U.S. patent application number 16/353146 was filed with the patent office on 2019-10-17 for installation of floorcovering article on chemically abated flooring surface and composite article.
The applicant listed for this patent is Milliken & Company. Invention is credited to Kirkland W. Vogt.
Application Number | 20190316365 16/353146 |
Document ID | / |
Family ID | 68159989 |
Filed Date | 2019-10-17 |
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United States Patent
Application |
20190316365 |
Kind Code |
A1 |
Vogt; Kirkland W. |
October 17, 2019 |
Installation of Floorcovering Article on Chemically Abated Flooring
Surface and Composite Article
Abstract
The present invention relates to the installation of
floorcovering articles on chemically abated flooring surfaces and
the composite article resulting therefrom. More specifically, the
invention relates to a process for chemical removal of mastic,
putty and/or paste material from a flooring surface. The process
includes applying abatement chemical to the mastic material on the
flooring surface to soften the mastic material and cause it to
physically separate and release from the flooring surface, removal
of the mastic material and abatement chemical, and the subsequent
application of a barrier coating to the flooring surface. The
barrier coating reduces and/or eliminates the migration of residual
abatement chemicals into floorcovering articles thereinafter
installed on the chemically abated flooring surface. The resulting
composite article is comprised of a chemically abated flooring
surface containing pores, at least one abatement chemical in said
pores, a polymer-containing barrier material, and a floorcovering
article.
Inventors: |
Vogt; Kirkland W.;
(Simpsonville, SC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Milliken & Company |
Spartanburg |
SC |
US |
|
|
Family ID: |
68159989 |
Appl. No.: |
16/353146 |
Filed: |
March 14, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62656387 |
Apr 12, 2018 |
|
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|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B32B 2262/0292 20130101;
B32B 2419/04 20130101; B32B 2266/06 20130101; B32B 5/024 20130101;
B32B 2262/062 20130101; C09D 133/04 20130101; E04F 15/0215
20130101; B32B 2255/10 20130101; B32B 2262/0269 20130101; B32B
2307/718 20130101; B32B 27/30 20130101; B32B 2262/0246 20130101;
A47G 27/02 20130101; B32B 2262/04 20130101; A47G 27/0475 20130101;
B32B 2307/7265 20130101; C11D 7/44 20130101; A47G 27/0437 20130101;
B32B 2266/08 20130101; B05D 3/104 20130101; B32B 2266/0221
20130101; B32B 5/08 20130101; B32B 2262/0261 20130101; B32B 5/26
20130101; C09D 163/00 20130101; B32B 2262/14 20130101; E04F 15/107
20130101; B32B 5/028 20130101; B32B 5/18 20130101; B32B 2255/02
20130101; B32B 27/08 20130101; B32B 27/12 20130101; B32B 7/12
20130101; C11D 7/5004 20130101; B32B 5/245 20130101; B05D 3/107
20130101; B32B 5/022 20130101; B32B 2262/12 20130101; B32B 27/065
20130101; B32B 2262/0253 20130101; B32B 2262/065 20130101; B32B
2262/0284 20130101; B32B 2255/26 20130101; B32B 2262/101 20130101;
B32B 2262/0276 20130101; B32B 2262/08 20130101; B32B 2266/0278
20130101; A47G 27/00 20130101; C09D 133/00 20130101; C09D 133/04
20130101; C08K 5/01 20130101 |
International
Class: |
E04F 15/10 20060101
E04F015/10; A47G 27/02 20060101 A47G027/02; E04F 15/02 20060101
E04F015/02 |
Claims
1. A composite article comprising: (a) A chemically abated flooring
surface, wherein the flooring surface contains a plurality of
pores, (b) At least one abatement chemical, wherein the at least
one abatement chemical is present in at least a portion of the
plurality of pores, (c) A polymer-containing barrier material, and
(d) A floorcovering article.
2. The composite article of claim 1, wherein the chemically abated
flooring surface is concrete.
3. The composite article of claim 1, wherein the at least one
abatement chemical is selected from petroleum-based chemicals,
natural-based chemicals, and mixtures thereof.
4. The composite article of claim 3, wherein petroleum-based
abatement chemicals are selected from the group consisting of
mineral spirits, glycol ethers, alcohols, and mixtures thereof.
5. The composite article of claim 3, wherein petroleum-based
abatement chemicals are selected from the group consisting of
diethylene glycol butyl ether, hydrotreated light petroleum
distillates, aminoethanol, 2-butoxyethanol,
2-(2-butoxyethoxy)ethanol, methylene chloride, methanol, toluene,
monoethanolamine, 1,2-dimethyl-4-ethylbenzene,
1,2,3,5-tertramethylbenzene, 1,2,4,5-tetramethylbenzene,
1,3-dimethyl-4-ethylbenzene, 1,3-dimethyl-5-ethylbenzene,
1,4-dimethyl-2-ethylbenzene, 1-methyl-3-propylbenzene, naphthalene,
1,2,4-trimethylbenzene, 3-ethyltoluene, mesitylene, 2-ethyltoluene,
4-ethyltoluene, 1,2,3-trimethylbenzene, propylbenzene, o-xylene,
ethoxylated nonylphenol, 2-(2-butoxyethoxy)ethanol, alcohol
alkoxylates, benzenemethanol, diethylene glycol monobutyl ether
acetate, N-methyl-2-pyrrolidone, 2-(2-aminoethoxy) ethanol, and
combinations thereof.
6. The composite article of claim 3, wherein natural-based
abatement chemicals are selected from the group consisting of
soy-containing materials, citrus-containing materials, and
combinations thereof.
7. The composite article of claim 6, wherein soy-containing
materials are selected from soybean oils.
8. The composite article of claim 7, wherein soybean oils are alkyl
esters of soybean oil.
9. The composite article of claim 8, wherein alkyl esters of
soybean oil are methyl esters of soybean oil.
10. The composite article of claim 6, wherein citrus-containing
materials are citrus oils.
11. The composite article of claim 10, wherein citrus oils include
D-limonene.
12. The composite article of claim 1, wherein the
polymer-containing barrier material is selected from the group
consisting of acrylic material, epoxy-based material, and
combinations thereof.
13. The composite article of claim 1, wherein the
polymer-containing barrier material further includes at least one
pigment.
14. The composite article of claim 13, wherein the at least one
pigment is selected from the group consisting of organic pigment,
inorganic pigment, extender pigment, and mixtures thereof.
15. The composite article of claim 14, wherein the extender pigment
is selected from the group consisting of kaolin, clay, silicate,
silica, calcium carbonate, talc, zinc oxide, and mixtures
thereof.
16. The composite article of claim 14, wherein the at least one
pigment is a kaolin-based material.
17. The composite article of claim 16, wherein the kaolin-based
material is layered silicate.
18. The composite article of claim 1, wherein the composite article
further includes at least one adhesive material.
19. The composite article of claim 18, wherein the at least one
adhesive material is selected from the group consisting of hot melt
adhesives, pressure sensitive adhesives, polyvinyl chloride,
acrylic/pvc copolymer, partially chlorinated acrylic polymer,
bitumen materials, and combinations thereof.
20. The composite article of claim 1, wherein the chemically abated
flooring surface is substantially free from mastic material.
21. The composite article of claim 1, wherein the floorcovering
article further contains at least one adhesive material.
22. The composite article of claim 1, wherein the floorcovering
article is selected from the group consisting of rugs, mats,
broadloom carpet, modular carpet, and combinations thereof.
23. The composite article of claim 22, wherein the floorcovering
article is modular carpet.
24. The composite article of claim 23, wherein the modular carpet
is carpet tile.
25. A process for installing a floorcovering article on a
chemically abated flooring surface comprising the steps of: (a)
Providing a chemically abated flooring surface; (b) Applying a
polymer-containing barrier material to at least a portion of the
chemically abated flooring surface to form a chemically abated
flooring surface containing a barrier coating thereon; and (c)
Applying a floorcovering article to the barrier-containing,
chemically abated flooring surface.
26. The process of claim 25, wherein the chemically abated flooring
surface is concrete.
27. The process of claim 25, wherein the polymer-containing barrier
material is selected from the group consisting of acrylic material,
epoxy-based material, and combinations thereof.
28. The process of claim 25, wherein the polymer-containing barrier
material further includes at least one pigment.
29. The process of claim 28, wherein the at least one pigment is a
kaolin-based material.
30. The process of claim 29, wherein the kaolin-based material is
layered silicate.
31. The process of claim 25, wherein the process further includes
the step of applying at least one adhesive material to the
chemically abated flooring surface having the barrier coating
thereon to form an adhesive-containing, chemically abated flooring
surface
32. The process of claim 31, wherein the at least one adhesive
material is selected from the group consisting of hot melt
adhesives, pressure sensitive adhesives, polyvinyl chloride,
acrylic/pvc copolymer, partially chlorinated acrylic polymer,
bitumen materials, and combinations thereof.
33. The process of claim 25, wherein the chemically abated flooring
surface is substantially free from mastic material.
34. The process of claim 25, wherein the floorcovering article
contains an adhesive material for contact with the flooring
surface.
35. The process of claim 25, wherein the floorcovering article is
selected from the group consisting of rugs, mats, broadloom carpet,
modular carpet, and combinations thereof.
36. The process of claim 35, wherein the floorcovering article is
modular carpet.
37. The process of claim 36, wherein the modular carpet is carpet
tile.
38. A process for installing a floorcovering article on a
chemically abated flooring surface comprising the steps of: (a)
Providing a flooring surface having a mastic material thereon; (b)
Applying at least one petroleum-based or natural-based abatement
chemical to the mastic material on the flooring surface; (c)
Agitating the at least one abatement chemical into and/or onto the
mastic material of the flooring surface to form a chemically
treated pre-abatement flooring surface; (d) Optionally, allowing
the chemically treated pre-abatement flooring surface to rest/soak
for a period of time; (e) Removing at least a portion of the mastic
material and the at least one abatement chemical from the flooring
surface to form a chemically abated flooring surface; (f) Applying
a polymer-containing barrier material to at least a portion of the
chemically abated flooring surface to form a chemically abated
flooring surface containing a barrier coating thereon; (g) Applying
at least one adhesive material to the chemically abated flooring
surface having the barrier coating thereon to form an
adhesive-containing, chemically abated flooring surface; and (h)
Applying a floorcovering article to the adhesive-containing,
chemically abated flooring surface.
39. The process of claim 38, wherein the flooring surface is
concrete.
40. The process of claim 38, wherein the at least one
petroleum-based abatement chemical is selected from the group
consisting of mineral spirits, glycol ethers, alcohols, and
mixtures thereof.
41. The process of claim 38, wherein the at least one
petroleum-based abatement chemical is selected from the group
consisting of diethylene glycol butyl ether, hydrotreated light
petroleum distillates, aminoethanol, 2-butoxyethanol,
2-(2-butoxyethoxy)ethanol, methylene chloride, methanol, toluene,
monoethanolamine, 1,2-dimethyl-4-ethyl benzene,
1,2,3,5-tertramethylbenzene, 1,2,4,5-tetramethylbenzene,
1,3-dimethyl-4-ethylbenzene, 1,3-dimethyl-5-ethylbenzene,
1,4-dimethyl-2-ethylbenzene, 1-methyl-3-propylbenzene, naphthalene,
1,2,4-trimethylbenzene, 3-ethyltoluene, mesitylene, 2-ethyltoluene,
4-ethyltoluene, 1,2,3-trimethylbenzene, propylbenzene, o-xylene,
ethoxylated nonylphenol, 2-(2-butoxyethoxy)ethanol, alcohol
alkoxylates, benzenemethanol, diethylene glycol monobutyl ether
acetate, N-methyl-2-pyrrolidone, 2-(2-aminoethoxy) ethanol, and
combinations thereof.
42. The process of claim 38, wherein the at least one natural-based
abatement chemical is selected from the group consisting of
soy-containing materials, citrus-containing materials, and
combinations thereof.
43. The process of claim 42, wherein soy-containing materials are
selected from soybean oils.
44. The process of claim 43, wherein soybean oils are alkyl esters
of soybean oil.
45. The process of claim 44, wherein alkyl esters of soybean oil
are methyl esters of soybean oil.
46. The process of claim 42, wherein citrus-containing materials
are citrus oils.
47. The process of claim 46, wherein citrus oils include
D-limonene.
48. The process of claim 38, wherein the chemically treated
pre-abatement flooring surface is allowed to rest and/or soak for a
period of about 0.25 hours to about 4 hours.
49. The process of claim 38, wherein the step of removing is
accomplished via at least one of the following methods: application
of and subsequent removal of dry absorbent material, application of
and subsequent removal of dry enzyme absorbent material, and
application of and subsequent removal of soap and/or surfactant and
water.
50. The process of claim 49, wherein the soap and/or surfactant
further includes an enzyme.
51. The process of claim 50, wherein the enzyme is a water-based
enzyme.
52. The process of claim 38, wherein the polymer-containing barrier
material is selected from the group consisting of acrylic
materials, epoxy-based materials, and combinations thereof.
53. The process of claim 38, wherein the polymer-containing barrier
material further includes at least one pigment.
54. The process of claim 53, wherein the at least one pigment is a
kaolin-based material.
55. The process of claim 54, wherein the kaolin-based material is
layered silicate.
56. The process of claim 38, wherein the at least one adhesive
material is selected from the group consisting of hot melt
adhesives, pressure sensitive adhesives, polyvinyl chloride,
acrylic/pvc copolymer, partially chlorinated acrylic polymer,
bitumen materials, and combinations thereof.
57. The process of claim 38, wherein the chemically abated flooring
surface is substantially free from mastic material.
58. The process of claim 38, wherein the floorcovering article
contains an adhesive material for contact with the flooring
surface.
59. The process of claim 38, wherein the floorcovering article is
selected from the group consisting of rugs, mats, broadloom carpet,
modular carpet, and combinations thereof.
60. The process of claim 59, wherein the floorcovering article is
modular carpet.
61. The process of claim 60, wherein the modular carpet is carpet
tile.
62. A process for installing a floorcovering article on a
chemically abated flooring surface comprising the steps of: (a)
Providing a flooring surface having a mastic material thereon; (b)
Applying at least one petroleum-based or natural-based abatement
chemical to the mastic material on the flooring surface; (c)
Agitating the at least one abatement chemical into and/or onto the
mastic material of the flooring surface to form a chemically
treated pre-abatement flooring surface; (d) Optionally, allowing
the chemically treated pre-abatement flooring surface to rest/soak
for a period of time; (e) Removing at least a portion of the
chemically treated pre-abatement flooring surface to form a
chemically abated flooring surface; (f) Applying a
polymer-containing barrier material to at least a portion of the
chemically abated flooring surface to form a chemically abated
flooring surface containing a barrier coating thereon; and (g)
Applying a floorcovering article to the chemically abated flooring
surface, wherein the floorcovering article contains at least one
adhesive material, wherein the at least one adhesive material is in
physical contact with the barrier coating of the chemically abated
flooring surface.
63. The process of claim 62, wherein the process further includes
the step of applying at least one adhesive material to the
chemically abated flooring surface having the barrier coating
thereon to form an adhesive-containing, chemically abated flooring
surface.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Patent
Application No. 62/656,387, entitled "Installation of Floorcovering
Article on Chemically Abated Flooring Surface and Composite
Article" which was filed on Apr. 12, 2018.
TECHNICAL FIELD
[0002] The present invention relates to the installation of
floorcovering articles on chemically abated flooring surfaces and
the composite article resulting therefrom. More specifically, the
invention relates to a process for chemical removal of mastic,
putty and/or paste material from a flooring surface. The process
includes applying abatement chemical to the mastic material on the
flooring surface to soften the mastic material and cause it to
physically separate and release from the flooring surface, removal
of the mastic material and abatement chemical, and the subsequent
application of a barrier coating to the flooring surface. The
barrier coating reduces and/or eliminates the migration of residual
abatement chemicals into floorcovering articles thereinafter
installed on the chemically abated flooring surface. The resulting
composite article is comprised of a chemically abated flooring
surface containing pores, at least one abatement chemical in said
pores, a polymer-containing barrier material, and a floorcovering
article.
BACKGROUND
[0003] Commercial and industrial buildings are generally known to
have concrete flooring as the foundation of their structures. When
installation of floorcovering articles is desired on this type of
flooring surface, a variety of adhesive materials and/or mastic
materials is used. Many of these materials are designed for
permanent or semi-permanent adhesion of the floorcovering article
to the flooring surface. A problem arises when it is time to
replace the floorcovering articles because it is often difficult to
remove the adhesive materials and/or mastic materials of the
previous installation. Thus, removal chemicals have been developed
and are used for abatement of these adhesive and/or mastic
materials from flooring surfaces. By using the abatement chemicals,
the physical scraping and mechanical force necessary to remove the
old adhesives and mastics is greatly reduced. No concrete,
asbestos, silica, or other dust is created. The original flat
concrete surface can typically be restored. Without the abatement
chemicals, mechanical grinding or bead blasting methods are
necessary. When dry mechanical methods are used, large amounts of
dust are put into the air creating potential health hazards,
especially when asbestos or silica is present. Dry methods require
appropriate air handling systems to prevent creating an airborne
mess in the building. The dust will settle on the floor, on walls,
and most problematically in the air handling system if special care
is not exercised. Alternatively, wet mechanical methods can also be
used. Unfortunately, these methods create a wet, concrete powder
slurry that also can be problematic to contain and dispose of.
Special care is needed to prevent the wet slurry from drying and
creating the dust issue discussed above. The water can damage walls
and adjacent floors if not contained. Since both grinding methods
remove some of the concrete from the surface, they require
additional restoration steps to produce a uniform, level surface
after grinding is completed.
[0004] However, the use of these abatement chemicals is not without
consequence. They are known to penetrate into the cracks and pores
in concrete while softening and freeing the adhesives from the
flooring surface. It is difficult to clean and remove the chemicals
from the cracks and pores of the concrete during subsequent washing
and removal steps of the abatement process. Later, after
floorcovering articles have been applied to the chemically abated
concrete, the chemicals are known to move (or migrate) into or onto
other articles in close contact with the flooring surface. This
movement/migration often leads to damage of the article.
[0005] Migration of chemicals from chemically treated flooring
surfaces into floorcovering articles can cause detrimental damage
to the floorcovering articles installed thereon. Invasion of
chemicals, such as petroleum-based materials like hydrotreated
light distillates (mineral spirits), alcohols, glycol ethers,
methylene chloride, toluene, alkylbenzenes, and the like, or
natural-based materials like alkyl esters of soybean oil, citrus
oils, and the like, into the floorcovering article generally occurs
through physical contact between the flooring surface and the
contact surface of the article. Unwanted compositional and
structural changes are possible. For example, issues with
delamination of layers, loss of adhesion, and edge curling (loss of
flatness) may occur. The result is reduced shelf-life and premature
replacement of the floorcovering articles.
[0006] The present invention addresses these issues by providing a
process that reduces the rate that the abatement chemical migrates
from the treated flooring surface into the floorcovering article
installed thereon by applying a barrier material to the flooring
surface after chemical abatement of the adhesive and/or mastic
material. The barrier material aids in reducing the migration of
residual abatement chemicals from the flooring surface to the
floorcovering articles. The process results in improved adhesion of
the article to the flooring surface and improved stability (e.g.
against delamination) of the article as well. Such improvements
lead to extended product life (i.e. reduced need to replace the
floorcovering articles), thereby providing a cost savings to the
end-user of the process.
BRIEF SUMMARY
[0007] In one aspect, the invention relates to a composite article
comprising: (a) a chemically abated flooring surface, wherein the
flooring surface contains a plurality of pores, (b) at least one
abatement chemical, wherein the at least one abatement chemical is
present in at least a portion of the plurality of pores, (c) a
polymer-containing barrier material, and (d) a floorcovering
article.
[0008] In another aspect, the invention relates to a process for
installing a floorcovering article on a chemically abated flooring
surface comprising the steps of: (a) providing a chemically abated
flooring surface; (b) applying a polymer-containing barrier
material to at least a portion of the chemically abated flooring
surface to form a chemically abated flooring surface containing a
barrier coating thereon; and (c) applying a floorcovering article
to the barrier-containing, chemically abated flooring surface.
[0009] In a further aspect, the invention relates to a process for
installing a floorcovering article on a chemically abated flooring
surface comprising the steps of: (a) providing a flooring surface
having a mastic material thereon; (b) applying at least one
petroleum-based or natural-based abatement chemical to the mastic
material on the flooring surface; (c) agitating the at least one
abatement chemical into and/or onto the mastic material of the
flooring surface to form a chemically treated pre-abatement
flooring surface; (d) optionally, allowing the chemically treated
pre-abatement flooring surface to rest/soak for a period of time;
(e) removing at least a portion of the mastic material and the at
least one abatement chemical from the flooring surface to form a
chemically abated flooring surface; (f) applying a
polymer-containing barrier material to at least a portion of the
chemically abated flooring surface to form a chemically abated
flooring surface containing a barrier coating thereon; (g) applying
at least one adhesive material to the chemically abated flooring
surface having the barrier coating thereon to form an
adhesive-containing, chemically abated flooring surface; and (h)
applying a floorcovering article to the adhesive-containing,
chemically abated flooring surface.
[0010] In yet another aspect, the invention relates to a process
for installing a floorcovering article on a chemically abated
flooring surface comprising the steps of: (a) providing a flooring
surface having a mastic material thereon; (b) applying at least one
petroleum-based or natural-based abatement chemical to the mastic
material on the flooring surface; (c) agitating the at least one
abatement chemical into and/or onto the mastic material of the
flooring surface to form a chemically treated pre-abatement
flooring surface; (d) optionally, allowing the chemically treated
pre-abatement flooring surface to rest/soak for a period of time;
(e) removing at least a portion of the chemically treated
pre-abatement flooring surface to form a chemically abated flooring
surface; (f) applying a polymer-containing barrier material to at
least a portion of the chemically abated flooring surface to form a
chemically abated flooring surface containing a barrier coating
thereon; and (g) applying a floorcovering article to the chemically
abated flooring surface, wherein the floorcovering article contains
at least one adhesive material, wherein the at least one adhesive
material is in physical contact with the barrier coating of the
chemically abated flooring surface.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a flow diagram illustrating the general process of
the invention.
[0012] FIG. 2 is a flow diagram illustrating the process of the
invention in greater detail.
[0013] FIG. 3 is an exploded schematic view of one embodiment of a
floorcovering article which may be applied to the chemically abated
flooring surface according to the present invention.
[0014] FIG. 4 is an expanded side view of one embodiment of a
vinyl-containing floor tile with individual adhesive units as
fasteners.
[0015] FIG. 5 is an expanded side view of another embodiment of a
vinyl-containing floor tile with individual adhesive units as
fasteners.
[0016] FIG. 6 is an expanded side view of yet a further embodiment
of a vinyl-containing floor tile with individual adhesive units as
fasteners.
[0017] FIG. 7 is an expanded side view of another embodiment of a
vinyl-containing floor tile with individual adhesive units as
fasteners.
[0018] FIG. 8 is a line graph illustrating the amount of abatement
chemical that migrated from the concrete flooring surface to the
floorcovering article for Examples 15, 17 and 18.
[0019] FIG. 9 is a line graph illustrating the amount of abatement
chemical that migrated from the concrete flooring surface to the
floorcovering article for Examples 3, 5 and 6.
[0020] FIG. 10 is a line graph illustrating the amount of abatement
chemical that migrated from the concrete flooring surface to the
floorcovering article for Examples 9, 11 and 12.
[0021] FIG. 11 is a line graph illustrating the amount of abatement
chemical that migrated from the concrete flooring surface to the
floorcovering article for Examples 13, 14 and 16.
[0022] FIG. 12 is a line graph illustrating the amount of abatement
chemical that migrated from the concrete flooring surface to the
floorcovering article for Examples 1, 2 and 4.
[0023] FIG. 13 is a line graph illustrating the amount of abatement
chemical that migrated from the concrete flooring surface to the
floorcovering article for Examples 7, 8 and 10.
DETAILED DESCRIPTION
[0024] The present invention relates to a process for the chemical
abatement of flooring surfaces and the subsequent application of
floorcovering articles to the chemically abated flooring
surfaces.
[0025] Definitions:
[0026] The term "floorcovering article," as used herein, is
intended to describe a textile substrate which comprises face
fibers and which is utilized to cover surfaces on which people are
prone to walk. Thus, floorcovering articles include broadloom
carpet; rugs; carpet tile; floor mats; indoor and outdoor rugs,
tiles and floor mats; and the like. Carpet tile is also known as
modular carpet.
[0027] The term "cement," as used herein, refers to a construction
adhesive comprised of powdered calcined rock and clay materials
that forms a paste when mixed with water and can be molded or
poured to set as a solid mass.
[0028] The term "concrete," as used herein, refers to a building
material made by mixing water with cement, gravel, and sand. It can
be molded or poured to set as a solid mass. It is generally
considered to be a porous material.
[0029] The term "mastic" and/or "mastic material," as used herein,
refers to an adhesive material used generally as a bonding agent in
commercial and industrial end-use applications and may be either
naturally or synthetically derived. It is generally known to those
skilled in the art as a quick and permanent binding agent which is
often difficult to later remove.
[0030] The term "adhesive" as used herein, refers to any mechanical
and/or chemical means used to create a lateral, frictional, and/or
peel force between at least two opposing surfaces.
[0031] The term "abate," as used herein, refers to decreasing in
amount, intensity and/or degree. Similarly, "abatement," as used
herein, refers to a decrease in amount, intensity and/or
degree.
[0032] The term "thermoplastic" is used herein in its conventional
sense to mean a resin having the property of softening or fusing
when heated and of hardening again when cooled. Thermoplastic
materials suitable for use herein are selected from the group
consisting of polyolefin polymers (such as polyethylene, linear low
density polyethylene, polypropylene, polybutylene and copolymers
made from ethylene, propylene and/or butylene), polyvinyl chloride
(including high density polyvinyl chloride), polyvinylidene
chloride, cellulosic resins (such as cellulose acetate, cellulose
acetate butyrate and cellulose acetate propionate), acrylic resins
(such as polymethyl methacrylate, styrene acrylonitrile,
polystyrene, polycarbonate and acrylonitrile-butadiene-styrene),
polyamides (such as nylon 6 and nylon 6,6), polyesters (such as
polyethylene terephthalate, glycol modified polyethylene
terephthalate and polybutylene terephthalate), and the like, and
combinations thereof.
[0033] The present invention will now be described with reference
to the Figures.
[0034] FIG. 1 illustrates the general process of the invention in
flowchart format. First, a decision is made about whether a
particular flooring surface (such as a concrete flooring surface)
contains mastic material that needs to be removed prior to further
use. If this is indeed the case, then the mastic material is
removed (abated) according to the steps described herein. Then, the
loosened mastic material and abatement chemical(s) are removed and
the chemically-abated flooring surface is cleaned. Next, a
polymer-containing barrier material is applied. Finally, the
floorcovering articles are applied and/or installed.
[0035] FIG. 2 is a process flow chart illustrating the process of
the invention in greater detail. As shown in FIG. 2, a concrete
floor is provided having some amount of mastic and/or mastic
material thereon. At least one abatement chemical is applied to the
mastic-containing concrete floor. The abatement chemical is
selected from the group consisting of petroleum-based abatement
chemicals, natural-based abatement chemicals, and combinations or
mixtures thereof.
[0036] Petroleum-based abatement chemicals generally include
chemicals derived from materials containing a mixture of
hydrocarbons such as alkanes (branched and/or linear hydrocarbons),
aromatic hydrocarbons, cycloalkanes, and asphaltenes. Exemplary
petroleum-based abatement chemicals are selected from the group
consisting of diethylene glycol butyl ether (herein also "DGBE"),
hydrotreated light petroleum distillates (mineral spirits, herein
also "MS"), aminoethanol, 2-butoxyethanol (herein also "BOE"),
2-(2-butoxyethoxy)ethanol, methylene chloride (dichloromethane),
methanol and other alcohols, toluene, monoethanolamine,
1,2-dimethyl-4-ethylbenzene, 1,2,3,5-tertramethylbenzene,
1,2,4,5-tetramethylbenzene, 1,3-dimethyl-4-ethylbenzene,
1,3-dimethyl-5-ethylbenzene, 1,4-dimethyl-2-ethylbenzene,
1-methyl-3-propylbenzene, naphthalene, 1,2,4-trimethylbenzene,
3-ethyltoluene, mesitylene, 2-ethyltoluene, 4-ethyltoluene,
1,2,3-trimethylbenzene, propylbenzene, o-xylene, ethoxylated
nonylphenol, 2-(2-butoxyethoxy)ethanol, alcohol alkoxylates,
benzenemethanol (benzyl alcohol), diethylene glycol monobutyl ether
acetate and other glycol ethers, N-methyl-2-pyrrolidone,
2-(2-aminoethoxy) ethanol, and combinations thereof.
[0037] Natural-based abatement chemicals generally include
chemicals derived from materials containing non-toxic ingredients
that exhibit useful abatement and/or cleaning properties. Exemplary
natural-based abatement chemicals are selected from the group
consisting of soy-containing materials (herein also "Soy"),
citrus-containing materials (such as orange), and combinations
thereof. Soy-containing materials include soybean oils. Soybean
oils include methyl ester of soybean oil. Citrus-containing
materials include citrus oils (such as orange oil, lemon oil, and
the like). Citrus oils include D-limonene.
[0038] The abatement chemical may be allowed to soak into and/or
onto the flooring surface for a period of time. In one aspect of
the invention, the abatement chemical is allowed to soak for a
period of about 0.25 hours to about 4 hours, or from about 0.5
hours to about 3 hours, or even from about 1 hour to about 2 hours.
During the soaking time, the surface may be mechanically agitated
with a scraper to improve the penetration of the chemical into and
under the mastic, allowing faster removal from the flooring
surface.
[0039] As further shown in FIG. 2, after application of the at
least one abatement chemical to the mastic-containing flooring
surface, the loosened mastic is pushed into a pile or puddle and
removed using dry absorbents, plastic shovels, and/or
explosion-proof wet vacuums. Preferably, the dry absorbent material
is used to aid in soaking up/absorbing the loosened and/or
removable mastic material and abatement chemical(s) for ease of
disposal. Examples of some dry absorbents include OIL DRI.RTM.
Granular Clay Absorbent (Uline, Wisconsin), Floor Dry Granular
Diatomaceous Earth Absorbent (West Coast Spill Supplies, Canada),
K-SORB.RTM. Cellulosic Absorbents (Ecosorb International, Texas),
Vermiculite Granular Absorbent (Uline, Wisconsin), Petroguard
Granular Absorbent (Guardian Environmental Technologies,
Connecticut) and Corn Cob Absorbents (The Andersons Cob Products,
Ohio). In one aspect of the invention, the dry absorbent includes
an enzyme that can aid the decomposition and further removal of the
abatement chemical. An example is BacKrete.RTM. Waterless Concrete
Cleaner (BacKrete Corporation, North Carolina).
[0040] After the mastic material has been removed from the concrete
floor, the flooring surface is cleaned with soap (or detergent) and
water. In one aspect of the invention, the soap includes an enzyme.
In another aspect of the invention, the enzyme is a water-based
enzyme. Exemplary enzyme-containing detergent products include
CoverClean HC and CoverClean FG (CoverTec Products, Florida), and
Serpro Tarmac and Asphalt Oil Stain Remover (Serpro, Kent,
England). Example enzymes include lipases that catalyze the
hydrolysis of organic chemicals, especially fats and oils. Some
commercial enzyme manufacturers include Dupont Industrial
Biosciences (US), Amano Enzyme (Japan), Novozymes (Denmark), AUM
Enzymes (India), AB Enzymes (Germany), BASF (Germany), and VTR
Bio-Tech (China).
[0041] While diligent efforts may be made to remove all of the
mastic material and abatement chemicals from the flooring surface,
it is generally known that concrete is a porous material. As such,
residual abatement chemicals may remain on the surface of the floor
and/or in the pores or cracks of the flooring surface. Such an
arrangement allows for the possibility that these residual
abatement chemicals will come into direct physical contact with (or
close/near physical contact with) other materials, such as
floorcovering articles. Without being bound by theory, it is
believed that these residual chemicals migrate onto and/or into the
floorcovering articles subsequently installed thereon. Measurements
by gas chromatography, for example, can be used to evaluate the
amount of chemical that has migrated. In one aspect of the
invention, the chemically abated flooring surface is substantially
free from mastic material.
[0042] In order to reduce and/or eliminate abatement chemical
migration, a polymer-containing barrier material is applied to the
chemically-abated flooring surface as illustrated in FIG. 2. The
polymer-containing barrier material may be applied to the flooring
surface using any of a variety of application techniques. Exemplary
application techniques include, without limitation, paint coating,
spray coating, roller coating, troweling methods, brush coating,
and the like, and mixtures thereof.
[0043] It is believed that the barrier material provides a
much-needed layer and/or coating for restricting and/or hindering
the passage of any remaining chemical residue into the subsequently
installed floorcovering article(s). Suitable polymer-containing
barrier materials are selected from the group consisting of acrylic
materials, epoxy-based materials, and mixtures and combinations
thereof. Examples of suitable manufacturers of acrylic-based
materials include Dow Chemical, Michigan (Roshield.RTM. and
Rhoplex.RTM. Acrylic Emulsions); BASF, Germany (Joncryl.RTM.
Acrylic Emulsions); Royal Adhesives, South Carolina (Hydra
FAST-EN.RTM. brand); Lubrizol, Ohio (Carboset.RTM., Hycar.RTM., and
Vycar.RTM. Emulsions); Star Seal, Ohio (SOS Sealer.RTM.); and
Dalton Enterprises, Connecticut (Latex-ite.RTM.). Epoxy-based
materials include, for example, two-component epoxy-amines such as
Epoxy Oil Stop Primer--For Oil Saturated Concrete (available from
Epoxy Systems Inc. of Dunnellon, Fla.) and EM Oil Stop--Oil
Saturated Concrete Floor Primer (available from Epoxy Master of
Troy, Mich.). Epoxy-based materials also include, for example,
solvent-based epoxy materials such as Oil Stop Primer (available
from CoverTec of Sunrise, Fla.), SCI Oil Stop Primer 195-120
(available from Specialty Coatings Inc. of Fraser, Mich.), and
Epoxy Oil Stop Coating HD 820 (available from Legacy Industrial of
Winter Garden, Fla.). Other polymer-containing barrier materials
may be utilized as well, either alone or in combination with those
discussed herein, so long as they provide the desired barrier
property of the present invention.
[0044] In one aspect of the invention, pigments may also be
included in the polymer-containing barrier material, as shown in
FIG. 2. The color pigments may be organic (such as pigment red 170,
pigment yellow 17, and/or pigment blue 1), inorganic (such as iron
oxide and/or titanium dioxide), and mixtures thereof. Extender
pigments include materials such as kaolin, clay, silicates, silica,
calcium carbonate, talc, zinc oxide, and mixtures thereof.
Exemplary suppliers of pigments include Lansco Colors (New York),
Dystar (Singapore), BASF (Germany), Chemours (Delaware), Imerys
(France), Malvern Minerals Company (Arkansas), and Thiele Kaolin
Company (Georgia). A preferred pigment is a kaolin-based material.
Kaolin-based materials add color to the barrier material, while
also improving the barrier properties of coatings. Commercially
available examples of kaolin-based materials are the Hydrite.RTM.
kaolin products from Imerys. As known in the art, wetting agents,
dispersing agents, defoamers, and the like (more broadly classified
as surfactants) may be added to improve the dispersion of the
pigments and the spreading properties of the coating. Exemplary
suppliers of surfactants include Dow (Michigan), Dystar
(Singapore), and BASF (Germany). In one aspect of the invention,
pigments having a plate-like morphology may be desired. Mixtures of
any of the aforementioned pigments may be suitable for use in the
present invention.
[0045] In one aspect of the invention, at least one adhesive
material is applied to the floorcovering article during the
manufacturing process. In this embodiment, the floorcovering
articles are ready to be installed on the chemically-abated
flooring surface that further contains a barrier material. After
installation, at least a portion of the adhesive material is in
direct physical contact with at least a portion of the barrier
material.
[0046] In another aspect of the invention, at least one adhesive
material is applied to the chemically-abated flooring surface that
further contains a barrier material (i.e. not applied to
floorcovering article during the manufacturing process).
[0047] It is also further contemplated to be within the scope of
this invention that the at least one adhesive material is applied
both to the floorcovering article during the manufacturing process
and to the chemically-abated flooring surface separately from the
manufacturing process. Alternatively, in another aspect of the
invention, no adhesive material is applied to the chemically-abated
flooring surface.
[0048] Adhesive materials are selected from the group consisting of
hot melt adhesives (such as polyurethane hotmelt, polyolefin
hotmelt, and the like), pressure sensitive adhesives, polyvinyl
chloride ("pvc"), acrylic/pvc copolymer, partially chlorinated
acrylic polymer, bitumen materials, and the like, and combinations
thereof. Pressure sensitive adhesives include emulsions, solutions
(also called solvent adhesives), hot melts adhesives, ultraviolet
light-cured adhesives, and solids (referring to the amount of
non-solvent content in an adhesive by weight). Pressure sensitive
adhesives may be selected from rubber-based adhesives,
acrylic-based adhesives, modified acrylic adhesives, silicone
adhesives, and combinations thereof.
[0049] Pressure-sensitive adhesives (or "PSAs") are generally
classified into two main classes: 100% solids and less than 100%
solids. A 100% solids refers to the amount of non-solvent content
in an adhesive by weight. These adhesive materials are further
characterized as being polymeric adhesive materials. In the class
of 100% solids, adhesive materials may be further characterized as
plastisol, thermoplastic, or thermoset. Thermoplastic adhesives are
also known as hot-melt adhesives. In the class of less than 100%
solids, adhesive materials may be further characterized as solvent
borne-solution or water-borne emulsion (also referred to as
water-borne latex). Within each of these further characterizations,
adhesive materials may be described as being either a permanent
adhesive or a removeable/repositionable adhesive. As used herein, a
"permanent" adhesive is an adhesive designed to stick to a
substrate (also known as the adherent) without edge lifting and
that cannot be removed without damaging either the adhesive
material itself or the substrate to which it has been adhered. A
"removeable" adhesive is an adhesive designed to stick to a
substrate without edge lifting and that can be removed without
damaging either the adhesive material itself or the substrate to
which it has been adhered. In addition, "permanent" or
"removeable/repositionable" can be determined by how the layers of
material which are adhered together with an adhesive material
fracture during stress (also known as "adhesive failure mode"). For
example, under stress, permanent adhesives are typically designed
to fracture in the adherent itself and not in the interface of
adhesive material and adherent. In contrast, repositionable
adhesives are typically designed to fracture under stress in the
interface of the adhesive material and the adherent. Additional
information regarding adhesive materials as described herein may be
found at
https://label.averydennison.asia/content/dam/averydennison/lpm/na/en/doc/-
home/res ource%20center/Adhesive%200verview(1).pdf, which is
entirely incorporated by reference herein. Also, adhesive materials
useful in the present invention are described in Pressure-Sensitive
Design and Formulation, Application by Istvan Benedek (Koninklijke
Brill Nev., Leiden, The Netherlands, Vol. 2, 2006), which book is
entirely incorporated by reference herein. Information regarding
adhesives under stress (e.g. adhesive failure modes) can be found
at http://www.nhml.com/adhesion-failure-modes, which is entirely
incorporated by reference herein.
[0050] In one aspect of the invention, and as shown in FIG. 1,
Adhesive A and Adhesive B are pressure sensitive adhesives.
Adhesive A is a waterborne acrylic pressure sensitive adhesive.
Adhesive B is a hotmelt pressure sensitive adhesive. Commercially
available acrylic pressure sensitive adhesives are available, for
example, from Bostik (US) and Royal Adhesives and Sealants (US).
Commercially available hotmelt pressure sensitive adhesives are
available, for example, from Bostik (US), Reynolds (US), and
Adhesive Specialists Inc. (US).
[0051] Standard methods of known floorcovering installation may be
used to achieve application and/or adherence of the floorcovering
article to the flooring surface. For the sake of completeness and
illustration, the construction of floorcovering articles is further
herein described.
[0052] Floorcovering articles, that may be applied to and/or
installed on the chemically-abated flooring surface of the
invention described herein include, without limitation, woven
carpet, knitted carpet, tufted carpet, graphics tufted carpet,
stitched on pile carpet, bonded pile carpet, hooked carpet, knotted
pile carpet, and the like. The floorcovering articles may be
broadloom carpet or carpet tiles. The floorcovering articles may be
of any suitable construction (e.g. hardback, cushion back, etc.).
The face may be constructed of any appropriate textile material in
yarn or pile form that is suitable for dyeing and patterning, and
may have a face height or pile height that is uniform or
non-uniform (e.g. may be textured, as found in a multi-level loop
pile) created by tufting, needling, flocking, bonding, and the
like, or the use of non-woven substrates. Patterning of the
floorcovering article may be achieved by weaving, tufting, and/or
printing processes.
[0053] In one aspect of the present invention, the tufted pile
carpet is comprised of yarn tufted into fabric, which is then
injection or fluid dyed, and then bonded with a rubber layer or
latex backing. The carpet yarn may be selected from nylon 6; nylon
6,6; polyester; and polypropylene fiber. The yarn is tufted into a
woven or nonwoven substrate. The yarn can be of any pile height and
weight necessary to support printing. The tufted pile carpet may be
printed using any print process. In one aspect, injection dyeing
may be utilized to print the tufted pile carpet.
[0054] Printing inks will contain at least one dye. Dyes may be
selected from acid dyes, direct dyes, reactive dyes, cationic dyes,
disperse dyes, and mixtures thereof. Acid dyes include azo,
anthraquinone, triphenyl methane and xanthine types. Direct dyes
include azo, stilbene, thiazole, dioxsazine and phthalocyanine
types. Reactive dyes include azo, anthraquinone and phthalocyanine
types. Cationic dyes include thiazole, methane, cyanine, quinolone,
xanthene, azine, and triaryl methine. Disperse dyes include azo,
anthraquinone, nitrodiphenylamine, naphthal imide, naphthoquinone
imide and methane, triarylmethine and quinoline types.
[0055] As is known in the textile printing art, specific dye
selection depends upon the type of fiber and/or fibers comprising
the floorcovering article being printed. For example, in general, a
disperse dye may be used to print polyester fibers. Alternatively,
for materials made from cationic dyeable polyester fiber, cationic
dyes may be used.
[0056] Printing processes useful in conjunction with the present
invention may employ a jet dyeing machine, or a digital printing
machine, to place printing ink on the surface of the floorcovering
article in predetermined locations. One suitable and commercially
available digital printing machine is the Millitron.RTM. digital
printing machine, available from Milliken & Company of
Spartanburg, S.C. The Millitron.RTM. machine uses an array of jets
with continuous streams of dye liquor that can be deflected by a
controlled air jet. The array of jets, or gun bars, is typically
stationary. Another suitable and commercially available digital
printing machine is the Chromojet.RTM. carpet printing machine,
available from Zimmer Machinery Corporation of Spartanburg, S.C. In
one aspect, a tufted carpet made according to the processes
disclosed in U.S. Pat. Nos. 7,678,159 and 7,846,214, both to
Weiner, may be printed with a jet dyeing apparatus as described and
exemplified herein.
[0057] Viscosity modifiers may be included in the printing ink
compositions. Suitable viscosity modifiers that may be utilized
include known natural water-soluble polymers such as
polysaccharides, such as starch substances derived from corn and
wheat, gum arabic, locust bean gum, tragacanth gum, guar gum, guar
flour, polygalactomannan gum, xanthan, alginates, and a tamarind
seed; protein substances such as gelatin and casein; tannin
substances; and lignin substances. Examples of the water-soluble
polymer further include synthetic polymers such as known polyvinyl
alcohol compounds and polyethylene oxide compounds. Mixtures of the
aforementioned viscosity modifiers may also be used. The polymer
viscosity is measured at elevated temperatures when the polymer is
in the molten state. For example, viscosity may be measured in
units of centipoise at elevated temperatures, using a Brookfield
Thermosel unit from Brookfield Engineering Laboratories of
Middleboro, Mass. Alternatively, polymer viscosity may be measured
by using a parallel plate rheometer, such as made by Haake from
Rheology Services of Victoria Australia.
[0058] One exemplary floorcovering construction is shown in FIG. 3.
In this exemplary construction, floorcovering article 325 is made
up of a primary carpet fabric 312 formed from a plurality of pile
yarns 314 tufted through a primary backing layer 316 such as a
scrim or nonwoven fibrous textile of polyester or polypropylene. A
precoat backing layer 318 of a resilient adhesive such as SBR latex
is disposed across the underside of primary carpet fabric 312 so as
to hold the pile yarns 314 in place within the primary backing 316.
An adhesive layer 320 such as a hot melt adhesive extends away from
the precoat backing layer 318. A layer of stabilizing material 322
such as woven or nonwoven glass is disposed at a position between
the adhesive layer 320 and a cushioning layer 324 such as virgin or
rebounded polyurethane foam or the like. A secondary backing layer
326 such as a nonwoven blend of polyester and polypropylene fibers
is disposed across the underside of the cushioning layer 324.
[0059] Pile yarns 314 may be either spun or filament yarns formed
of natural fibers such as wool, cotton, or the like. The pile yarns
314 may also be formed of synthetic materials such as polyamide
polymers including nylon 6 or nylon 6,6; polyesters such as PET and
PBT; polyolefins such as polyethylene and polypropylene; rayon; and
polyvinyl polymers such as polyacrylonitrile. Blends of natural and
synthetic fibers such as blends of cotton, wool, polyester and
nylon may also be used within the pile yarns 314. In FIG. 3, the
pile yarns 314 are illustrated in a loop pile construction. Of
course, it is to be understood that other pile constructions as
will be known to those of skill in the art including cut pile
constructions and the like may likewise be used.
[0060] Floorcovering articles may have a fiber face weight in the
range from about 1 to about 75 ounces/square yard, or in the range
from about 5 to about 60 ounces/square yard, or in the range from
about 10 to about 55 ounces/square yard, or in the range from about
20 to about 50 ounces/square yard.
[0061] In addition, the textile materials and/or fabrics comprising
the floorcovering article, for example, the pile surface of a
floorcovering article, may be synthetic fiber, natural fiber,
man-made fiber using natural constituents, inorganic fiber, glass
fiber, or a blend of any of the foregoing. By way of example only,
synthetic fibers may include polyester, acrylic, polyamide,
polyolefin, polyaramid, polyurethane, or blends thereof. More
specifically, polyester may include polyethylene terephthalate,
polytrimethylene terephthalate, polybutylene terephthalate,
polylactic acid, or combinations thereof. Polyamide may include
nylon 6, nylon 6,6, or combinations thereof. Polyolefin may include
polypropylene, polyethylene, or combinations thereof. Polyaramid
may include poly-p-phenyleneteraphthalamide (i.e., Kevlar.RTM.),
poly-m-phenyleneteraphthalamide (i.e., Nomex.RTM.), or combinations
thereof. Exemplary natural fibers include wool, cotton, linen,
ramie, jute, flax, silk, hemp, or blends thereof. Exemplary
man-made materials using natural constituents include regenerated
cellulose (i.e., rayon), lyocell, or blends thereof.
[0062] The textile substrates of the floorcovering article may be
formed from staple fiber, filament fiber, slit film fiber, or
combinations thereof. The fiber may be exposed to one or more
texturing processes. The fiber may then be spun or otherwise
combined into yarns, for example, by ring spinning, open-end
spinning, air jet spinning, vortex spinning, or combinations
thereof. Accordingly, the textile substrates will generally be
comprised of interlaced fibers, interlaced yarns, loops, or
combinations thereof.
[0063] The textile substrates may be comprised of fibers or yarns
of any size, including microdenier fibers or yarns (fibers or yarns
having less than one denier per filament). The fibers or yarns may
have deniers that range from less than about 0.1 denier per
filament to about 2000 denier per filament or, more preferably,
from less than about 1 denier per filament to about 500 denier per
filament.
[0064] Furthermore, the textile substrates may be partially or
wholly comprised of multi-component or bi-component fibers or yarns
in various configurations such as, for example, islands-in-the-sea,
core and sheath, side-by-side, or pie configurations. Depending on
the configuration of the bi-component or multi-component fibers or
yarns, the fibers or yarns may be splittable along their length by
chemical or mechanical action.
[0065] Additionally, the fibers comprising the textile substrates
may include additives coextruded therein, may be precoated with any
number of different materials, including those listed in greater
detail below, and/or may be dyed or colored to provide other
aesthetic features for the end user with any type of colorant, such
as, for example, poly(oxyalkylenated) colorants, as well as
pigments, dyes, tints, and the like. Other additives may also be
present on and/or within the target fiber or yarn, including
antistatic agents, brightening compounds, nucleating agents,
antioxidants, UV stabilizers, fillers, permanent press finishes,
softeners, lubricants, curing accelerators, and the like.
[0066] As will be appreciated, the actual construction of
floorcovering article 325 may be subject to a wide range of
variations. Accordingly, the multi-layered construction illustrated
in FIG. 3 is to be understood as constituting merely an exemplary
construction representative of a floorcovering article and that the
present invention is equally applicable to any other construction
of carpeting and/or other textiles as may be desired. By way of
example only, various suitable carpet tile constructions are
described in U.S. Pat. Nos. 6,203,881 and 6,468,623.
[0067] Other floorcovering articles may include vinyl tile, such as
luxury vinyl tile. FIGS. 4 to 7 illustrate various vinyl tile
constructions which may be utilized with the process of the present
invention. FIGS. 4 to 7 are representative examples of
multi-layered vinyl floor tile also known as a luxury vinyl tile
(or "LVT"). FIG. 4 illustrates vinyl tile 400 comprised of seven
sequential layers that include polyurethane coating 410,
transparent wear layer 420, printed layer 430, vinyl core layer
450, vinyl backing layer 460, adhesive layer 470, and textile
substrate layer 490. In one aspect of the invention, transparent
wear layer 420 may be comprised of a vinyl-containing material.
Adhesive layer 470 may also be comprised of a vinyl-containing
adhesive material. In another aspect of the invention, textile
substrate layer 490 is a nonwoven textile substrate and is
comprised of polyester fiber, polypropylene fiber or blends of
polyester and polypropylene fibers. An adhesive system is
illustrated as adhesive fastener 440. Adhesive fastener 440 is
comprised of adhesive materials as described herein. Adhesive
fastener 440 is positioned and attached to vinyl tile 400. A
plurality of vinyl tiles may be attached to one another via the
adhesive fasteners. Additional adhesive material is utilized with
the adhesive system to form a non-floating floorcovering article
comprised of a plurality of vinyl tiles attached to one another via
adhesive fasteners.
[0068] FIG. 5 illustrates vinyl tile 500 comprised of eight
sequential layers that include polyurethane coating 510,
transparent wear layer 520, printed layer 530, vinyl core layer
550, vinyl backing layer 560, adhesive layer 570, foam layer 580,
and textile substrate layer 590. In one aspect of the invention,
transparent wear layer 520 may be comprised of a vinyl-containing
material. Adhesive layer 570 may also be comprised of a
vinyl-containing adhesive material. Foam layer 580 is an open cell
or closed cell foam material. Foam layer 580 may be a polyurethane
foam, a foamed vinyl material, or a foamed layer comprised of other
suitable polymer materials known for use as foam articles. In
another aspect of the invention, textile substrate layer 590 is a
nonwoven textile substrate and is comprised of polyester fiber,
polypropylene fiber or blends of polyester and polypropylene
fibers. An adhesive system is illustrated as adhesive fastener 540.
Adhesive fastener 540 is comprised of adhesive materials as
described herein. Adhesive fastener 540 is positioned and attached
to vinyl tile 500.
[0069] FIG. 6 illustrates vinyl tile 600 comprised of eight
sequential layers that include polyurethane coating 610,
transparent wear layer 620, printed layer 630, vinyl core layer
650, glass fiber layer 655, vinyl backing layer 660, adhesive layer
670, and textile substrate layer 690. In one aspect of the
invention, transparent wear layer 620 may be comprised of a
vinyl-containing material. Adhesive layer 670 may also be comprised
of a vinyl-containing adhesive material. In another aspect of the
invention, textile substrate layer 690 is a nonwoven textile
substrate and is comprised of polyester fiber, polypropylene fiber
or blends of polyester and polypropylene fibers. An adhesive system
is illustrated as adhesive fastener 640. Adhesive fastener 640 is
comprised of adhesive materials as described herein. Adhesive
fastener 640 is positioned and attached to vinyl tile 600.
[0070] FIG. 7 illustrates vinyl tile 700 comprised of nine
sequential layers that include polyurethane coating 710,
transparent wear layer 720, printed layer 730, vinyl core layer
750, glass fiber layer 755, vinyl backing layer 760, adhesive layer
770, foam layer 780, and textile substrate layer 790. In one aspect
of the invention, transparent wear layer 720 may be comprised of a
vinyl-containing material. Adhesive layer 770 may also be comprised
of a vinyl-containing adhesive material. Foam layer 780 is an open
cell or closed cell foam material. Foam layer 780 may be a
polyurethane foam, a foamed vinyl material, or a foamed layer
comprised of other suitable polymer materials known for use as foam
articles. In another aspect of the invention, textile substrate
layer 790 is a nonwoven textile substrate and is comprised of
polyester fiber, polypropylene fiber or blends of polyester and
polypropylene fibers. An adhesive system is illustrated as adhesive
fastener 740. Adhesive fastener 740 is comprised of adhesive
materials as described herein. Adhesive fastener 740 is positioned
and attached to vinyl tile 700.
[0071] It should be noted that the layers of the vinyl article
described herein (e.g. as described in FIGS. 4 to 7) are typically
prepared and combined together in larger roll form, and not
initially in smaller tile form. Thus, after assembling the layers
of the vinyl article together, the article is then cut into vinyl
tiles. The vinyl article may be cut using a computer controlled
cutting device, such as a Gerber machine, or by using a mechanical
dye cutter. The vinyl article should be cut with precision such
that the resulting cut tiles fit in place with the surrounding cut
tiles. The vinyl article may be cut into vinyl tiles having sizes
in the range from 4 inches by 4 inches to 72 inches by 72 inches.
The vinyl tiles may be of the same length and width, thus forming a
square shape. Or, the vinyl tiles may have different dimensions
such that the width and the length are not the same. For example,
the vinyl tiles may be a rectangular shape.
[0072] It should be understood that the construction of the vinyl
tile described herein is not limited only to that which is shown by
the Figures. Additional layers of substrate may be included in the
vinyl tile. For example, a removeable and/or/repositionable
adhesive may be included on the floor facing surface of the vinyl
tile. Alternatively, one or more layers of substrate may be removed
from the vinyl tile and still be within the scope of the present
invention.
[0073] The following examples further illustrate the subject matter
of the present invention but should not be construed as in any way
limiting the scope thereof.
[0074] The chemical abatement process of the invention was
conducted and tested as described herein below. The flooring
surface was concrete having mastic material thereon. The
floorcovering article applied to the chemically abated flooring
surface was carpet tile. The carpet tile was commercially available
Underscore--Formwork carpet tile and Underscore--Tractionback
Plus--Formwork carpet tile, both available from Milliken &
Company of Spartanburg, S.C. The size of each carpet tile was 50 cm
by 50 cm.
[0075] The following process for chemical abatement of the flooring
surface according to this invention was used: [0076] 1. Abatement
chemical was poured onto the concrete flooring surface and spread
across the flooring surface with a plastic short bristle brush.
[0077] 2. The abatement chemical was allowed to soak and penetrate
into the mastic material for 15-25 minutes. [0078] 3. A floor
scraper was used to rub and scrape the concrete surface. Loosened
mastic material was moved and into a pile and removed with a
plastic shovel. [0079] 4. The flooring surface was scrubbed with a
short bristle brush. [0080] 5. As needed, additional abatement
chemical was added to the flooring surface. [0081] 6. The abatement
chemical was allowed to soak for 1 to 2 hours. [0082] 7. "Oil-Dri"
dry absorbent was spread on the flooring surface at a rate of
40#/100-150 ft.sup.2 until all of the visible abatement chemical
was removed. [0083] 8. The dry absorbent was collected into plastic
drums for proper waste disposal. [0084] 9. The flooring surface was
cleaned with detergent and water per product instructions. [0085]
10. The liquid on the flooring surface was then squeegeed and
removed with a wet vacuum and/or mop. [0086] 11. Using clean water
and a mop, the flooring surface was mopped several times, with
frequent water changes. [0087] 12. The flooring surface was allowed
to dry for 3 days. [0088] 13. A barrier chemical was applied to the
chemically abated flooring surface using a 3/8'' nap paint roller.
The paint roller was rolled in both horizontal and vertical
directions in order to thoroughly and uniformly coat the flooring
surface with the barrier chemical. [0089] 14. The chemically abated
flooring surface containing a barrier coating was allowed to air
dry. [0090] 15. Carpet tile was then applied to the flooring
surface using the appropriate installation techniques for each
respective carpet.
[0091] The following materials were used in the process of the
invention:
[0092] Abatement Chemicals:
[0093] Three abatement chemicals were tested according to the
process of the invention. Sentinel Low Odor Mast Remover SC-170
(referred to as "Petroleum" in Tables) was a petroleum-based
chemical available from Jon-Don Atlanta of Norcross, Ga. Mast-Away
77 (referred to as "Citrus" in Tables) was a natural-based citrus
chemical available from Mast-Away Mastic Removers of St. Louis, Mo.
Blue Bear.RTM. 500 MR (referred to as "Soy" in Tables) was an alkyl
ester soybean oil-based chemical available from Jon-Don Atlanta of
Norcross, Ga.
[0094] Cleaning Materials:
[0095] Two cleaning materials were tested according to the process
of the invention. CoverClean HC (referred to as "Bio Soap" in
Tables) was a microbial cleaner available from CoverTec Products of
Sunrise, Fla. Phlex Cleaner/Degreaser (also referred to as
"Standard Soap" in Tables) was a solvent-free cleaner and degreaser
detergent available from Mast-Away Mastic Removers of St. Louis,
Mo.
[0096] Barrier Materials:
Several barrier materials were tested according the process of the
invention. Star.RTM. SOS Sealer.TM. (referred to as "SOS" in
Tables) was a latex-based coating available from Hercules Sealcoat
Mfg., Inc. Star.RTM. SOS Sealer.TM. was also diluted with water to
create a mixture that was 50% by weight of the SOS material
(referred to as "50% SOS" in Tables). Latex-Ite.RTM. Oil Spot
Primer (referred to as "Latex-Re" in Tables) was a synthetic resin
liquid material available from Dalton Enterprises, Inc. of
Cheshire, Conn. In several embodiments of testing, no barrier
material was used (indicated as "None" in Tables).
[0097] Adhesive Materials:
[0098] Two adhesive materials were tested according the process of
the invention.
[0099] Adhesive A was Milliken Non-Reactive Standard Modular Carpet
Adhesive, an acrylic emulsion adhesive available from Milliken
& Company of Spartanburg, S.C. It was applied to the cleaned
floor using a 3/4'' nap roller and air dried as specified in the
product's published installation instructions.
[0100] Adhesive B was TractionBack.RTM. Plus backing system also
from Milliken & Company. A hotmelt-based, high friction,
pressure sensitive adhesive was applied to the carpet tile during
the manufacturing process. The carpet tiles were further bound
together using 4 inch square adhesive strips containing 3 mils of
acrylic pressure sensitive adhesive.
[0101] Table 1 provides information regarding the various
embodiments tested according to the process of the invention.
Sample Nos. 1, 2, 5, 7, 8, 11, 13, 14, 17 and 19-27 are considered
to be Inventive Examples. Sample Nos. 3, 4, 6, 9, 10, 12, 15, 16
and 18 are considered to be Comparative Examples.
TABLE-US-00001 TABLE 1 Chemical Abatement of Flooring Surface
Sample Abatement Detergent Barrier Adhesive No. Chemical Material
Material Material 1 Petroleum BioSoap Latex-Ite B 2 Petroleum
BioSoap SOS B 3 Petroleum BioSoap None A 4 Petroleum BioSoap None B
5 Petroleum Standard Soap SOS A 6 Petroleum Standard Soap None A 7
Citrus Bio Soap Latex-Ite B 8 Citrus Bio Soap SOS B 9 Citrus Bio
Soap None A 10 Citrus Bio Soap None B 11 Citrus Standard Soap SOS A
12 Citrus Standard Soap None A 13 Soy Bio Soap Latex-Ite B 14 Soy
Bio Soap SOS B 15 Soy Bio Soap None A 16 Soy Bio Soap None B 17 Soy
Standard Soap SOS A 18 Soy Standard Soap None A 19 Petroleum Bio
Soap SOS A 20 Petroleum Bio Soap 50% SOS A 21 Petroleum Bio Soap
Latex-Ite A 22 Citrus Bio Soap SOS A 23 Citrus Bio Soap 50% SOS A
24 Citrus Bio Soap Latex-Ite A 25 Soy Bio Soap SOS A 26 Soy Bio
Soap 50% SOS A 27 Soy Bio Soap Latex-Ite A
[0102] Upon visual inspection, it was noted that the chemically
abated flooring surfaces exhibited altered depths of color. More
specifically, the use of citrus oil and soybean oil abatement
chemicals provided chemically abated flooring surfaces having a
darker depth of color than petroleum-based abatement chemicals.
Also, the barrier-coated flooring surfaces exhibited a
light-reflecting sheen.
[0103] Evaluation of Adhesion of Floorcovering Article to
Chemically Abated Flooring Surface with Barrier Coating:
[0104] Carpet tile samples containing Adhesive A were tested for
24-hour bonding to the flooring surface. The test method was as
follows:
[0105] The adhesive was applied to the cleaned concrete for a
releasable installation using a 3/4'' roller at approximately a 35
to 40 sq. yds./gallon application rate. The adhesive was allowed to
dry completely prior to installation of the modular carpet. The
properly dried adhesive did not transfer to the finger and had a
tacky feel. After placing the carpet tile on the dried adhesive,
downward pressure was applied to assure contact with the substrate.
After 24 hours, a carpet tile from the installation was pulled up
to see if the modular carpet was adequately bonded to the concrete
substrate, inhibiting any lateral movement, and confirming that the
adhesive remained firmly bonded to the concrete substrate. For
properly adhered adhesive, all the adhesive should remain on the
floor, and no adhesive should transfer to the back of the tile.
[0106] A "pass" rating means that (a) no delamination of the layers
of the carpet tile was visually observed and (b) no movement of
carpet tile, gapping between carpet tiles or curling of the carpet
tile edge(s) was visually observed. A "fail" rating means at least
one of the following was visually observed: some amount of
delamination of the layers of the carpet tile, movement of the
carpet tile, gapping between carpet tiles, and curling of edge(s)
of carpet tile.
[0107] The test results are provided in Table 2.
TABLE-US-00002 TABLE 2 Adhesive A Test Results for 24-Hour Bonding
Abatement Detergent Barrier Adhesive Test Sample No. Chemical
Material Chemical Material Result 19 Petroleum Bio Soap SOS A Fail*
20 Petroleum Bio Soap 50% SOS A Pass 21 Petroleum Bio Soap
Latex-Ite A Pass 3 Petroleum Bio Soap None A Pass 22 Citrus-Based
Bio Soap SOS A Pass 23 Citrus-Based Bio Soap 50% SOS A Pass 24
Citrus-Based Bio Soap Latex-Ite A Pass 9 Citrus-Based Bio Soap None
A Pass 25 Soy-Based Bio Soap SOS A Pass 26 Soy-Based Bio Soap 50%
SOS A Pass 27 Soy-Based Bio Soap Latex-Ite A Pass 15 Soy-Based Bio
Soap None A Pass *Two carpet tiles independently produced a
quarter-sized (24-25 mm; 0.5-1.0 inch) delamination area.
[0108] Evaluation of Migration of Abatement Chemicals:
[0109] The samples were analyzed by headspace solid-phase
microextraction gas chromatography-mass spectrometry-flame
ionization detection (SPME-GC-MS-FID) to estimate the rate that the
abatement chemical migrated from the concrete and into the carpet.
The samples were measured twice over a 40-day period. Periodically,
small pieces of the carpet were cut from the center of modular
tile, weighed, and placed into vials and sealed for analysis.
Samples were equilibrated at 50.degree. C. for 10 minutes prior to
sampling with an analysis fiber. Samples containing the soybean
oil-based chemical and the petroleum-based chemical were sampled
for 1 minute. Samples containing the citrus-based treatment were
sampled for 6 seconds. The fiber was subsequently desorbed to the
GC system. For the petroleum-based chemical, dodecane and tridecane
were tracked. For the soybean oil-based chemical, hexanal was
tracked. Since hexanal is expected to be significantly more
volatile than other soy derivatives, the results might overestimate
the amount of this substance present in the carpet. For the
citrus-based chemical, d-limonene was tracked. The species were
identified by mass spectrometry with a FID detector. The FID peak
areas were used due to the larger linear dynamic range of this
detector and because no significant interferences were noted that
necessitated the use of the mass spectrometer to enhance
resolution. Toluene standards were injected along with the sequence
to reduce error in measurements due to the significant length of
instrument time. The normalized peak area for the species of
interest was calculated by dividing the peak area of the sample
peak by the peak area of the toluene standard. The response was
then adjusted to a per weight basis by dividing the normalized peak
area by the mass of the sample in the vial. The peak area was
directly proportional to the concentration of abatement chemical in
the sample.
[0110] Gas chromatography test results are shown in FIGS. 8 to 13.
FIG. 8 is a line graph illustrating the results for soybean
oil-based abatement chemicals and Adhesive A for Examples 15, 17
and 18. FIG. 9 is a line graph illustrating the results for
petroleum-based abatement chemicals and Adhesive A for Examples 3,
5 and 6. FIG. 10 is a line graph illustrating the results for
citrus-based abatement chemicals and Adhesive A for Examples 9, 11
and 12. FIG. 11 is a line graph illustrating the results for
soybean oil-based abatement chemicals and Adhesive B for Examples
13, 14 and 16. FIG. 12 is a line graph illustrating the results for
petroleum-based abatement chemicals and Adhesive B for Examples 1,
2 and 4. FIG. 13 is a line graph illustrating the results for
citrus-based abatement chemicals and Adhesive B for Examples 7, 8
and 10.
[0111] As shown in FIGS. 8 to 13, the SPME-GC-MS-FID results
indicate that the barrier coating decreases the rate at which the
abatement chemical moves from the concrete into the carpet tile. In
general, bio-soap aids in lowering the amount of chemical available
to transfer into the carpet tile.
[0112] Pigment Evaluation:
[0113] In further testing, a mixture of 100 g of Latex-ite.RTM. Oil
Spot Primer (Dalton Enterprises, Inc., Connecticut), 8.9 g of
Hydrite SB100 (Imerys, Georgia), 0.6 g of Tamol 731A (Dow,
Michigan), 0.2 g of Triton N-57 (Dow, Michigan), 0.17 g of Imperon
Red K-GC (Dystar, North Carolina), and 0.11 g of Masil SF19
(Dystar, North Carolina) was made and coated onto the concrete
flooring surface previously abated with Sentinel Low Odor Mast
Remover SC-170, Mast-Away 77, and Blue Bear.RTM. 500 MR. After air
drying for about 5 minutes, a uniform red-colored coating was
created. In this instance, the barrier-coated flooring surface did
not exhibit a light-reflecting sheen.
[0114] All references, including publications, patent applications,
and patents, cited herein are hereby incorporated by reference to
the same extent as if each reference were individually and
specifically indicated to be incorporated by reference and were set
forth in its entirety herein.
[0115] The use of the terms "a" and "an" and "the" and similar
referents in the context of describing the subject matter of this
application (especially in the context of the following claims) are
to be construed to cover both the singular and the plural, unless
otherwise indicated herein or clearly contradicted by context. The
terms "comprising," "having," "including," and "containing" are to
be construed as open-ended terms (i.e., meaning "including, but not
limited to,") unless otherwise noted. Recitation of ranges of
values herein are merely intended to serve as a shorthand method of
referring individually to each separate value falling within the
range, unless otherwise indicated herein, and each separate value
is incorporated into the specification as if it were individually
recited herein. All methods described herein can be performed in
any suitable order unless otherwise indicated herein or otherwise
clearly contradicted by context. The use of any and all examples,
or exemplary language (e.g., "such as") provided herein, is
intended merely to better illuminate the subject matter of the
application and does not pose a limitation on the scope of the
subject matter unless otherwise claimed. No language in the
specification should be construed as indicating any non-claimed
element as essential to the practice of the subject matter
described herein.
[0116] Preferred embodiments of the subject matter of this
application are described herein, including the best mode known to
the inventors for carrying out the claimed subject matter.
Variations of those preferred embodiments may become apparent to
those of ordinary skill in the art upon reading the foregoing
description. The inventors expect skilled artisans to employ such
variations as appropriate, and the inventors intend for the subject
matter described herein to be practiced otherwise than as
specifically described herein. Accordingly, this disclosure
includes all modifications and equivalents of the subject matter
recited in the claims appended hereto as permitted by applicable
law. Moreover, any combination of the above-described elements in
all possible variations thereof is encompassed by the present
disclosure unless otherwise indicated herein or otherwise clearly
contradicted by context.
* * * * *
References