Polyester binder for flooring products

Patent metadata

Field	Value
Publication number	US-9637631-B2
Application number	US-201615009430-A
Country	US
Kind code	B2
Filing date	Jan 28, 2016
Priority date	Oct 2, 2006
Publication date	May 2, 2017
Grant date	May 2, 2017

Abstract

Described herein is a flooring product comprising a base layer, the base layer comprising: a filler and a polymeric binder, the polymeric binder comprising: an amorphous thermoplastic polyester and a semi-crystalline thermoplastic polyester, wherein the thermoplastic amorphous polyester has a T g less than 30° C.

First claim

The invention claimed is:

1. A flooring product comprising a base layer, the base layer comprising:
a filler; and
a polymeric binder comprising:
an amorphous thermoplastic polyester; and
a semi-crystalline thermoplastic polyester;

wherein the thermoplastic amorphous polyester has a T g less than 30° C. and wherein the polymeric binder is present in an amount ranging from about 10 wt. % to about 30 wt. % based on the total weight of the base layer.

2. The flooring product of claim 1 , wherein the semi-crystalline thermoplastic polyester has a Tg less than 25° C.

3. The flooring product of claim 2 , wherein the semi-crystalline thermoplastic polyester has a melt temperature less than 200° C.

4. The flooring product of claim 1 , wherein the amorphous thermoplastic polyester has a number average molecular weight of at least 5,000.

5. The flooring product of claim 4 , wherein the amorphous thermoplastic polyester has a number average molecular weight of at least 10,000.

6. The flooring product of claim 1 , wherein the amorphous thermoplastic amorphous polyester comprises the reaction product of an aliphatic diol and an aromatic diacid.

7. The flooring product of claim 6 , wherein at least one of the thermoplastic amorphous polyester is biobased.

8. The flooring product of claim 1 , wherein the filler comprising at least one of talc, limestone, and combinations thereof.

9. A flooring product comprising a base layer, the base layer comprising:
a filler; and
a polymeric binder comprising:
an amorphous polyester; and
an semi-crystalline polyester;

wherein the amorphous polyester has a T g less than 30° C. and the semi-crystalline polyester has a T g less than 25° C.;
wherein the base layer has a thickness ranging from 75 mils to about 125 mils.

10. The flooring product of claim 9 , wherein the semi-crystalline thermoplastic polyester has a melt temperature less than 200° C.

11. The flooring product of claim 9 , wherein the amorphous thermoplastic polyester has a number average molecular weight of at least 5,000.

12. The flooring product of claim 11 , wherein the amorphous thermoplastic polyester has as number average molecular weight of at least 10,000.

13. The flooring product of claim 9 , wherein the amorphous thermoplastic amorphous polyester comprises the reaction product of an aliphatic diol and an aromatic diacid.

14. The flooring product of claim 13 , wherein the thermoplastic amorphous polyester is biobased.

15. The flooring product of claim 9 , wherein the polymeric binder is present in an amount ranging from about 10 wt. % to about 30 wt. % based on the total weight of the base layer.

16. The flooring product of claim 11 , wherein the filler comprising at least one of talc, limestone, and combinations thereof.

17. A flooring product comprising a base layer, the base layer comprising:
a filler; and
a polymeric binder comprising:
an amorphous thermoplastic polyester; and
an semi-crystalline thermoplastic polyester having a Tg less than 25° C.;

wherein the amorphous thermoplastic polyester and the semi-crystalline polyester are each biobased, and wherein the polymeric binder is present in an amount ranging from about 10 wt. % to about 30 wt. % based on the total weight of the base layer.

Assignees

• Armstrong World Ind Inc
• Afi Licensing Llc

Inventors

• Tian Dong
• Sigel Gary A
• Qiao Fang
• Winey Rebecca L
• Ross Jeffrey S

Classifications

• C09D167/02

  Polyesters derived from dicarboxylic acids and dihydroxy compounds (C09D167/06 takes precedence) · CPC title

• C08L2666/18

  Polyesters or polycarbonates according to C08L67/00 - C08L69/00; Derivatives thereof · CPC title

• C08L2205/025

  containing two or more polymers of the same hierarchy C08L, and differing only in parameters such as density, comonomer content, molecular weight, structure · CPC title

• C08L67/02 Primary

  Polyesters derived from dicarboxylic acids and dihydroxy compounds (C08L67/06 takes precedence) · CPC title

• C08L2207/20

  Recycled plastic · CPC title