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.
Description
DETAILED DESCRIPTION OF THE INVENTION

This invention provides a flooring product having at least one layer including a polymeric binder comprising thermoplastic polyester resin, wherein the polyester resin comprises at least one renewable component. The flooring product can comprise sheet or tile product structures. At least one layer in these structures may be solid or foamed, and filled or unfilled. In some embodiments, at least one layer comprises a transparent wear layer or wear layer component. Another example is similar to a vinyl composition tile (VCT), as described by ASTM Specification 1066-04. As used herein a polyester composition tile (PCT) is similar to a VCT except a polyester resin is substituted for the PVC. While the present invention is intended for use in such type tile, the invention is also directed to various other types of flooring, including tile type products such as Type III solid vinyl tile, surface applied tile, and to various sheet flooring products, wherein a polyester resin is substituted for the PVC. In one embodiment, at least one layer may comprise consolidated chips/particles having a binder comprising thermoplastic polyester resin. In another embodiment, at least one layer may be a homogeneous, melt processed layer having a binder comprising thermoplastic polyester resin. In yet another embodiment, the flooring product comprises renewable and recycle components that qualify the product for at least one point under the LEED System.


Unless at least one layer is transparent, it typically comprises a filler in addition to the polymeric binder. Limestone, talc, or other minerals are utilized as filler in flooring. Interest in using recycle materials as fillers has increased due to “green” issues. Such recycle filler materials include those obtained from wood or plants. These include pecan shells, wood flour, saw dust, walnut shells, rice hulls, corn cob grit, and others. Additionally, ground shells from animals such as clams and coral are renewable inorganic fillers. Such renewable fillers contain biobased carbon in the form of carbonates. These can be considered post-industrial or renewable materials.


Mineral fillers generated from post-industrial processes include limestone, quartz, ceramic powders, glass, fly ash, and concrete powder.


Recycle thermoset resin based fillers can also be employed. For example, powders produced by grinding thermoset polyester materials, such as products made from bulk molding compounds (BMC) or sheet molding compounds (SMC) can be post-industrial, as well as post-consumer materials. Another thermoset material of interest is recycled fillers made from Urea Formaldehyde thermoset resins. Depending upon the source, these materials can also be post-industrial or post-consumer. Another example includes ground, cured (cross-linked) rubber materials such as used in tires. These rubbers materials can be based on natural or synthetic rubbers, polyurethanes, or other well known thermoset rubber compositions.


Additionally, recycled thermoplastic resin based materials may be employed as fillers if they are incompatible with the polyester binder. For example, polyethylene (PE), polypropylene, polyamide, polyester, polystyrene, polycarbonate, acrylonitrile butadiene styrene, and thermoplastic rubbers maybe incompatible with the high molecular weight polyester binder. Such materials, if added as particulate will essentially function as fillers in these compositions. If the recycled thermoplastic resin is compatible with the binder, it may function as a binder and not as a filler in the composition. DuPont “Sarrona” Bio-PDO based carpet fiber may be recycled and would be a filler or binder depending upon compatibility with the binder. Compatibility may be dependent upon the processing conditions employed. Depending upon the source, these materials can be post-industrial or post-consumer.


In one embodiment, the thermoplastic, polyester resin is high molecular weight and has a number average molecular weight (Mn) of at least 5,000 and in some embodiments the polyester resins have a molecular weight (Mn) of at least 10,000. The polyesters may be biodegradable, and/or may contain renewable components. In one embodiment, the polyester comprises at least 50% by weight renewable components. In another embodiment, the polyester comprises greater than 80% by weight renewable components. In yet another embodiment, the polyester comprises essentially 100% renewable and recycle components.


In one embodiment, the polyester resin may comprise aliphatic diacid and aliphatic diol components. Although a wide range of aliphatic diacids and aliphatic diols may be used, these components may come from renewable sources. Renewable aliphatic diacid and aliphatic diol components may include but are not limited to Bio-PDO (1,3-propanediol), 1,4-butanediol, sebacic acid, succinic acid, adipic acid, azelaic acid, glycerin, and citric acid. These materials may also be modified by reaction with epoxidized soybean, epoxidized linseed oil, or other natural oils.


The polyesters may be pre-reacted with epoxidized natural oils, or the reaction can occur during the melt processing into flooring layers. Such reaction during melt processing is a type of dynamic vulcanization. Dynamic vulcanization is the process of intimate melt mixing of two or more reactive components, such as an acid-terminated polyester and epoxidized natural oil, and the reaction occurs between at least two of these components during the melt mixing.


Other diacid and diol components from renewable resources will become available as the need for renewable materials continues to grow. The diol components may also include diols which are branched or hindered to limit crystallinity in the final polyester binder. These can include neopentyl glycol, glycerin, and others.


Renewable components based on plants, animals, or biomass processes have a different radioactive C14 signature than those produced from petroleum. These renewable, biobased materials have carbon that comes from contemporary (non-fossil) biological sources. A more detailed description of biobased materials is described in a paper by Ramani Narayan, “Biobased & Biodegradable Polymer Materials: Rationale, Drivers, and Technology Exemplars”, presented at American Chemical Society Symposium, San Diego 2005; American Chemical Society Publication #939, June 2006. The Biobased Content is defined as the amount of biobased carbon in the material or product as fraction weight (mass) or percent weight (mass) of the total organic carbon in the material or product. ASTM D6866 (2005) describes a test method for determining Biobased Content. Theoretical Biobased Content was calculated for the resultant polyester resins in Table 2 and Table 3.


In one embodiment, the Biobased Content is at least 20% by weight. In another embodiment, the Biobased content is at least 50% by weight. In still another embodiment, the Biobased content is at least 75% by weight. The higher the Biobased Content the “greener” the product. The Biobased Content may be at least 25% by weight or at least 10% by weight or at least 5% by weight, particularly when the polyester resin is a blend of two or more resins.


In another embodiment, the thermoplastic polyester resin can comprise aromatic diacid components and aliphatic diol components. The aromatic acid components may include but are not limited to phthalic acid (anhydride), isophthalic, or terephthalic acids. In some cases an amount of trimellitic anhydride can also be used.


In another embodiment, the thermoplastic polyester resin may comprise aliphatic diacid and aromatic diacid components reacted with various aliphatic diols.


The thermoplastic polyester resin may also be branched. For example, utilizing aliphatic alcohols that have more than two functional groups, such as glycerin, or aromatic acids having more than two functional groups such as trimellitic anhydride may be used to produce branched polyesters.


Although, the above diacid components are described, it is understood that their simple diesters such as from methanol or ethanol can be used to prepare the thermoplastic polyester resin via known transesterification techniques.


Depending upon the diacid and diol selected, the polyester resin can be amorphous or crystalline/semi-crystalline materials. In one embodiment, the polyester resin is amorphous. Table 2 shows some examples of amorphous polyester resins of the invention and their % by weight renewable components.









TABLE 2







Compositions of Amorphous Polyesters With Renewable Content














EX-1
EX-2
EX-3
EX-4
EX-5
EX-6


Ingredient
Amt (g)
Amt (g)
Amt (g)
Amt (g)
Amt (g)
Amt (g)
















1,3-Propanediol
367.60
380.88
381.80
372.21
370.19
357.64


Isophthalic acid
545.99
232.94
233.50
292.68
291.08
218.72


Phthalic anhydride
85.90
385.69
208.18
260.94
259.52
195.01


Adipic acid
0
0
176.03
0
0
0


Azelaic acid
0
0
0
73.66
0
0


Sebacic acid
0
0
0
0
78.71
228.13


Dibutytin bis-lauryl
0.50
0.50
0.50
0.50
0.50
0.50


mercaptide


Biobased Content wt %
27
27
47
34
36
53


Wt % Renewable Content of
37
38
56
45
45
59


starting material


Tg Differential Scanning
25° C.
3° C.
−22° C.
−9° C.
−10° C.
29° C.


Calorimetry (DSC)









In another embodiment, the polyester resin is crystalline and comprises a Tg below about 25° C. and a crystalline melting temperature Tm greater than about 25° C. In yet another embodiment, the polyester resin has a Tg at or below about 25° C. and a Tm between about 25° C. and about 200° C. Table 3 shows some examples of polyester resins having a Tg at or below about 25° C. and Tm above about 25° C. Tg and Tm were determined by standard Differential Scanning Calorimetry (DSC) techniques. The polyester compositions include modifying essentially 100% renewable aliphatic polyester resin by the addition of an amount of aromatic diacid, such as terephthalic acid, to help control crystalline regions and Tm. Example 3 describes tile flooring comprising blends of polyester resins, including a commercially available polyester resin, Ecoflex FBX7011, sold by BASF Plastics. Ecoflex FBX7011 is a high molecular weight, biodegradable, aliphatic-aromatic copolyester based on butanediol, adipic acid, and terephthalic acid exhibiting a Tg of about −25° C. and a Tm of about 115° C.


The blend of polyester resins allow processing in low intensity mixers typically used for VCT Tile manufacturing. Also, a desired Tg can be obtained by blending two or more polyester resins.









TABLE 3







Compositions of Crystalline Polyesters With Renewable Content















EX-7
EX-8
EX-9
EX-10
EX-11
EX-12
EX-13


Ingredient
Amt (g)
Amt (g)
Amt (g)
Amt (g)
Amt (g)
Amt (g)
Amt (g)

















Glycerin
25




24



Phthalic anhydride


62
67
387


1,3-Propanediol
510
238
138
258
241
228
334


Trimellitic anhydride




122


Sebacic acid
1130
281



538


Isophthalic acid






765


Terephthalic acid
232
231
394
425

110


1,6-Hexanediol


156


T-20 Catalyst
3.8
1.8
1.5
1.5
1.5
1.8
0.5


Tg ° C.
−21
−35
7
25
22
−41
2


Tm ° C.
122
125
135
197
77
40
141


Wt % Renewable
88
69
18
34
32
85
33


Content of starting


material


Biobased Content wt %
85
67
13
27
26
87
27









The polyester resin may be prepared by several known methods. One method involves esterification of a diacid and a diol components at elevated temperature. Typically, an excess of diol is employed (see Procedure 1A). After the acid functional groups have essentially reacted, a high vacuum is applied and excess diol is stripped off during transesterification, thereby increasing molecular weight. In some embodiments, 1,3-PDO is the diol of choice to build high molecular weight in this step of the process.


We have also found that polyester resin can be made by esterification of a diacid and diol at elevated temperature using an excess of diacid (See Procedure 1B). After all the hydroxyl groups are reacted, a high vacuum is applied to build molecular weight. The mechanism by which high molecular weight is achieved is not clear. Table 4 shows some examples of polyester resins comprising renewable components and the number average molecular weights obtained from the processes of Procedure 1.


Another method for obtaining high molecular weight polyester resin involves the co-reaction of a renewable polyester resin with recycle polyester resin such as PET (polyethylene terephthalate), PBT (polybutylene terephthalate), PPT (polypropylene terephthalate) or other polyester resins. In these co-reactions, an aliphatic polyester resin comprising renewable ingredients was first prepared as described in Procedure 1. The recycle polyester resin was then mixed with the aliphatic polyester resin and transesterification between the two polyesters was accomplished at high temperature and preferably under high vacuum. In one embodiment, the polyester resin co-reaction product had a Tm at or below about 150° C. that allowed processing with in low intensity mixers. It is obvious that these transesterification reactions may be carried out on virgin PET, PPT or PBT resin if desired.









TABLE 4







High Molecular Weight Polyester Compositions Having Renewable Content














Ingredient
EX-14
EX-7
EX-12
EX-15
EX-16
EX-17
EX-18

















Glycerin

25
24

1.53
1.53



Phthalic anhydride
159


133
4

91


1,3-Propanediol
212
510
228
199
38
44
310


Trimellitic anhydride


Sebacic acid
84
1130
538
155
40
51
87


Isophthalic acid
416


347


508


Terephthalic acid

232
110

50
42


Neopentyl glycol
124



2


Cyclohexane



161


dimethanol


1,6-Hexanediol




9


T-20 Catalyst
5
3.8
1.8
5
0.4
0.4
5


Molecular Weight, Mn
16,900
15,900
10,400
8,000
8,490
7,530
7,000









Molecular weight of the polyester resins were determined by Gel Permeation Chromatography (GPC) using the following procedure. The polyester resin was dissolved into tetrahydrofuran (THF), quantitatively diluting to ˜30 mg/ml and filtering with a 0.45 micron filter. Two drops of toluene were added to each sample solution as an internal flow rate marker.


Samples soluble in THF were run by the following conditions. GPC analysis was run on the TriSec instrument using a four column bank of columns with pore sizes: 106, 2 mixed D PLGel and 500 Angstroms. Three injections were made for the sample and calibration standards for statistical purposes. Universal Calibration (UC) GPC was used to determine MW. UC is a GPC technique that combines Refractive Index (RI) detection (conventional GPC) with Intrinsic Viscometry (IV) detection. Advantages of UC over conventional GPC are:


1. MW is absolute (not relative only to standards).


2. Yields information about branching of molecules.


The mobile phase for the THF soluble samples was THF at 1.0 ml/min. The data was processed using the Viscotek OmniSec UC software. The instrument is calibrated using a series of polystyrene narrow standards. To verify calibration, secondary standards were run. They include a 250,000 MW polystyrene broad standard, and a 90,000 MW PVC resin. The calculated molecular weight averages are defined as follows:







M
n

=




(

Area
i

)






(

Area
i

)

/

(

M
i

)











M
w

=




[


(

Area
i

)

×

(

M
i

)


]





(

Area
i

)










M
z

=




[



(

Area
i

)

2

×

(

M
i

)


]





[


(

Area
i

)

×

(

M
i

)


]










Area
i

=

The





area





of





the






i
th






slice





of





polymer





distribution








M
i

=

The





molecular





weight





of





the






i
th






slice





of





polymer





distribution








Polydispersity






(
Pd
)


=

a





number





value





used





to





described





the





molecular





weight





distribution





and





is





obtained





by






Mw
Mn






Highly crystalline or some high molecular weight samples insoluble in THF were dissolved in a 50/50 (wt.) mixture of tetrachloroethylene (TTCE)/phenol. The column set is 104 and 500 Angstrom 50 cm Jordi columns. The mobile phase was 50/50 (wt.) mixture of TTCE/phenol at 0.3 ml/min. flow rate. The slower flow rate is due to the greater back pressure of the solvent system on the columns. The data was processed using the Viscotek UC OmniSec software.


Since MW data must be compared from one column set to the other, standards and selected samples were run on both column sets in THF for comparison. A calibration curve was made for each column set. There is good agreement of the standards between the two sets.


Flooring products having at least one layer comprising thermoplastic polyester resin binder may be manufactured by processing methods known in the art, including but not limited to calendering, extruding, casting, consolidating, and laminating. In one embodiment, a formulation comprising the polyester resin binder was melt mixed using low intensity “dough type” mixers traditionally utilized in the manufacturing of VCT tile (See Example 3). In another embodiment, the temperature of the melt mixing in the low intensity “dough type” mixers was in the range typically used in the manufacture of PVC based VCT Tile. In yet another embodiment, the formulation comprising the polyester resin binder was melt mixed using traditional extruder type mixers, including Farrell type mixers. These may be processed at higher temperatures than typically utilized in “dough type” mixers for the preparation of PVC based VCT Tile. Varied techniques may be utilized to form these melt mixed formulations into layers of flooring products. In one embodiment, the melt mixed formulation comprising the polyester resin binder was calendered into a layer. In another embodiment, the melt mixed formulation may be processed into chips or particles. Various techniques for consolidating these chips or particles into flooring layers are well known in the art. In another embodiment, the melt mixed formulation may be extruded into a flooring layer.


Procedure 1 Procedure for Preparation of High Molecular Weight Polyesters from Diacids and Diols

1A: This describes the general procedure utilized to make thermoplastic, high molecular weight polyesters from diacids and diols. A desired polyester formulation was developed based upon mole equivalent weight of the diacid and diol functional groups. An excess of diol of the most volatile diol component of the formulation was employed in the formulation. In one embodiment, 1,3-propanediol was the excess diol of choice. The diacid and diol ingredients were added into a stainless steel vessel of a RC1 automated reactor (Mettler-Toledo Inc, 1900 Polaris Parkway, Columbus, Ohio), stirred and heated under a continuous flow of pure, dry nitrogen. Typically, the ingredients were heated to 200° C. for 2 hours and temperature increased to 230° C. for an additional 4 to 6 hours until essentially all acid end groups were reacted and theoretical amount of water removed. Subsequently, the nitrogen was stopped and a high vacuum was applied. The mixture was heat and stirred under high vacuum for an additional 4 or more hours at 230° C. to 300° C. In some cases the temperature of the transesterification step was increased to 250° C. or higher. Depending upon the experiment, a vacuum in the range of 5 mm of mercury was utilized. Subsequently, the polymer was allowed to cool to 150° C. to 200° C. and physically removed from the reactor under a flow of nitrogen and allowed to cool to room temperature.


It is understood that removal of the volatile diol component during transesterification leads to high molecular weight. High molecular weight may be obtained faster if higher vacuum is utilized (below 1 mm of mercury). It is also known that as the melt viscosity increases due to increased molecular weight, the removal of diol becomes more difficult. The increase in molecular weight can become diffusion dependent because of the high viscosity of the molten polyester. This means that the released volatile diol from the transesterification reaction reacts back into the polymer before it can diffuse out of the melt, and be removed. Renewing the surface of the melt can facilitate the loss of diol and increase molecular weight. The polyesters obtained by this procedure generally have terminal hydroxyl end groups.


Although, diacid components are described above, it is understood that their simple diesters such as from methanol or ethanol can be used to prepare the thermoplastic polyester resin via known transesterification techniques. The polyesters from this procedure generally have ester terminated end groups.


1B: The same general procedure as in 1A is employed. A desired polyester formulation was developed based upon mole equivalent weight of the diacid and diol functional groups. An excess of about 0.01 to 0.5 mole excess of diacid was typically employed in the formulation. The ingredients were mixed and heated as in 1A above, except that the temperature was generally held below 200° C. to keep acid/anhydride from being removed until all hydroxyl groups were reacted. Subsequently, a high vacuum was applied as in 1A and the mixture heated to between 230° C. and 280° C. and stirred as in Procedure 1A. The resultant high molecular weight polyester was removed from the reactor and cooled as in 1A.


The mechanism of achieving high molecular weight is not clear. In some formulations containing phthalic anhydride, the phthalic anhydride was identified as being removed from the mixture. Using a nitrogen sparge below the surface of the molten polyester during the vacuum step also helped produce high molecular weight polyesters. The polyesters obtained by this procedure generally have terminal acid end groups.


Tables 5A to 5E provide examples of polyester resins having renewable components made according to the procedure of Procedure 1.















TABLE 5A





Raw Material
EX-19
EX-20
EX-21
EX-22
EX-23
EX-24


Ingredient
Amt (g)
Amt (g)
Amt (g)
Amt (g)
Amt (g)
Amt (g)





















1,3-
380.88
383.65
378.15
382.15
384.72
375.80


Propanediol


Isophthalic acid
232.94
167.59
297.34
210.34
164.70
206.85


Phthalic
385.69
448.26
324.01
348.28
272.71
342.49


anhydride


Trimellitic
0.00
0.00
0.00
0.00
0.00
0.00


anhydride


Adipic acid
0
0
0
58.73
177.38
0.00


Azelaic acid
0
0
0
0
0
74.37


T-20
0.50
0.50
0.50
0.50
0.50
0.50


Tg (° C.)
−1° C.
−5° C.
22° C.
−11° C.
−23° C.
4° C.






















TABLE 5B







Raw Material
EX-25
EX-26
EX-27
EX-28



Ingredient
Amt (g)
Amt (g)
Amt (g)
Amt (g)






















1,3-Propanediol
366.04
373.73
360.20
261.06



Neopentyl glycol
0
0
0
112.82



Isophthalic acid
156.70
205.71
154.20
294.12



Phthalic
259.46
340.60
255.33
112.38



anhydride



Azelaic acid
217
0
0
0



Sebacic acid
0
79.47
229.77
219.12



T-20
0.50
0.50
0.50
0.50



Tg (° C.)
−12° C.
−12° C.
−29° C.
−21° C.






















TABLE 5C





Raw Material
EX-29
EX-30
EX-31
EX-32
EX-33


Ingredient
Amt (g)
Amt(g)
Amt (g)
Amt(g)
Amt (g)




















1,3-Propanediol
481.32
247.27
449.21
410.46
303.48


Isophthalic acid
0
0
0
0
696.01


Phthalic anhydride
198.83
481.53
211.15
639.45
0


Trimellitic anhydride
319.35
270.70
339.15
449.34
0


T-20
0.50
0.50
0.50
0.50
0.50


Tg (° C.)
25° C.
−22° C.
−11° C.
21° C.
35° C.*





*May be partially crystalline



















TABLE 5D





Raw Material
EX-34
EX-35
EX-36
EX-37
EX-38
EX-39


Ingredient
Amt (g)
Amt (g)
Amt (g)
Amt (g)
Amt (g)
Amt (g)





















1,3-
311.32
147.21
210.67
86.45
344.66
161.58


Propanediol


Neopentyl

201.45
123.55
276.04
0
223.72


glycol


Isophthalic acid
475.99
450.16
460.15
440.6
385.09
361.07


Phthalic
212.19
200.68
205.12
196.41
269.76
252.93


anhydride


T-20
0.50
0.50
0.50
0.50
0.50
0.66


Tg (° C.)
32° C.
35° C.
41° C.
42° C.
46° C.
56° C.




















TABLE 5E








EX-40
EX-41



Ingredient
Amt (g)
Amt (g)




















1,3-Propanediol
211.61
200.93



Neopentyl glycol
124.10
0



1,4-Cyclohexanedimethanol
0
163.15



Isophthalic acid
415.99
394.98



Phthalic anhydride
158.95
150.92



Sebacic acid
84.37
80.10



T-20
10.00
9.90



Tg(° C.)
26° C.
34° C.










EXAMPLE 2
Preparation of High Molecular Weight Polyesters by Co-Reaction with Recycle Crystalline Polyesters

The following formulation was processed as per Procedure 1 to prepare the aliphatic polyester Ex-42 comprising 100% renewable components and a Biobased Content of 100%.















EX-42



Amt (g)



















1,4-Butanediol
400.5



Sebacic acid
600



T-20 Catalyst
0.4










The aliphatic polyester Ex-42 was mixed with clear PET bottle recycle resin obtained from Nicos Polymers & Grinding of Nazareth, Pa., and catalyst added as listed below.















EX-43



Amt (g)



















PET recycle bottle
100



EX-42
100



T-20 Catalyst
0.13










The mixture was heated and stirred under nitrogen at 265° C. for a period of about 3 hours, and a high vacuum applied as in Procedure 1 for an additional 3 hours at 265° C. Subsequently, the resultant polyester having 50% by weight renewable content and 50% by weight recycle content was shown to have a molecular weight Mn of 17,200 with a Tg of −9° C. and a Tm of 114° C. Molecular weight Mn of the starting PET recycle bottle resin was determined by GPC techniques described above and found to be 14,000. A sample of PET film obtained from Nicos Polymers & Grinding was also analyzed by GPC and molecular weight Mn determined to be 17,300.


EXAMPLE 3
Preparation of Vinyl Composition Type Tile Having a Binder Comprising Thermoplastic, High Molecular Weight Polyester Resin

This is an example of PCT tile flooring product prepared with a binder comprising a thermoplastic, high molecular weight polyester resin. Traditionally, VCT tile manufacturing processes have utilized low intensity “dough” type heated mixers to compound/melt mix the tile formulation which is subsequently calendered into a layer. Higher intensity mixers such as extruders or Farrell type mixers may also be employed, and these high intensity mixers may also be heated to higher temperatures to compound the tile formulation.


The following PCT tile formulations Table 6B-D, comprising amorphous, polyester resins GPa02176—of Table 5C and 5D, were mixed using a low intensity Baker Perkins heated mixer. The ingredients were added to the mixer which was heated to 325° F. The formulations were mixed and heated for approximately 7-11 minutes on average in the Baker Perkins mixer to a drop temperature of approximately 280° F. Depending upon the formulation, mixing time varied between 7-28 minutes and drop temperature varied between approximately 270° F. and 290° F. (See Table 6B-D).


The hot, mixed formulations were then dropped into the nip of a two roll calender. The rolls of the calendar were set at different temperatures—one roll hotter than the other. Typically, the hot roll was set at about 290° F. and the cold roll set at about 250° F. The nip opening between the calendar mill rolls were set to provide a final sheet thickness of about 125 mils. The processability of the formulations were evaluated using the key described in Table 6A.









TABLE 6A





Key for Baker Perkins and Mill Evaluations















Mix Appearance


1. very soft, wet, flowable mix


2. tough mix, dough like


3. soft mix, small beads


4. dry mix with some clumps


5. very dry powdery mix, no clumps


6. unmelted pellets/polyester


Sheet Appearance


1. soft flexible sheet


2. smooth sheet


3. cracks in sheet and/or voids


4. ragged edges, uneven sheet thickness, wavy


5. lots of folds from being taken off with the blade


Sheet Hot Strength


1. falls apart when removed from roll, powder


2. falls apart when removed from roll, small pieces or partial sheet


3. full sheet which falls apart under sheet weight


4. no stretch under sheet weight


5. slight stretch under sheet weight


6. sheet shrinks when pulled off the mill


Roll Tack


1. sticks to a roll, all can't be removed with the blade


2. sticks to a roll, removed with the blade but not cleanly (chatter marks)


3. sticks to a roll, removed cleanly with the blade


4. material split between two rolls


5. material does not stick to either roll


Roll Residue


1. a lot


2. a little


3. none


Self Feeding


1. yes


2. marginal


3. no









As can be seen from a formulation and processing datasheet Tables 6B-6D, the formulation based upon high molecular weight polyesters processed very similar to a standard PVC formulations. Formulations of Tables 6B-6D are based on blends of Armstrong amorphous polyesters of Tables 5C-5D with Ecoflex FBX7011 polyester sold by BASF. Ecoflex FBX7011 is a high molecular weight, biodegradable, aliphatic-aromatic copolyester based on butanediol, adipic acid, and terephthalic acid exhibiting a Tg of about −25° C. and a Tm of about 115° C. The tiles exhibited acceptable physical properties, with a significant improvement in breaking load strength.


It is important to note that formulations based only on Ecoflex FBX7011 in pellet form could not be adequately mixed in the low intensity mixer. There was not enough heat transfer and shear within the mix to breakdown the pellet form of the Ecoflex 7011. The addition of the amorphous polyester resin changed the physical nature of the mix allowing the Ecoflex 7011 to be incorporated.


Tile and sheet formulations may also contain other ingredients such as processing aids, tackifiers, hydrophobic agents, stabilizers, colorants and other known additives. Of particular interest, the tile formulations may also contain up to 30% by weight of one or more additional polymers and sheet formulations may also contain up to 50% by weight of one or more additional polymers. These additional polymers may assist in processing in low intensity mixers, and also may assist in achieving improved physical properties. These polymers may consist of acid functionalized polymers including EAA, EMA, and partially neutralized versions thereof (ionomers), Surlyn, or other (methacrylic) acrylic acid, or maleic acid (anhydride) copolymers to obtain desired process and physical properties.


The use of recycle fillers in these formulations also allows for the flooring product having at least one layer comprising the high molecular weight polyester binder to achieve at least one point within the LEED System.
















TABLE 6B








EX-44
EX-45
EX-46
EX-47
EX-48


Ingredient
Trade Name
Supplier
Amt (g)
Amt (g)
Amt (g)
Amt (g)
Amt (g)






















ESO
Flexol EPO
Dow
7.6
14.32
6.13
11.55
6.13


Filler
Global stone 229
PenRoc
926.2
926.2
924.74
924.74
924.74


(Limestone)


Pigment
Kronos 2220
Kronos
6.6
6.6
6.6
6.6
6.6


(TiO2)


Aromatic
Ecoflex FBX7011
BASF
83.6
83.6
101.2
101.2
101.2


Polyester


Aromatic
EX-30
Armstrong
76
69.28
61.33
55.91
0


Polyester


Aromatic
EX-32
Armstrong
0
0
0
0
61.33


Polyester




Total

1100
1100
1100
1100
1100



Wt % Binder

0.15
0.15
0.15
0.15
0.15



Wt % Filled

0.85
0.85
0.85
0.85
0.85



Mixer Temp ° F.

324
324
324
324
324



Batch Time (min)

12
11
9
9
7



Mix Drop Temp

275
272
278
279
280



° F.



East Roll Temp

290
290
290
290
290



° F.



West Roll Temp

250
250
250
250
250



° F.



Gap Setting

2.1
2.1
2.1
2.1
2.1



Sheet Thickness

125
125
125
125
125



Mix Appearance

2–3
2–3
2–3
2–3
2–3



Sheet

2
2
2–4
2
3



Appearance



Sheet Hot

4
4
5
5
5



Strength



Roll Tack

2–3
3
2–3
3
3



Roll Residue

2
2
2
2
2



Self Feeding

1
1
1
1
1






















TABLE 6C








EX-49
EX-50
EX-51
EX-52


Ingredient
Trade Name
Supplier
Amt (g)
Amt (g)
Amt (g)
Amt (g)





















ESO
Flexol EPO
Dow
11.55
0

0


Filler
Global stone 229
PenRoc
924.74
923.77
926.2
924.74


(Limestone)


Pigment
Kronos 2220
Kronos
6.6
6.6
6.6
6.6


(TiO2)


Aromatic
Ecoflex FBX7011
BASF
101.2
127.22
83.6
101.2


Polyester


Aromatic
EX-32
Armstrong
55.91
0
0
0


Polyester


Aromatic
EX-33
Armstrong
0
42.41
83.6
67.47


Polyester




Total

1100
1100
1100
1100



Wt % Binder

0.15
0.15
0.15
0.15



Wt % Filled

0.85
0.85
0.85
0.85



Mixer Temp ° F.

324
324
321
324



Batch Time (min)

15
15
15
10



Mix Drop Temp ° F.

283
279
279
278



East Roll Set Pressure

78
78
78
78



psi



West Roll Set Pressure

26
26
26
26



psi



East Roll Temp ° F.

290
290
290
290



West Roll Temp ° F.

250
250
250
250



Gap Setting

2.1
2.1
2.1
2.0



Sheet Thickness

125
125
125
125



Mix Appearance

2
2
2
2



Sheet Appearance

2
2
2
2



Sheet Hot Strength

5
5
5
4



Roll Tack

3
3
3
3



Roll Residue

2
2
2
2



Self Feeding

2
2
2
2























TABLE 6D









EX-54








EX-53
Amt
EX-55
EX-56
EX-57


Ingredient
Trade Name
Supplier
Amt (g)
(g)
Amt (g)
Amt (g)
Amt (g)






















Filler (Limestone)
Global stone 229
PenRoc
961.08
926.20
924.74
926.20
924.74


Pigment (TiO2)
Kronos 2220
Kronos
6.60
6.60
6.60
6.60
6.60


Aromatic
Ecoflex FBX7011
BASF
79.39
83.60
101.20
83.60
101.20


Polyester


Aromatic
EX-34
Armstrong
52.93
0.00
0.00
0.00
0.00


Polyester


Aromatic
EX-35
Armstrong
0.00
83.60
67.47
0.00
0.00


Polyester


Aromatic
EX-36
Armstrong
0.00
0.00
0.00
83.60
0.00


Polyester


Aromatic
Ex-37
Armstrong
0.00
0.00
0.00
0.00
67.47


Polyester




Total

1100
1100
1100
1100
1100



Wt % Binder

0.12
0.15
0.15
0.15
0.15



Wt % Filled

0.88
0.85
0.85
0.85
0.85



Mixer Temp ° F.

324
324.00
324.00
324.00
324



Batch Time (min)

28
12
11
13
8



Mix Drop Temp ° F.

288
274
272
278
288



East Roll Set

78
78
78
78
78



Pressure psi



West Roll Set

26
26
26
26
26



Pressure psi



East Roll Temp ° F.

290
290
290
290
290



West Roll Temp ° F.

250
250
250
250
250



Gap Setting

2.1
2.1
2.1
2.1
2.0



Sheet Appearance

2
2
2
2
2



Mix Appearance

3
2–3
2–3
2–3
2–3



Sheet Thickness

124
124
122
124
124



Sheet Hot Strength

5
4
4
4
5



Roll Tack

3
3
3
3
3



Roll Residue

2
2
2
2
2



Self Feeding

1
1
2
2
1









EXAMPLE 4
Preparation of Vinyl Composition Type Tile Having a Binder Comprising Thermoplastic, High Molecular Weight Polyester Resin

High molecular weight polyester of the composition in table 5E was prepared as per Procedure 1. The high molecular weight polyester was formulated into a PCT tile formulation and processed as in Example 3. The datasheet Table 7 describes the conditions used to make the tile. The tile exhibited acceptable physical properties, with a significant improvement in breaking load strength.













TABLE 7








EX-58
EX-59


Ingredient
Trade Name
Supplier
Amt (g)
Amt (g)



















Filler (Limestone)
Global stone 229
PenRoc
880.00
880.00


Pigment (TiO2)
Kronos 2220
Kronos
6.00
6.00


Polyester
EX-40
Armstrong
114.00
0


Polyester
EX-41
Armstrong
0
114.00



Total

1000.00
1000.00



Wt % Binder

11.40%
11.40%



Wt % Filled

88.60%
88.60%



Mixer Temp ° F.

326
327



Batch Time (min)

30
20



Mix Drop Temp ° F.

284
278



East Roll Set

77
72



Pressure psi



West Roll Set

30
30



Pressure psi



East Roll Temp ° F.

292
290



West Roll Temp ° F.

252
248



Gap Setting

2.1
2.0



Sheet Appearance

2
2



Mix Appearance

2.3
2.3



Sheet Thickness

124
121



Sheet Hot Strength

4
4



Roll Tack

3
3



Roll Residue

3
3



Self Feeding

1
1









EXAMPLE 5
Examples of Polyesters Made by Transesterification Between High Molecular Weight Aliphatic, Renewable Polyesters and Recycle Polyester Resin

High molecular weight polyesters comprising the compositions of Table 8A were made according to Procedure 1.















TABLE 8A










T-20




Azelaic Acid
1,4-Butanediol
Sebacic Acid
Amt
Total



Amt (g)
Amt (g)
Amt (g)
(g)
Amt (g)





















EX-60
511
489

0.4
1000


EX-61
582
417.6

0.4
1000


EX-62

400.5
600
0.4
1001


EX-63

471.2
528
0.4
1000


Ex-42
674
325.74

0.5
1000


Ex-64

354
529
0.4
883









The polyesters of Table 8A, were each mixed with recycle PET bottle resin obtained from Nicos Polymers & Grinding of Nazareth, Pa., and 0.1% T-20 catalyst added and transesterification conducted as per Example 2. In some examples, transesterification was also carried out on PBT resin Celanex 1600A obtained from Ticona (formerly Hoechst Celanese Corp.), Summit, N.J. Table 8B shows some of the resultant polyester co-reaction products and their Tm. It is obvious that these transesterification reactions may be carried out on virgin PET or PBT type resin.

















TABLE 8B













Mid-



Polyester





melt range
point


PE
ID used
Recycled




(deg C.)
mp


Transesterification
in Transesterification
Bottle
PBT
PB
Ecoflex
PB
trans
(Tm)


Rxn #
Rxn
PET
Celanex
Azelate
FBX7011
Sebacate
product
° C.























Nicos






255–259
256


Scrap


PET


EX-65
EX-60
70

30


138–154
145


EX-66
EX-61
50

50


 84.5–104.8
94.9


EX-67
EX-61
70

30


140–159
146


EX-68
EX-62
50



50
 99–126
102.9


EX-69
EX-62
70



30
155–170
160


EX-70
EX-63
50



50
101–125
109


EX-71
EX-63
70



30
149–156
151


EX-72
EX-42
50

50


100–111
105


EX-73
EX-42
70

30


133–141
136


EX-74
EX-64
50



50
 92–106
97


EX-75
EX-65
70



30
110–170
140


EX-76
EX-60

75
75


135–141
137


EX-77
EX-64

75


75
145–166
156


EX-78
EX-63
180



120
 79–153
87


EX-79
EX-42
180

120


 73–108
79


EX-80
Ecoflex
180


120

122–158
137



FXB7011









The melting points listed in Table 8B were determined using an “Optimelt” automated unit. Higher Tm co-reacted polyesters may be produced by using less aliphatic polyester than described in the Table 8B above.


EXAMPLE 6
PCT Tile Compositions Comprising High Molecular Weight Polyester Binders of Example 5

Formulations based on the polyester reaction products of Table 8B were developed to allow processing in low shear Baker Perkins heated mixers and VCT type calendaring processing. The formulations in Table 8C and Table 8D include EAA (ethylene acrylic acid copolymer) and an acrylic processing aid. The use of EAA not only effect processing in the Baker Perkins and through the calendar, but the polymer also imparts stiffness and some improved properties.
















TABLE 8C








EX-81
EX-82
EX-83
EX-84
EX-85


Ingredient
Trade Name
Supplier
Amt (g)
Amt (g)
Amt (g)
Amt (g)
Amt (g)






















Filler
Global stone 229
PenRoc
479.9
479.9
479.9
479.9
479.9


(Limestone)


Pigment
Kronos 2220
Kronos
3.4
3.4
3.4
3.4
3.4


(TiO2)


Polyester
EX-66
Armstrong
65.0


Polyester
EX-68
Armstrong

65.0


Polyester
EX-70
Armstrong


65.0


Polyester
EX-72
Armstrong



65.0


Polyester
EX-74
Armstrong




65.0


EAA
Primacor 1410
Dow
13
6.5
13
13
13


Acrylic
Plasti-strength 530
Arkema
10

10
10
10



Total

548.3
548.3
548.3
548.3
548.3



Wt % Binder



Wt % Filled



Mixer Temp ° F.

326
325
326
326
326



Batch Time (min)


11
5
5
5



Mix Drop Temp ° F.

284
292
284
278
278



East Roll Temp ° F.

295
293
287
278
278



West Roll Temp ° F.

293
277
236
200
225



Gap Setting

0.71
6, 7
0.7
0.7
0.7



Sheet Appearance

2
2, 1
2
2
2



Mix Appearance

5
5
5
5
5



Sheet Thickness

75–80
55–65
75–80
75–80
75–80



Sheet Hot Strength

5
5
5
5
5



Roll Tack

3
2
3
3
3



Roll Residue

2
2
2
2
2



Self Feeding

2
2
1
1
1





















TABLE 8D








EX-86
EX-87
EX-88


Ingredient
Trade Name
Supplier
Amt(g)
Amt(g)
Amt(g)




















Filler (Limestone)
Global stone 229
PenRoc
959.8
959.8
959.8


Pigment (TiO2)
Kronos 2220
Kronos
6.8
6.8
6.8


Polyester
EX-78
Armstrong
130.0

0.0


Polyester
EX-79
Armstrong

130.0


Polyester
EX-68
Armstrong


130.0


EAA
Primacor 1410
Dow
26
26
52


Acrylic
Plasti-strength 530
Arkema
20
20
40



Total

1142.6
1142.6
1188.6



Wt % Binder



Wt % Filled



Mixer Temp ° F.

325
327
327



Batch Time (min)

26
30




Mix Drop Temp ° F.

278
278




East Roll Temp ° F.

225
232
297



West Roll Temp ° F.

225
235
292



Gap Setting

2
2
6.2, 4.2



Sheet Appearance

2
2
2



Mix Appearance

3
4, 3
3, 2



Sheet Thickness

120
123–128
125–134



Sheet Hot Strength

5
5
5



Roll Tack

3, 2
3, 2
3, 2



Roll Residue

2
2
2



Self Feeding

1
1
1









EXAMPLE 7
PCT Tile Comprising High Molecular Weight Polyester Binder and Processing Additives

A high molecular weight polyester comprising the composition in Table 9A was prepared as per Procedure 1.














TABLE 9A










Ex-89



Ingredient
Supplier
Function
Amt (g)





















Phthalic Anhydride

acid
495



Trimellitic Anhydride

acid
47.6



Neopenyl Glycol

diol
347.9



1,6 hexanediol

diol
109.6



T-20
Air Products
catalyst
0.4





Total
1000.5










PCT tile formulations based on the polyester of Table 9A were developed to allow processing in low shear Baker Perkins heated mixers and VCT type calendaring processing. The formulations in Table 9B include EAA (ethylene acrylic acid copolymer) and an acrylic processing aid. The use of EAA not only effect processing in the Baker Perkins and through the calendar, but the polymer also imparts stiffness and some improved properties.














TABLE 9B








Ex-90
Ex-91
Ex-92


Ingredient
Trade Name
Supplier
Amt (g)
Amt (g)
Amt (g)




















Filler (Limestone)
Global stone 229
PenRoc
768.0
768.0
768.0


Filler (Limestone)
Emerys DB04

192.0
192.0
192.0


Pigment (TiO2)
Kronos 2220
Kronos
6.8
6.8
6.8


Polyester
EX-63
Armstrong
100
80.0
65.0


Ecoflex FBX7011


30
50
65


EAA
Primacor 1410
Dow
26
26
26


Acrylic
Plasti-strength 530
Arkema
20
20
20



Total

1142.8
1142.8
1142.8



Mixer Temp ° F.

327
327
327



Batch Time (min)

12
14
12



Mix Drop Temp ° F.

272
271
277



East Roll Temp ° F.

243
241
241



West Roll Temp ° F.

237
235
235



Gap Setting

2
2
2



Sheet Appearance

2
2
2



Mix Appearance

4
4
4



Sheet Thickness

130
128–130
128–130



Sheet Hot Strength

4
4
4



Roll Tack

3, 2
3, 2
3, 2



Roll Residue

2
2
2



Self Feeding

1
1
1









The use of different sized limestone filler yields better processibility and improved performance.


EXAMPLE 8
PCT Tile Comprising High Molecular Weight Polyester and Processing Additives

A high molecular weight polyester comprising the composition Table 10A was prepared according to Procedure 1.












TABLE 10A








EX-93



Ingredient
Amt (g)



















Sebacic acid
279.11



Terephthalic acid
343.83



Phthalic anhydride
25.55



1,3-Propanediol
262.55



Glycerin
10.59



1,6 Hexanediol
61.16



Neopentyl glycol
10.76



T-20
2.99



Total
996.54



Tg
−16° C.



Tm
113° C.










PCT tile formulations based on the high molecular weight polyester of Table 10A were developed to allow processing in low shear Baker Perkins heated mixers and VCT type calendaring processing as per Example 3. The formulation datasheets in Table 10B include the use of a hydrocarbon tackifier, epoxidized soybean oil and Surlyn ionomer additives. Surlyn ionomer may not only effect processing in the Baker Perkins and through the calendar rolls, but Surlyn may also impart some improved properties to the finished tile. In cases where ESO or other epoxidized oils are also used in combination with acid functionalized polymers, these may react with each other (dynamic cross-linking) during processing of the formulation at elevated temperature.














TABLE 10B








EX-94
EX-95
EX-96


Ingredient
Trade Name
Supplier
Amt (g)
Amt (g)
Amt (g)




















Pigment 348
Kronos 2220
Kronos
5.5
5.5
5.5


Limestone 229
Marble Hill 40X0
JMHuber Corp
908.0
1008.0
958.0


Polyester
EX-93
Armstrong
168.0
168.0
168.0


Copal rosin
Copal
Ornya Peralta GmbH
15.0


ESO


10.0
15.0
15.0


Ethylene-methacrylic
Surlyn 8920
Du Pont


20.0


acid copolymer,


partial metal salt




Total

1106.5
1196.5
1166.5



Mixer Temp ° F.

324
324
324



Batch Time (min)

13
13
13



Mix Drop Temp ° F.

282
284
284



East Roll Temp ° F.

280
280
288



West Roll Temp ° F.

255
255
255



Gap Setting

2.2
2.2
2



Sheet Appearance

1–2
1–2
2, 1



Mix Appearance

2/3
2/3
2/3



Sheet Thickness

0.125
0.124
0.125



Sheet Hot Strength

5
5
5



Roll Tack

3
3
3



Roll Residue

2
2
3



Self Feeding

2
2
1








Claims
  • 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.