Laminated floor covering

Abstract

There is disclosed herein various floor coverings and methods for making the same. In one embodiment, there is disclosed a floor covering including a primary backing layer having a fibrous face and an underside, wherein the fibrous face is formed from a bulked continuous filament yam comprising a plurality of continuous filaments formed from a biobased polyhexamethylene sebacamide polymer or a blend of a biobased polyhexamethylene sebacamide polymer together with up to 80 wt % of at least one other polymer compatible with the biobased polyhexamethylene sebacamide polymer. There is also described a method of making a floor covering comprising: tufting or implanting a bulked continuous filament yarn into a primary backing material, wherein the yam comprises a plurality of continuous filaments formed from a multi-component fibre comprising a biobased polyhexamethylene sebacamide polymer or a blend of a biobased polyhexamethylene sebacamide polymer together with up to 80 wt % of at least one other polymer compatible with the biobased polyhexamethylene sebacamide polymer.

What is claimed is: 
     
         1 . A floor covering including a primary backing layer having a fibrous face and an underside, wherein the fibrous face is formed from a bulked continuous filament yarn comprising a plurality of continuous filaments formed from a multi-component fibre comprising a biobased polyhexamethylene sebacamide polymer or a blend of a biobased polyhexamethylene sebacamide polymer together with up to 80 wt % of at least one other polymer compatible with the biobased polyhexamethylene sebacamide polymer. 
     
     
         2 . A method of making a floor covering comprising the step of
 tufting or implanting a bulked continuous filament yarn into a primary backing material, wherein the yarn comprises a plurality of continuous filaments formed from a biobased polyhexamethylene sebacamide polymer or a blend of a biobased polyhexamethylene sebacamide polymer together with up to 80 wt % of at least one other polymer compatible with the biobased polyhexamethylene sebacamide polymer.   
     
     
         3 . The floor covering of  claim 1  further comprising:
 a cured precoat layer on the underside of the primary backing; and a backing layer fixed to the primary backing. 
 
     
     
         4 . The method of  claim 2   wherein the yarn comprises a plurality of continuous filaments formed from a multi-component fibre comprising a biobased polyhexamethylene sebacamide polymer or a blend of a biobased polyhexamethylene sebacamide polymer together with up to 80 wt % of at least one other polymer compatible with the biobased polyhexamethylene sebacamide polymer; and wherein the method further comprises the steps of precoating the underside of the primary backing layer by applying a precoating composition; applying a backing layer to the precoated primary backing layer; and curing the precoating composition.   
     
     
         5 . The method of  claim 2  wherein the yarn comprises a plurality of continuous filaments formed from a multi-component fibre comprising a biobased polyhexamethylene sebacamide polymer or a blend of a biobased polyhexamethylene sebacamide polymer together with up to 80 wt % of at least one other polymer compatible with the biobased polyhexamethylene sebacamide polymer; and wherein the method further comprises the steps of:
 coating a first layer of a thermoplastic resin plastisol on a support surface; 
 optionally placing a dimensionally stable sheet material onto the top surface of the first layer and heating the layer to gel the layer and position the sheet material; 
 optionally applying a second layer of a thermoplastic resin plastisol onto the gelled surface of the first layer; 
 precoating the underside of the primary backing; 
 optionally coating a thermoplastic resin plastisol over the precoat layer; 
 layering the precoated primary backing onto the top surface of the plastisol of the first or second thermoplastic resin layer; 
 heating the floor covering so formed to fuse the thermoplastic layers into an integrally-fused backing layer; 
 cooling the flooring covering; and 
 optionally cutting the floor covering into a carpet tile. 
 
     
     
         6 . A floor covering produced by the method of  claim 2 . 
     
     
         7 . A floor covering produced by the method of  claim 4 . 
     
     
         8 . A floor covering produced by the method of  claim 5 .