agents, processing aids, plasticizers, foaming agents, pigments, antioxidants, antimicrobial agents, cross-linking agents, flame retardants, polymer stabilizers, tackifiers, and the like. It will be understood that where the floor covering or floor covering component is intended to include or be made from a renewable resource material, the various additives may be selected accordingly. It also will be understood that the amount of each additive used to form the floor covering component will vary depending on which component is being formed, the particular end use for the component, and numerous other factors.

Various fillers may be used to extend the secondary backing. Such fillers tend to increase the density of the sheet. This increase and density may

be desirable for use in, for example, a carpet tile, which might otherwise tend to curl, dome, or otherwise not lay flat. Examples of renewable resource fillers that may be suitable include, but are not limited to, organic materials such as bagasse fillers, recycled paper fillers, coconut hull/fiber fillers, cork fillers, com cob fillers, cotton-based fillers, gilsonite fillers, nutshell fillers (such as peanuts), rice hull fillers, sisal fillers, hemp fillers, soybean fillers, starch fillers, wood flour fillers, animal fibers such as turkey feather fibers, and any combination thereof. Other examples include, but are not limited to, pulverized glass and other glass based materials, metallic and magnetic materials, aluminum trihydrate, fly ash, coal ash, other ash products resulting from energy generation facilities or incineration, carbon black, wollastonite, solid microspheres, hollow microspheres, kaolin, clay-based minerals, bauxite, calcium carbonate, feldspar, nepheline syenite, barium sulfate, titanium dioxide, talc, pyrophyllite, quartz, natural silicas, such as crystalline silica, microcrystalline silica, synthetic silicates, such as calcium silicate, zirconium silicate, and aluminum silicate (including mullite, sillimanite, cyanite, andalusite, and synthetic alkali metal aluminosilicates), microcrystalline novaculite, diatomaceous silica, perlite, synthetic silicas, such as fumed silica and precipitated silicas, antimony oxide, bentonite, mica, vermiculite, zeolite, and combinations of metals with various salts, such as calcium, magnesium, zinc, barium, aluminum combined with oxide, sulfate, borate, phosphate, carbonate, hydroxide, and the like, and any combination thereof.

Likewise, one or more antioxidants or heat stabilizers may be included in the backing formulation to prevent polymer degradation and for other purposes. BHT (2,6-di-t-butyl-p-cresol), phosphite antioxidants, such as TNPP (tris(mono-nonyl phenyl)phosphite), hindered phenolic antioxidants, such as tetrakis[methylene-3(3',5'-di-tert-butyl-4-hydroxy phenyl)propionate]methane, and thioesters, such as DLTDP, DSTDP, DTDTDP, or any combination thereof, may be used along with other antioxidants or heat stabilizers.

One or more flame retardants also may be included in the formulation. Examples of flame retardants that may be suitable include, but are not limited to, aluminum trihydrate, magnesium hydroxide, boron compounds, zinc borate, AOM, halogenated flame retardants, such as deca-DBP, PBDPO, TBBPA, HBCD, TBPA, antimony trioxide, phosphorus compounds, such as red phosphorus, ammonium polyphosphate, triphenyl phosphate, resorcinol diphosphate, bisphenol A diphosphate, 2-ethyl hexyl diphenyl phosphate, nitrogen containing compounds, mica, and any combination thereof.

Various plasticizers also may be used to prepare a floor covering or floor covering component in accordance with various aspects of the invention. Examples of plasticizers that may be suitable include, but are not limited to, aromatic diesters such as DINP, DIDP, L9P, DOTP, DBP, DOP, BBP, DHP, aliphatic diesters such as DINA, DIDA, DHA, aromatic sulfonamides such as BSA, aromatic phosphate esters such as TCP and TXP, alkyl phosphate esters such as TBP and TOF, dialkylether aromatic esters such as DBEP, dialkylether diesters, tricarboxylic esters, polymeric polyester plasticizers, polyglycol diesters, alkyl alkylether diesters such as DBEG, DBEA, DBEEG, and DBEEA, aromatic triesters such as TOTM and TIOTM, epoxodized esters, epoxidized oils such as ESO, chlorinated hydrocarbons or parrafins, aromatic oils, alkylether monoesters, naphthenic oils, alkylmonoesters, glyceride oils, paraffinic oils, silicone oils, and any combination thereof.

Examples of plasticizers formed or derived from a renewable resource include, but are not limited to, cottonseed oil, Biodiesel, lecithin, triethyl citrate (e.g., CITROFLEX commercially available from Morflex Inc.), linseed oil, citrate plasticizers such as tributyl citrate, process castor oil, raw castor oil, derivatives of castor oil such as butyl ricinoleate, sebacate plasticizers such as dibutyl sebacate, and any combination thereof.

One or more pigments also may be included in the backing formulation. Examples of pigments that may be suitable include, but are not limited to,

carbon black, organic dyes, natural dyes, zinc sulfide, titanium dioxide, and any combination thereof.

One or more lubricants also may be included in the backing formulation.

Examples of lubricants include, but are not limited to, derivatives of fatty acids, calcium stearate, zinc stearate, stearic acid, saturated and unsaturated fatty primary monoamides, fatty glicerides such as C 14-Cl 8 mono- and di-glycerides, and any combination thereof.

Thus, in one example, the composition used to foπn the backing may include from about 20 wt % to about 40 wt % polymer, from about 15 wt % to about 40 wt % plasticizer, from about 25 wt % to about 50 wt % filler, and from about 0.01 wt % to 5 wt % lubricant. In another example, the composition used to form the backing may include from about 25 wt % to about 35 wt % polymer, from about 20 wt % to about 30 wt % plasticizer, from about 35 wt % to about 45 wt % filler, and from about 0.05 wt % to 2 wt % lubricant. In yet another example, the composition used to form the backing may include from about 30 wt % to about 35 wt % polymer, from about 25 wt % to about 30 wt % plasticizer, from about 35 wt % to about 42 wt % filler, and from about 0.05 wt % to 1 wt % lubricant. In one particular example, the composition used to foπn the backing may include about 33 wt polymer, for example ethyl cellulose, about 26 wt % plasticizer, for example, castor oil, about 40 wt % filler, for example, calcium carbonate, and about 0.08 wt % lubricant, for example, calcium stearate.

If desired, the backing formulation also may include one or more cross- linking agents such as phenolics, dialdehydes, aziridines, isocyanates, and melamines, or any combination thereof.

One or more tackifiers also may be included in the backing formulation. For example renewable resource tackifiers include Damar resin, ester gums, and any combination thereof.

As shown in FIG. 1, an optional reinforcing layer 114 may be used to provide integrity and strength to the carpet 100. In this example, the reinforcing layer 114 lies between the polymer precoat 106 and the secondary backing 110. If needed, additional reinforcing layers (not shown) may be provided, for example, within or between one or more layers, or as an outermost layer, for example, overlying and forming a bottom surface. Other configurations with and without reinforcing layers are contemplated hereby.

The reinforcing material may comprise a veil, scrim, tissue, felt, nonwoven, or other planar textile fabric that has been created using a weaving, knitting, nonwoven, or other textile manufacturing process. For example, the reinforcing material may be an open weave scrim. As another example, the reinforcing material may be a knitted fabric including a weft inserted knit. As yet another example, the reinforcing material may be a cross-laid scrim including an over/under laid scrim or a triaxial laid scrim. The reinforcing material may be formed from any polymer (e.g. nylon or polyester) fibers, or glass fibers, any other suitable material or combination of materials that enhances the strength and/or dimensional stability of the backing and that does not degrade or soften significantly during processing of the carpeting. In one example, the reinforcing material is a glass fiber scrim. Glass does not contain carbon in its molecular structure and as a result intrinsically is not derived from fossil fuels. Woven or nonwoven glass scrims or fabrics may be used.

While the use of reinforced carpets or other floor covering or floor covering components is described in detail herein, it will be understood that non-reinforced carpets or other floor covering or floor covering components also find broad utility with various other aspects of the invention.

One exemplary process 200 for forming a carpet 202 is depicted schematically in FIG. 2. In this example, a web of tufted yarns 204 is unwound from a supply roll 206. A precoat layer 208 is applied to the back

side of the web of yarns 204 using any suitable technique that allows the precoat layer to cure, film form, or fuse to the textile material. For example, the precoat layer may be applied to the carpet using extrusion coating, may be applied as a dispersion, may be applied as a hot melt, or may be applied or formed using any other suitable technique.

If desired, a reinforcing material 210, for example, a glass scrim, is unwound from a supply roll 212 and applied to the precoat layer 208. Further, if desired, a secondary backing 214 is applied to the reinforcing material 210, for example, using extrusion coating or as a pre-formed layer formed from a dispersion or otherwise. For example, a pre-formed backing may be made using Thermofϊx® technology (Schilling-Knobel, GMBH, Germany), described in U.S. Patent No. 6,217,700, or using any other suitable process.

The resulting carpet 202 then may be wound into rolls, cut into tiles, or otherwise processed, as will be understood by those of skill in the art. Various aspects of the invention are illustrated further by the following examples, which are not to be construed as limiting in any manner.

EXAMPLES

In the Examples, calcium stearate was used as a release aid where needed to prepare sample sheets. Calcium stearate is derived from a nonrenewable resource. However, a release aid derived from a renewable resource, for example, beeswax, may be used where needed or desired.

EXAMPLE 1 Various secondary backing compositions including a renewable resource derivative were evaluated. Each composition included 100 phr Ethocel® ethyl cellulose from Dow Chemical Company, 100 phr castor oil, and 100 phr, 400 phr, 500 phr, or 600 phr calcium carbonate from H&S filler (standard carpet grade).

Each composition was placed into a Banbury mixer, where the components were melted and blended for about 10 minutes. The molten composition was dropped out of the Banbury mixer and placed onto a 2-roll mill maintained at about 250 ⁰ F, where it was mixed further and formed into a sheet. The temperature of the composition when dropped out of the Banbury mixer was about 275°F to about 300 ⁰ F.

Six dog-bone samples were cut from each sheet and tested for physical properties as indicated in Tables 1-3 using ASTM D747-93 titled "Standard Test Method for Apparent Bending Modulus of Plastics by Means of a Cantilever Beam." The samples were tested using a 6 inch-pound stiffness testing machine manufactured by Tinius Olsen Testing Machine Company, Inc. (Willow Grove, PA). All specimens widths (w) were cut to 0.5 inches. The stiffness of each sample was calculated using the following formula:

E = (4S/wddd) x [(M x LSR)/100D], where:

E is the stiffness in psi; S is the span length in inches; w is the specimen width in inches; d is the specimen thickness in inches; M is the total bending moment value of the pendulum system in inch- pounds based on the moment of the basic pendulum system, plus the moments indicated on the calibrated weights;

LSR is the load scale reading; and D is the angular deflection converted to radians.

The samples also were tested for tensile strength. The properties of the Samples 1-3 were similar to those of a standard polyvinyl chloride carpet backing. Sample 4 was more brittle when folded upon itself. The samples were odorless.

Table 1. Tensile strength

Table 2. 45 degree angular deflection

Table 3. 90 degree angular deflection

EXAMPLE 2

Various plasticizers derived from a rapidly renewable resource were evaluated for compatibility with ethyl cellulose. Each plasticizer was compounded with ethyl cellulose and formed into a sheet. Pressure sensitive adhesive was applied to the sheets, and the coated sheets were aged for about 2 hours in an oven maintained at about 180 ⁰ F. An incompatible plasticizer migrates from the backing sheet, softens the adhesive, and lowers its shear strength. In contrast, a compatible plasticizer will not leach out of the polymer sheet and change the adhesive properties.

Of the various plasticizers evaluated, castor oil obtained from Acme- Hardesty Company (CAS No. 8001-79-4) was the most compatible with ethyl cellulose. Numerous other plasticizers may be compatible with ethyl cellulose, and the use of such plasticizers is contemplated hereby.

EXAMPLE 3

Ethocel 300 ethyl cellulose polymer from Dow Chemical was compounded with castor oil (plasticizer), calcium carbonate (filler), and calcium stearate according to Table 4 to form pellets suitable for forming a carpet backing.

The materials were mixed in Hobart mixer for about 30 seconds on low and then about 1 minute on medium using the paddle mixing blade. Three batches were mixed.

Table 4. Composition of compounded ethyl cellulose polymer

The individual mixes were transported to a single screw extruder using mixing bowls and supplied to the extruder under starve feed conditions, as set forth in Table 5. The extruded rope was pelletized successfully, although the conditions and resulting pellets may not have been optimal. The pellets were collected into a small drum.

Table 5. Extrusion conditions

EXAMPLE 4

Ethyl cellulose polymer plasticized with castor oil and filled with calcium carbonate was extruded through a 4 inch wide slot die and laminated to various substrates. The resulting laminates were evaluated for penetration and quality of lamination. The various samples produced and results are presented in Table 6, where:

"EC 100" refers to Ethocel 100 ethyl cellulose polymer, commercially available from Dow Chemical Company (Midland,

Michigan);

"EC 300" refers to Ethocel 300 ethyl cellulose polymer, commercially available from Dow Chemical Company (Midland, Michigan); "wool" refers to a felt comprising 80% wool and 20% bicomponent polyester having a basis weight of 27 ounce/square yard, commercially available from Tec Yarns GmbH;

"tufted" refers to a 100% Legacy Nylon, level loop construction, 1/13 gauge (50.4 rows/lOcm), having a face weight of 20 ounces/square yard, commercially available from Invista (Wichita, Kansas);

"10 X 10 LW" refers to a 10 by 10 lenowoven textile fabric (visual) with 10 yarns/inch (warp) and 10 yarns/inch (weft), including a latex size or binder, commercially available from BGF Industries Inc. (Greensboro, NC) as style 1659; and "nonwoven" refers to a fiberglass scrim with an acrylic latex binder, commercially available from ELK Corporation (Ennis, Texas).

Table 6. Lamination with ethyl cellulose based backing

Accordingly, it will be readily understood by those persons skilled in the art that, in view of the above detailed description of the invention, the present invention is susceptible of broad utility and application. Many adaptations of the present invention other than those herein described, as well as many variations, modifications, and equivalent arrangements will be apparent from or reasonably suggested by the invention and the above detailed description thereof, without departing from the substance or scope of the invention.

While the present invention is described herein in detail in relation to specific aspects, it is to be understood that this detailed description is only illustrative and exemplary of the invention and is made merely for purposes of providing a full and enabling disclosure of the invention and to provide the best mode contemplated by the inventor or inventors of carrying out the invention. The detailed description set forth herein is not intended nor is to be construed to limit the invention or otherwise to exclude any such other embodiments, adaptations, variations, modifications, and equivalent arrangements of the present invention.