Polyester binder for flooring products

Abstract

A flooring product is provided comprising at least one layer including a polymeric binder comprising at least one thermoplastic polyester resin, wherein the polyester resin comprises at least one renewable component. A flooring product is also provided that includes at least one layer comprising filler and at least one thermoplastic, high molecular weight polyester resin. The flooring product may also qualify for at least one point under the LEED System. A composition is also provided that can be melt mixed in low intensity mixers and processed into flooring layers.

1 . A resilient flooring product comprising a layer, the layer comprising a polymeric binder, the polymeric binder comprising a first thermoplastic polyester resin, wherein the polyester resin comprises a renewable component. 
     
     
         2 . The flooring product of  claim 1 , wherein the polyester resin is amorphous. 
     
     
         3 . The flooring product of  claim 1 , wherein the polyester resin is crystalline. 
     
     
         4 . The flooring product of  claim 1 , wherein the polyester resin has a number average molecular weight of at least 5,000. 
     
     
         5 . The flooring product of  claim 4 , wherein the polyester resin has a number average molecular weight of at least 10,000. 
     
     
         6 . The flooring product of  claim 1 , wherein the polymeric binder further comprises a second polyester resin. 
     
     
         7 . The flooring product of  claim 6 , wherein the first polyester resin is amorphous and the second polyester resin is crystalline. 
     
     
         8 . The flooring product of  claim 6 , wherein one of the polyester resins has a number average molecular weight of at least 5,000. 
     
     
         9 . The flooring product of  claim 8 , wherein one of the polyester resins has a number average molecular weight of at least 10,000. 
     
     
         10 . The flooring product of  claim 3 , wherein the crystalline polyester resin has a Tm below about 200° C. 
     
     
         11 . The flooring product of  claim 3 , wherein the crystalline polyester resin has a Tg of about room temperature or below. 
     
     
         12 . The flooring product of  claim 2 , wherein the amorphous polyester has a Tg of about room temperature. 
     
     
         13 . The flooring product of  claim 2 , wherein the amorphous polyester has a Tg is between 20° C. and 35° C. 
     
     
         14 . The flooring product of  claim 6 , wherein one of the first and second polyester resins is amorphous and has a Tg at or below room temperature and the other polyester resin is amorphous and has a Tg above room temperature. 
     
     
         15 . The flooring product of  claim 1 , wherein the polyester resin comprises the co-reaction product of a renewable polyester resin and a recycle polyester resin. 
     
     
         16 . The flooring product of  claim 1 , wherein the polyester resin further comprises a recycle component. 
     
     
         17 . The flooring product of  claim 16 , wherein the polyester resin comprises at least 98% by weight of renewable and recycle components. 
     
     
         18 . The flooring product of  claim 1 , wherein the layer is a non-PVC layer. 
     
     
         19 . The flooring product of  claim 1 , wherein the polyester resin comprises a Biobased Content of at least 5% by weight. 
     
     
         20 . The flooring product of  claim 1 , wherein the polyester resin comprises an epoxidized natural oil moiety. 
     
     
         21 . The flooring product of  claim 1 , further comprising an epoxidized natural oil. 
     
     
         22 . The flooring product of  claim 1 , wherein the polyester resin comprises a carboxylic acid end group. 
     
     
         23 . The flooring product of  claim 1 , wherein the polyester resin comprises an aromatic diacid component and an aliphatic diacid component. 
     
     
         24 . The flooring product of  claim 23 , wherein the polyester resin further comprises a second aromatic diacid component. 
     
     
         25 . A resilient flooring product comprising a layer, the layer comprising filler and a polymeric binder, the polymeric binder comprising a polyester resin. 
     
     
         26 . The flooring product of  claim 25 , wherein the polyester resin is amorphous. 
     
     
         27 . The flooring product of  claim 25 , wherein the polyester resin is crystalline. 
     
     
         28 . The flooring product of  claim 25 , wherein the polyester resin has a number average molecular weight of at least 5,000. 
     
     
         29 . The flooring product of  claim 28 , wherein the polyester resin has a number average molecular weight of at least 10,000. 
     
     
         30 . The flooring product of  claim 25 , wherein the polymeric binder further comprises a second polyester resin. 
     
     
         31 . The flooring product of  claim 30 , wherein the first polyester resin and the second polyester resin are amorphous. 
     
     
         32 . The flooring product of  claim 30 , wherein the first polyester resin is amorphous and the second polyester resin is crystalline. 
     
     
         33 . The flooring product of  claim 30 , wherein one of the polyester resins has a number average molecular weight of at least 5,000. 
     
     
         34 . The flooring product of  claim 33 , wherein one of the polyester resins has a number average molecular weight of at least 10,000. 
     
     
         35 . The flooring product of  claim 30 , wherein the crystalline polyester resin has a Tm below about 200° C. 
     
     
         36 . The flooring product of  claim 27 , wherein the crystalline polyester resin has a Tg of about room temperature or below. 
     
     
         37 . The flooring product of  claim 26 , wherein the amorphous polyester has a Tg about room temperature. 
     
     
         38 . The flooring product of  claim 26 , wherein the amorphous polyester has a Tg is between 20° C. and 35° C. 
     
     
         39 . The flooring product of  claim 30 , wherein one of the first and second polyester resins is amorphous and has a Tg at or below room temperature and the other polyester resin is amorphous and has a Tg above room temperature. 
     
     
         40 . The flooring product of  claim 25 , wherein the polyester resin comprises the co-reaction product of a renewable polyester resin and a recycle polyester resin. 
     
     
         41 . The flooring product of  claim 25 , wherein the polyester resin further comprises a renewable component. 
     
     
         42 . The flooring product of  claim 25 , wherein the polyester resin further comprises a recycle component. 
     
     
         43 . The flooring product of  claim 25 , wherein the polyester resin comprises at least 98% by weight of renewable and recycle components. 
     
     
         44 . The flooring product of  claim 25 , wherein the filler comprises recycle filler. 
     
     
         45 . The flooring product of  claim 25 , wherein the layer is a non-PVC layer. 
     
     
         46 . The flooring product of  claim 25 , wherein the polyester resin has a Biobased Content of at least 5% by weight. 
     
     
         47 . The flooring product of  claim 25 , wherein the polyester resin comprises an epoxidized natural oil moiety. 
     
     
         48 . The flooring product of  claim 25 , further comprising an epoxidized natural oil. 
     
     
         49 . The flooring product of  claim 25 , wherein the polyester resin comprises a carboxylic acid end group. 
     
     
         50 . The flooring product of  claim 25 , wherein the polyester resin comprises an aromatic diacid component and an aliphatic diacid component. 
     
     
         51 . The flooring product of  claim 50 , wherein the polyester resin further comprises a second aromatic diacid component. 
     
     
         52 . A resilient flooring product, wherein the flooring product qualifies for at least one point in the LEED System and comprises a layer, the layer comprising a polymeric binder, the polymeric binder comprising a first polyester resin. 
     
     
         53 . The flooring product of  claim 52 , wherein the polyester resin is amorphous. 
     
     
         54 . The flooring product of  claim 52 , wherein the polyester resin is crystalline. 
     
     
         55 . The flooring product of  claim 52 , wherein the polyester resin has a number average molecular weight of at least 5,000. 
     
     
         56 . The flooring product of  claim 55 , wherein the polyester resin has a number average molecular weight of at least 10,000. 
     
     
         57 . The flooring product of  claim 52 , wherein the polymeric binder further comprises a second polyester resin. 
     
     
         58 . The flooring product of  claim 57 , wherein the first and second polyester resins are amorphous. 
     
     
         59 . The flooring product of  claim 57 , wherein the first polyester resin is amorphous and the second polyester resin is crystalline. 
     
     
         60 . The flooring product of  claim 54 , wherein the crystalline polyester resin has a Tm below about 200° C. 
     
     
         61 . The flooring product of  claim 54 , wherein the crystalline polyester resin has a Tg of about room temperature or below. 
     
     
         62 . The flooring product of  claim 53 , wherein the amorphous polyester has a Tg around room temperature. 
     
     
         63 . The flooring product of  claim 53 , wherein the amorphous polyester has a Tg is between about 20° C. and about 35° C. 
     
     
         64 . The flooring product of  claim 58 , wherein one of the first and second amorphous polyester resin has a Tg at or below room temperature and the other amorphous polyester resin has a Tg above room temperature. 
     
     
         65 . The flooring product of  claim 52 , wherein the polyester resin comprises the co-reaction product of a renewable polyester resin and a recycle polyester resin. 
     
     
         66 . The flooring product of  claim 52 , wherein the polyester resin comprises a renewable component. 
     
     
         67 . The flooring product of  claim 52 , wherein the polyester resin comprises a recycle component. 
     
     
         68 . The flooring product of  claim 52 , wherein the polyester resin comprises a renewable and a recycle component. 
     
     
         69 . The flooring product of  claim 68 , wherein the polyester resin comprises at least 98% by weight of renewable and recycle components. 
     
     
         70 . The flooring product of  claim 52 , wherein the layer further comprises recycle filler. 
     
     
         71 . The flooring product of  claim 52 , wherein the layer is a non-PVC layer. 
     
     
         72 . The flooring product of  claim 52 , wherein the polyester resin has a Biobased Content of at least 5% by weight. 
     
     
         73 . The flooring product of  claim 52 , wherein the polyester resin comprises an epoxidized natural oil moiety. 
     
     
         74 . The flooring product of  claim 52 , further comprising an epoxidized natural oil. 
     
     
         75 . The flooring product of  claim 52 , wherein the polyester resin comprises a carboxylic acid end group. 
     
     
         76 . A resilient floor tile having a PCT structure comprising a polymeric binder, the polymeric binder comprising a polyester resin. 
     
     
         77 . The floor tile of  claim 76 , wherein the polyester resin is amorphous. 
     
     
         78 . The floor tile of  claim 76 , wherein the polyester resin is crystalline. 
     
     
         79 . The floor tile of  claim 76 , wherein the polyester resin has a number average molecular weight of at least 5,000. 
     
     
         80 . The floor tile of  claim 79 , wherein the polyester resin has a number average molecular weight of at least 10,000. 
     
     
         81 . The floor tile of  claim 76 , wherein the polymeric binder further comprises a second polyester resin. 
     
     
         82 . The floor tile of  claim 81 , wherein the first polyester resin and the second polyester resin are amorphous. 
     
     
         83 . The floor tile of  claim 81 , wherein one of the first and second polyester resins is amorphous and the other polyester resin is crystalline. 
     
     
         84 . The floor tile of  claim 78 , wherein the crystalline polyester resin has a Tm below about 200° C. 
     
     
         85 . The floor tile of  claim 78 , wherein the crystalline polyester resin has a Tg of about room temperature or below. 
     
     
         86 . The floor tile of  claim 77 , wherein the amorphous polyester has a Tg about room temperature. 
     
     
         87 . The floor tile of  claim 77 , wherein the amorphous polyester has a Tg is between 20° C. and 35° C. 
     
     
         88 . The floor tile of  claim 81 , wherein one of the first and second polyester resins is amorphous and has a Tg at or below room temperature and the other polyester resin is amorphous and has a Tg above room temperature. 
     
     
         89 . The floor tile of  claim 76 , wherein the polyester resin comprises the co-reaction product of a renewable polyester resin and a recycle polyester resin. 
     
     
         90 . The floor tile of  claim 76 , wherein the polyester resin further comprises a renewable component. 
     
     
         91 . The floor tile of  claim 76 , wherein the polyester resin further comprises a recycle component. 
     
     
         92 . The floor tile of  claim 76 , wherein the polyester resin comprises at least 98% by weight of renewable and recycle components. 
     
     
         93 . The floor tile of  claim 76 , wherein the floor tile further comprises recycle filler. 
     
     
         94 . The floor tile of  claim 76 , wherein the floor tile is a non-PVC floor tile. 
     
     
         95 . The floor tile of  claim 76 , wherein the floor tile qualifies for at least one point in the LEED System. 
     
     
         96 . The floor tile of  claim 76 , wherein the polymeric binder comprises less than about 20% by weight of the floor tile. 
     
     
         97 . The floor tile of  claim 76 , wherein the polyester resin has a Biobased Content of at least 5% by weight. 
     
     
         98 . The floor tile of  claim 76 , wherein the polyester resin comprises an epoxidized natural oil moiety. 
     
     
         99 . The floor tile of  claim 76 , further comprising an epoxidized natural oil. 
     
     
         100 . The floor tile of  claim 76 , wherein the polyester resin comprises a carboxylic acid end group. 
     
     
         101 . The floor tile of  claim 76 , wherein the polyester resin comprises an aromatic diacid component and an aliphatic diacid component. 
     
     
         102 . The floor tile of  claim 101 , wherein the polyester resin further comprises a second aromatic diacid component. 
     
     
         103 . A composition including filler and a polymeric binder, the binder comprising a first polyester resin, wherein the composition is capable of being melt mixed in a low intensity mixer and processed into a flooring layer. 
     
     
         104 . The composition of  claim 103 , wherein the composition further comprises an acid functionalized polymer resin. 
     
     
         105 . The composition of  claim 104 , wherein the acid functionalized polymer resin comprises less than about 60 weight percent of the binder resin in the composition. 
     
     
         106 . The composition of  claim 103 , wherein the filler comprises recycle filler material. 
     
     
         107 . The composition of  claim 103 , wherein the polyester resin is amorphous. 
     
     
         108 . The composition of  claim 103 , wherein the polyester resin is crystalline. 
     
     
         109 . The composition of  claim 103 , wherein the polyester resin has a number average molecular weight of at least 5,000. 
     
     
         110 . The composition of  claim 109 , wherein the polyester resin has a number average molecular weight of at least 10,000. 
     
     
         111 . The composition of  claim 103 , wherein the polymeric binder comprises a second polyester resin. 
     
     
         112 . The composition of  claim 111 , wherein the first and second polyester resins are amorphous. 
     
     
         113 . The composition of  claim 111 , wherein the first polyester resin is amorphous and the second polyester resin is crystalline. 
     
     
         114 . The composition of  claim 108 , wherein the crystalline polyester resin has a Tm below about 200° C. 
     
     
         115 . The composition of  claim 108 , wherein the crystalline polyester resin has a Tg of about room temperature or below. 
     
     
         116 . The composition of  claim 107 , wherein the amorphous polyester has a Tg of about room temperature. 
     
     
         117 . The composition of  claim 107 , wherein the amorphous polyester has a Tg is between 20° C. and 35° C. 
     
     
         118 . The composition of  claim 112 , wherein one of the first and second amorphous polyester resins has a Tg at or below room temperature and the other amorphous polyester resin has a Tg above room temperature. 
     
     
         119 . The composition of  claim 103 , wherein the polyester comprises the co-reaction product of a renewable polyester resin and a recycle polyester resin. 
     
     
         120 . The composition of  claim 103 , wherein the polyester resin comprises a renewable component. 
     
     
         121 . The composition of  claim 103 , wherein the polyester resin comprises a recycle component. 
     
     
         122 . The composition of  claim 103 , wherein the polyester resin comprises a renewable component and a recycle component. 
     
     
         123 . The composition of  claim 122 , wherein the polyester resin comprises at least 98% by weight of renewable and recycle components. 
     
     
         124 . The composition of  claim 103 , wherein the polyester resin has a Biobased Content of at least 5% by weight. 
     
     
         125 . The composition of  claim 103 , wherein the polyester resin comprises an epoxidized natural oil moiety. 
     
     
         126 . The composition of  claim 103 , further comprising an epoxidized natural oil. 
     
     
         127 . The composition of  claim 103 , wherein the polyester resin comprises a carboxylic acid end group.