RECYCLABLE SURFACE COVERING AND METHOD OF MANUFACTURING

Abstract

A surface covering is provided, comprising a substrate with a flocking layer adhered to the substrate by an adhesive. The substrate is formed at least partially from granulated recycled rubber and a binding agent. In an exemplary embodiment, a design is applied to the flocking layer. A method of manufacturing the surface covering comprises the steps of producing a substrate formed at least partially from granulated recycled rubber and a binding agent, flocking the substrate with fibers of a selected base color to form a base covering, printing a transfer paper with a design and transferring the design from the transfer paper to fibers of the base covering.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

Exemplary embodiments of the invention will be described in detail with reference to the accompanying drawing figures, of which:

FIG. 1 is a sectional view of a surface covering according to an exemplary embodiment of the invention;

FIG. 2 shows a manufacturing sequence for forming a surface covering using recycled product according to an exemplary embodiment of the invention;

FIG. 3 shows an exemplary embodiment of a decorative design applied to the surface covering.; and

FIG. 4 shows a manufacturing and distribution method according to an exemplary embodiment of the invention.

Claims

1. A surface covering, comprising: a substrate formed at least partially from granulated recycled rubber and a binding agent;a flocking layer adhered to the substrate with an adhesive to form a base covering anda decorative design is applied to the base covering.

2. The surface covering of claim 1, wherein the binding agent is urethane.

3. The surface covering of claim 1, wherein the adhesive is an acrylic adhesive

4. The surface covering of claim 1, wherein the substrate is shaved from a cylindrical billet of granulated recycled rubber.

5. The surface covering of claim 1, wherein the substrate comprises granulated recycled rubber from recycled surface covering.

6. The surface covering of claim 5, wherein the substrate further comprises granulated recycled rubber from other sources.

7. The surface covering of claim 5, wherein the substrate further comprises a filler.

8. The surface covering of claim 5, wherein the substrate comprises at least 10 wt-% of reground rubber from recycled surface covering.

9. The surface covering of claim 1, wherein a decorative design is formed on the flocking layer.

10. The surface covering of claim 9, wherein the decorative design is formed using a dye sublimation process.

11. The surface covering of claim 9, wherein the decorative design comprises a picture.

12. The surface covering of claim 9, wherein the decorative design comprises a pattern.

13. A method of manufacturing a recyclable surface covering comprising flocking adhered to a granulated recycled rubber substrate, comprising the steps of: producing a substrate formed at least partially from granulated recycled rubber and a binding agent;flocking the substrate with fibers of a selected base color to form a base covering;printing a transfer paper with a design; andtransferring the design from the transfer paper to fibers of the base covering.

14. The method of claim 13 wherein the base covering is warehoused prior to printing.

15. The method of claim 14 wherein a number of transfer papers are printed and stored.

16. The method of claim 15 wherein the base covering is produced in a first facility and then shipped to a distribution center for printing.

17. The method of claim 16 wherein the transfer papers are stored at the distribution facility.