Decorative composite floor coverings

A composite floor covering having an upper decorative layer, a stabilizing layer, and an optional cushioning layer is characterized in that the decorative layer itself comprises a fabric base and a plastic matrix having a transparent portion. The plastic matrix may include an opaque portion. At least the transparent portion of the plastic matrix has discrete fibrous structures embedded therein. The plastic matrix material is selected with melting and rheological characteristics such that the plastic matrix is prepared and applied to the fabric base in fluid form and solidifies under conditions at which the fabric base and embedded fibrous structures remain substantially intact. The fabric layer may be totally embedded within the plastic matrix or may form the lower surface of the plastic matrix. The decorative layer may include (i) fabric fragments, (ii) groupings of multi-oriented individual fibers, or (iii) mixtures of fragments and individual fibers. The fabric base may, if desired, have a decorative facing.

FIELD OF THE INVENTION 
This invention relates to a composite floor covering, and in particular, to 
a composite floor covering having a decorative layer comprising a fabric 
base and a plastic matrix, the plastic matrix having discrete fibrous 
structures embedded therein. 
BACKGROUND OF THE INVENTION 
Decorative floor coverings such as carpets and vinyl flooring are well 
known. Carpets offer greater comfort than vinyl flooring due to their 
soft, cushioning feel and better warmth. Notwithstanding the wide variety 
of available design choice, vinyl flooring is seen by some to lack the 
aesthetic appearance usually associated with carpet. 
It is believed that there exists a need for a composite floor covering 
which includes the advantages of vinyl flooring but which also offers what 
is believed to be more aesthetically pleasing decorative designs. The 
present invention is believed to provide such a composite floor covering. 
SUMMARY OF THE INVENTION 
The present invention is directed to a composite floor covering comprising 
a decorative layer, a stabilizing layer, and an optional cushioning layer. 
The decorative layer itself comprises a continuous fabric base and a 
transparent plastic matrix having discrete fibrous structures embedded 
therein. The plastic matrix material is selected with predetermined 
melting and rheological characteristics such that the plastic matrix is 
prepared and applied to the fabric base in fluid form and solidifies under 
conditions at which the fabric base and embedded fibrous structures remain 
substantially intact. If desired, the plastic matrix may include an opaque 
portion that is disposed beneath the transparent portion. In such an 
instance the discrete fibrous structures are embedded in at least the 
transparent portion of the plastic matrix. 
In one embodiment the fabric layer is embedded within the plastic matrix. 
In an alternate embodiment the fabric layer is layered beneath and adhered 
to the plastic matrix. The fabric base is selected from the group 
consisting of velours, felts, woven, non-woven, knitted, flocked, 
needle-punched, tufted and fusion-bonded fabrics. 
The fabric base may have a decorative design on the upper surface (facing) 
thereof. The design (if present) is visible through the transparent 
portion of the plastic matrix and adds to the aesthetic effect of the 
decorative layer imparted by the presence of the fibrous structures. The 
opaque portion of the plastic matrix (if present) is disposed beneath the 
fabric base. 
The fibrous structures disposed within the plastic matrix of the decorative 
layer may comprise (i) fabric fragments, (ii) groupings of multi-oriented 
individual fibers, or (iii) mixtures of fragments and individual fibers. 
If individual fibers are used (whether alone or with the fragments) the 
length of the individual fibers is greater than about nine (9) 
millimeters. The individual fibers may be crimped and crinkled. The 
individual fibers are selected from the group consisting of polyester, 
polypropylene, cotton, silk, wool, acrylic and nylon. Alternatively, the 
fibrous structures comprises fabric fragments. Preferably, the fabric 
fragments have no dimension greater than about one-and-one-half (1.5) 
inch. The fabric fragments are selected from the group consisting of 
velours, felts, woven, non-woven, knitted, flocked, needle-punched, tufted 
and fusion-bonded fabrics. 
The loading of the fibrous structures (whether implemented as individual 
fibers or as fabric fragments) within the plastic matrix is dependent upon 
the presence of the decorative design on the surface of the fabric base. 
Without a decorative design on the fabric base the fibrous structures may 
occupy up to about eighty-five percent (85%) of the surface area of the 
decorative layer. However, if the fabric base does carry a decorative 
design the fibrous structures may occupy from about five percent (5%) to 
about fifty percent (50%) of the of the surface area of the decorative 
layer. 
At least one stabilizing layer is disposed beneath the decorative layer. In 
instances in which the fabric base is embedded within the plastic matrix 
the stabilizing layer is implemented as a separate layer attached beneath 
the decorative layer. A separate adhesive layer, or the adhesive 
properties of the plastic matrix itself, may be used to secure the 
stabilizing layer to the plastic matrix. Alternatively, in the instance 
wherein the fabric base is adhered beneath the plastic matrix, the fabric 
base may be used to function as a stabilizing layer. In this event the 
fabric base is selected from a material that has sufficient strength, 
elongation, dimensional stability and puncture resistance so as to 
function as a stabilizing layer. Of course, even in the instance where the 
fabric base is adhered beneath the plastic matrix, a separate stabilizing 
layer may also be provided. As will be developed herein, any of a variety 
of materials may be used to form the stabilizing layer. 
The composite floor covering may further include an optional cushioning 
layer disposed beneath the stabilizing layer. The cushioning layer 
comprises fiber felt or a foamed composition selected from the group 
consisting of rubber, latex, urethane and poly(vinyl chloride). 
If desired, a transparent flexible wear layer may be disposed over the 
plastic matrix of the decorative layer. Preferably, the transparent wear 
layer may be fabricated from the group consisting of urethanes, poly(vinyl 
chloride), silicone or fluoropolymer.

DETAILED DESCRIPTION OF THE INVENTION 
Throughout the following detailed description, similar reference numerals 
refer to similar elements in all figures of the drawings. 
Referring to FIGS. 1 and 2 shown in side sectional views are alternate 
embodiments of a composite floor covering 10 (FIG. 1) and 10' (FIG. 2) in 
accordance with the present invention. Generally speaking, each embodiment 
of the composite floor covering 10, 10' includes a decorative layer 12, at 
least one stabilizing layer 24 (of various forms, as will be described), 
and an optional cushioning layer 28. 
DECORATIVE LAYER 
The decorative layer 12 itself comprises a fabric base 14 and a plastic 
matrix 16. The upper portion 16T of the plastic matrix 16 is transparent. 
The plastic matrix 16 may include an optional opaque portion 16D disposed 
beneath the transparent upper portion 16T. At least the transparent 
portion 16T of the plastic matrix 16 has discrete fibrous structures 
generally indicated by the reference character 18 embedded therein. The 
decorative effect imparted by the fibrous structures 18, whether taken 
alone or in combination with the fabric base 14, will be discussed in 
connection with FIGS. 3A through 3D. 
Fabric Base 
The fabric base 14 is selected from the group consisting of velours, felts, 
woven, non-woven, knitted, flocked, needle-punched, tufted, and 
fusion-bonded fabrics, each of which is well known in the art. By the term 
"fabric" as used herein it is meant a planar textile structure composed of 
yarns, fibers, or filaments and having an upper surface (facing) and lower 
surface. The fabrics are composed of natural or synthetic fibers. Such 
fibers include, for example, wool, cotton, polyamides (such as nylon 6,6, 
nylon 6, and copolymers thereof), polyesters, polyolefins (such as 
polypropylene), acrylics, rayon, silk and blends thereof. The fabrics may 
be textured or non-textured. 
Generally, woven fabrics refer to fabrics formed by weaving (i. e., 
interlacing) two sets of yarns, known as warp and fill. The three basic 
weaves are plain, twill, and satin. In the plain weave, yarns running in 
one direction (fill) go under and over alternate single yarns running in 
the other direction (warp). Plain weave fabrics are strong and durable. In 
the twill weave, yarns running in the filling direction go over one or 
more warp yarns and under groups of other yarns. Twill weave fabrics are 
strong with good shape-holding ability. In the satin weave, the face of 
the fabric consists almost entirely of warp or filling floats produced in 
the repeat of a weave. The points of yarn intersection are distributed as 
evenly and widely separated as possible. Satin-weave fabrics have a 
smooth, lustrous appearance. 
Generally, non-woven fabrics refer to an assembly of textile fibers held 
together by interlocking in a random web or mat, by fusing of the fibers, 
or by bonding with an adhesive. Spun-bonded fabrics, such as those sold 
under the registered trademarks Tyvek.RTM. or Typar.RTM., are composed of 
randomly arranged, continuous filament fibers bonded at filament 
cross-over points. These fabrics are lightweight and have good tensile and 
tear strengths. Spun-laced fabrics, such as that manufactured and sold by 
E. I. DuPont de Nemours and Company under the registered trademark 
Sontara.RTM., are composed of fibers entangled in a predetermined 
repeating pattern to form a strong, non-bonded structure. 
Knitted fabrics generally refer to fabrics which are constructed by 
interlocking a series of loops of one or more yarns. In warp knitting the 
yarns generally run lengthwise in the fabric. In weft knitting one 
continuous thread runs crosswise in the fabric making all of the loops in 
one course. Weft knitting includes circular knitting and flat knitting. In 
circular knitting the fabric is produced on the knitting machine in the 
form of a tube, wherein the threads run continuously around the fabric. In 
flat knitting the fabric is produced on the knitting machine in flat form, 
wherein the threads alternate back and forth across the fabric. 
The upper surface (facing) of the fabric base 14 may be plain or may carry 
a decorative design. In the present invention colors and designs can be 
applied to the fabrics by conventional techniques such as by dyeing the 
yarns, fibers or filaments which compose the fabric or by dyeing or 
printing the fabric itself. For example, in solution-dyeing processes, 
pigments are added to the fiber-spinnable polymer melt or solution prior 
to extrusion of the melt or solution through a spinneret to form 
solution-dyed fibers. Alternatively, the fibers may be pre-dyed by such 
techniques as "stock-dyeing" (the dyeing of fibers in staple form). 
Alternatively, the yarn may be pre-dyed before it used to form a fabric. 
Yarn dyeing techniques include skein-dyeing, space-dyeing and 
package-dyeing. Dyed yarns of different colors may be used to give the 
fabric multicolored patterns. 
A second method for imparting a decorative design to fabrics is printing. 
In general, printing involves applying coloring agents onto the fabric 
which is then treated with heat or chemicals to fix the coloring agents. 
Printing techniques include, for example, pigment printing, roller 
printing, screen printing, and heat transfer printing. 
Plastic Matrix 
The plastic matrix 16 is formed by a plastisol that comprises, at a 
minimum, a base resin, a plasticizer, and a stabilizer system. 
The ingredients are selected such that at least the upper portion 16T of 
the finished plastic matrix 16 is sufficiently transparent (i. e., clear) 
that the fibrous structures may be seen therethrough. 
The base resin is typically poly(vinyl chloride). 
Suitable for use as the plasticizer is a polyester plasticizer sold by Huls 
America, Inc., as NUOPLAS 6000. 
The stabilizer system may include a primary stabilizer, such as a mixture 
of metallo-organic salts. Suitable for use is a mixture of organic salts 
and barium and zinc, such as that sold by Witco Corporation as Mark 4737. 
The stabilizer system may also include a secondary stabilizer, such as 
epoxidized soybean oil. 
The plastic matrix material is selected with predetermined melting and 
rheological characteristics such that the plastic matrix is prepared and 
applied to the fabric base as a liquid when at room temperature. The 
plastic matrix is such that during the thermal and shear history 
experienced during the incorporation of the embedded fibrous structures, 
and the application of the plastic matrix to the fabric base, the fabric 
base and embedded discrete fibrous structures remain substantially intact. 
As used in the context of this application the term "intact" means that 
the fibrous structures are not melted, burned, or otherwise removed during 
the solidification of the plastic matrix while fabricating the floor 
covering 10, 10'. 
Any transparent polymer that can be processed below the melting point of 
the fibrous structures 18 can be used as the plastic matrix 16. Any 
transparent polymers, such as the polymers selected from the group 
consisting of PVC plastisol, PVC/Elvaloy.RTM. polymers, urethanes, 
poly(vinyl chlorides), silicones, fluoropolymers or ionomers like that 
sold under the registered trademark Surlyn.RTM. may be used for the 
transparent portion of the plastic matrix 16. A polymer that flows like a 
liquid at room temperature so it may be easily applied to the fabric base 
is preferred. Some of the polymers listed may have to be heated to become 
sufficiently fluid to apply to the fabric base. It should also be noted 
that when certain materials selected for the fabric base, care would have 
to be exercised to insure that the solidification temperature of the 
polymer selected for the plastic matrix is less than the melting 
temperature of the fabric base. 
As noted, the plastic matrix 16 may also include an opaque portion 16D 
lying below the transparent portion 16T in which fibrous structures are 
disposed. If a fabric base having a decorative facing is used, the opaque 
portion 16D, if one is provided, is always positioned below the fabric 
base. 
Polymers suitable for use as the opaque portion of the plastic matrix 
include plasticized PVC, PVC/Elvaloy.RTM. polymers, ethylene/vinyl acetate 
copolymer, flexible polyolefin compounds derived from ethylene/propoylene 
homopolymers and copolymers. 
Fibrous Structure 
The fibrous structures 18 disposed within the plastic matrix 16 of the 
decorative layer 12 may themselves take a variety of forms. 
In one instance the fibrous structures 18 comprises fabric fragments. 
Preferably, the fabric fragments have no dimension greater than about 
one-and-one-half (1.5) inch. The fabric fragments are selected from the 
group consisting of velours, felts, woven, non-woven, knitted, flocked, 
needle-punched, tufted and fusion-bonded fabrics. 
Alternatively or additionally, the fibrous structures 18 comprises 
groupings of multi-oriented individual fibers. The fibers are illustrated 
in the drawings as filamentary members, while the fragments are 
illustrated an irregularly shaped members generally having a length and a 
width dimension. 
If implemented as individual fibers the length of the individual fibers is 
greater than about nine (9) millimeters. The individual fibers may be 
crimped and crinkled. The individual fibers are selected from the group 
consisting of polyester, polypropylene, cotton, silk, wool, acrylic and 
nylon. A convenient source for such individual fibers is recycled carpet 
or other textile materials. 
The loading of the fibrous structures (whether implemented as fabric 
fragments, individual fibers, or a mixture thereof) within the plastic 
matrix 16 (i. e., in at least the transparent portion 16T thereof) is 
dependent upon the presence of the decorative design on the facing of the 
fabric base 14. If the fabric base is plain (i. e., without a decorative 
design on the facing of the fabric base 14) the fibrous structures may 
occupy up to about eighty-five percent (85%) of the surface area of the 
transparent portion 16T of the decorative layer. However, if the facing of 
the fabric base does carry a decorative design, the fibrous structures may 
occupy from about five percent (5%) to about fifty percent (50%) of the 
surface area of the transparent portion 16T of the decorative layer. 
The decorative effect imparted to the decorative layer 12 by the presence 
of the fibrous structures 18 is best illustrated in FIGS. 3A through 3D, 
to which reference is invited. (The reference numerals and lead lines are 
omitted for clarity of illustration.) The fibrous structures 18 (whether 
implemented as individual fibers or as fabric fragments) are visible 
through the plastic matrix owing to the transparency of the transparent 
portion thereof. FIG. 3A illustrates the effect with the fibrous 
structures 18 implemented as individual fibers viewed against a plain 
fabric base 14. FIG. 3B illustrates the effect with the fibrous structures 
18 implemented as fabric fragments viewed against a plain fabric base 14. 
The effect imparted by a combination of individual fibers and fabric 
fragments, again viewed against a plain base, is shown in FIG. 3C. From 
FIGS. 3A and 3C it should be noted that the fabric base 14, whether it is 
totally or partially embedded within the matrix 16, is visible and serves 
as a backdrop against which the fibrous structures 18 may be viewed. As 
shown in FIG. 3D, the decorative effect is still further enhanced if the 
fabric base 14 is itself carries a decorative design. In FIG. 3D, the 
situation in which the fibrous structures are implemented as a combination 
of individual fibers and fabric fragments is illustrated. It should be 
apparent that the implementation in which the fibrous structures are all 
fibers or all fragments (as in FIGS. 3A and 3B, respectively) may be used 
in the situation of FIG. 3D (in which the fabric base carries a decorative 
design on the facing thereof), if desired. 
In all cases the fibrous structures 18 are incorporated into the plastic 
matrix 16 in a manner such that they remain substantially intact. As used 
in the context of this application the term "intact" means that the 
fibrous structures are not melted, burned, or otherwise removed during the 
solidification of the plastic matrix. 
STABILIZING LAYER 
At least one stabilizing layer 24 is disposed beneath the decorative layer 
12. The stabilizing layer provides dimensional stability for the composite 
floor covering 10, 10'. 
The stabilizing layer 24 has an upper and lower surface. The upper surface 
is attached to the lower surface of the decorative layer 12, while the 
lower surface is in contact and preferably attached to the cushioning 
layer 28, as described further below. It is important that the floor 
covering 10, 10' have at least one stabilizing layer, and in some 
instances where additional stability is required, there should be multiple 
stabilizing layers. The stabilizing layer also promotes better adhesion 
between the decorative layer 12 and the cushioning layer 28. The 
stabilizing layer 24 also provides resistance against punctures to the 
decorative layer and cushioning layer and tends to reduce the degree of 
indentation marks when furniture legs and the like are placed on the floor 
covering. Finally, the stabilizing layer can also provide resistance 
against wear when the floor covering is subjected to heavy foot traffic. 
As seen from FIG. 1, in instances in which the fabric base 14 is embedded 
within the plastic matrix 16, the stabilizing layer 24 is implemented as a 
separate layer attached beneath the decorative layer 12. The stabilizing 
layer 24 may be attached to the decorative layer 12 using a suitable 
adhesive 26 which may be permanent or releasable. Examples of such 
adhesives include the following. Suitable aqueous latex adhesives include, 
for example, styrene-butadiene copolymers, ethylene/vinyl acetate 
copolymers, polyacrylates and blends thereof. Non-aqueous latex adhesives 
may also be used. Suitable thermoplastic adhesives include, for example, 
polyvinyl chlorides, polyurethanes, polyolefins, ethylene/vinyl ester 
copolymers, ethylene/alkyl (meth) acrylate copolymers, and ethylene/olefin 
copolymers. Suitable hot-melt adhesives include, for example, adhesives 
comprising a thermoplastic resin, tackifying resins, waxes, and 
plasticizers. 
The thermoplastic and hot-melt adhesives in the form of films may be used. 
The stabilizing layer may be coated with the adhesive in any manner such 
as by spraying, dipping, kiss-roll coating, or by lamination. In other 
embodiments, the stabilizing layer may be attached to the underside of the 
decorative fabric by a pressure sensitive adhesive, mechanical means such 
as by a Velcro.RTM. hook and loop fastening system or by ultrasonic 
bonding. 
Alternatively, the adhesive properties of the plastic matrix 16 itself may 
be used to adhere the stabilizing layer to the decorative layer. The 
material of the stabilizing layer may be adhered to the lower surface of 
the opaque portion 16D (if provided) of the plastic matrix 16. If no 
opaque portion 16D is provided, the stabilizing layer may be adhered to 
the lower surface of the transparent portion 16T of the plastic matrix 16. 
No separate adhesive layer is required in such a case. 
As illustrated in FIG. 2, in instances wherein the fabric base 14 is 
adhered beneath the decorative layer, the stabilizing layer 24 is attached 
beneath the fabric base 14 using the adhesive 26. However, it should be 
understood that in cases as shown in FIG. 2 it may be desirable to 
eliminate a separate stabilizing layer 24. In this event the fabric base 
14 is selected from a material that has sufficient elongation, strength, 
dimensional stability and puncture resistance so as to function as a 
stabilizing layer. 
The stabilizing layer is typically a scrim or sheet material comprising a 
fibrous non-woven material or thermoplastic compound. The scrim may 
comprise an open network of intersecting strands such as, for example, 
fiberglass, polyolefin, polyamide, cotton, jute, acrylic and polyester 
strands. Fiberglass strands are particularly effective, because of their 
good tensile strength and "moisture stability." By the term, "moisture 
stability", it is meant that the length of the strands are substantially 
unchanged due changes in the temperature and humidity. For purposes of 
this invention, the thickness of the scrim should generally be in the 
range of about three (3) to about two-hundred-fifty (250) mils. 
Typically, the amount of strands running in the "machine direction" (length 
direction), i. e., the direction in which the scrim is being produced by 
the machine and the amount of strands running in the "cross direction" 
(width direction), i. e., the direction perpendicular to the direction in 
which the scrim is being produced by the machine are equal. The strands 
should also be equally spaced apart in the length direction and width 
direction. 
Fibrous non-woven sheets are described above and include spun-bonded 
fabrics such as those sold under the registered trademarks Tyvek.RTM., 
Typar.RTM., and Reemay.RTM. and spun-laced fabrics such as that sold under 
the registered trademark Sontara.RTM.. Thermoplastic compounds can also be 
used to make sheet materials having good stabilizing properties. A scrim 
of glass coated polyester strands is particularly suitable. 
In addition to scrims and sheet materials, other materials may be used as 
the stabilizing layer. For example, velours, felts, woven, knitted, 
flocked, needle-punched and fusion-bonded fabrics may be used along with 
poly(vinyl chloride) resins, paper felts, reinforced paper, foamed 
urethane, and composite structures such as PVC vinyl flooring. These 
materials may be used independently or in combination with each other. For 
instance, the stabilizing layer may comprise a non-woven sheet adhered to 
a scrim. A brushed knitted fabric having loopy surface can also be used as 
a stabilizing layer. It is also recognized that these materials may be 
used in combination with each other. The type of material used for the 
stabilizing layer will vary depending on the desired properties of the 
composite floor covering. For instance, certain materials may be more 
effective in providing resistance against indentation marks from heavy 
furniture and appliances. Other materials may be more effective in 
providing puncture resistance or may provide better fabrication. 
CUSHIONING LAYER 
The composite floor covering may further include a cushioning 28 provided, 
as an option, for cushioning and support. The cushioning layer 28 is 
disposed beneath the stabilizing layer 24 (if provided). If a stabilizing 
layer is not provided, as in the instance in which the fabric base 14 
functions as a stabilizing layer, the cushioning layer 28 is attached to 
the undersurface of the fabric base 14. The cushioning layer 28 comprises 
fiber felts or a foamed composition selected from the group consisting of 
rubber, latex, urethane, and poly(vinyl chloride). 
Preferably, the lower surface of the stabilizing layer is attached to the 
cushioning layer by such permanent or releasable adhesive means as 
described above, but this is not necessary. In some instances, it may be 
desirable to have the stabilizing layer simply lay on the cushioning 
layer. As will be discussed herein, the alternate embodiment of the 
invention comprehends this possibility. 
The cushioning layer may comprise any suitable material such as for 
example, foamed compositions of rubber, latex, hot-melt resins, urethane, 
poly(vinyl chloride) resins. These compositions may be combined with 
fabrics such as velours, felts, wovens, non-wovens, knitted, flocked, 
needle-punched, and fusion-bonded to provide a good cushioning layer. 
Fibers used for the cushioning layer are polyamide, polyester, polyolefin, 
jute, acrylic or cotton. Carpets such as unitary carpets and particularly 
tufted carpets having a tufted primary backing laminated to a secondary 
backing may also be used. 
The thickness of the cushioning layer is at least one-tenth (0.1) inches 
and is preferably in the range of about 0.125 inches to about 0.625 
inches. Preferably, the density of the cushioning layer is greater than 
three (3) lbs/ft.sup.3. The thickness and density of the cushioning layer 
are significant, because these properties help provide the desired 
resilience and cushioning effect to the entire floor covering. 
If a carpet having a tufted primary and secondary backing is used as the 
cushioning layer, it is preferable that the secondary backing be attached 
to the lower surface of the stabilizing layer and that the projecting 
tufts be in contact with the floor. However, in some instances, it may be 
desirable to attach the projecting tufts from the primary backing to the 
lower surface of the stabilizing layer. This may be done by spraying the 
tufts and decorative fabric with an adhesive. 
WEAR LAYER 
If desired, a transparent flexible wear layer 32 may be disposed over the 
plastic matrix of the decorative layer. Preferably, the transparent wear 
layer may be implemented using urethane, poly(vinyl chloride), silicone or 
fluoropolymer. 
MANUFACTURE 
The fibrous structures 18 may be incorporated into the plastic matrix 16 by 
a number of different methods. In one instance the fibrous structures 18 
are mixed into the liquid plastisol. This mixture is then applied to the 
fabric base 14. This composite is then placed in an oven and the plastisol 
is solidified. 
An alternate method may be used in which the plastisol containing the 
fibrous structures is solidified first, and the resulting solid, clear 
plastic is cut into pieces. These pieces are then distributed randomly 
over a base opaque PVC layer and supported underneath with a stabilizing 
fabric base. When the fabric base is a decorative fabric, the plastic 
matrix containing the fibrous material in the form of pellets or small 
pieces are distributed directly over the decorative fabric, so that the 
fabric base design shows through. The product is then compressed under 
conditions in which the plastic matrix will melt, but the fibrous 
structures will not. 
A third method includes feeding the solid plastic matrix material and the 
fibrous structures into an extruder. The extruder is operated at 
conditions at which the plastic matrix material melts but the fibrous 
structures do not. In all cases minimal shear is applied to the mixture so 
that the fibrous structures remain as discrete pieces, visible within the 
plastic matrix. 
The fabric base 14 may be embedded within the plastic matrix 16, as is 
illustrated for the composite floor covering 10 of FIG. 1. This 
arrangement is realized by placing the fabric base 14 above and below a 
suitable layer of plastic matrix material prior to solidification of the 
plastic matrix. 
Alternatively, as is shown in the composite floor covering 10' of FIG. 2, 
the fabric base 14 may define the lower surface of the plastic matrix 16. 
This arrangement may be achieved by layering plastic matrix material over 
the fabric base 14 prior to solidification of the plastic matrix 16. The 
adhesive properties of the matrix serves to hold the base 14 in place. 
Alternatively, the base 14 may be secured to the lower surface of the 
matrix 16 after is has been formed using a a suitable adhesive 26. 
Although the product of the present invention is primarily used for a 
floorcovering, other uses should be apparent. For example, the present 
invention may be used for tile, as a baseboard material, or as countertop 
material. 
The present invention is further illustrated by the following examples, but 
these examples should not be considered as limiting the scope of the 
invention. 
EXAMPLE 1 
A plastisol is prepared with the following composition: 
______________________________________ 
Parts by Weight 
______________________________________ 
Poly(vinyl chloride) 
100 
NUOPLAS 6000 (a) 50 
Mark 4737 (b) 3 
Epoxidized soybean oil 
5 
______________________________________ 
(a) NUOPLAS 6000 is a polyester plasticizer sold by Huls America, Inc. 
(b) Mark 4737 is a barium and zinc stabilizer sold by Witco Corporation. 
Ninety-five percent (95%) by weight of this plastisol and five percent (5%) 
by weight of nylon 6,6 yarns with different colors are mixed to distribute 
the yarns throughout the plastisol composition. Mixing of the plastisol 
and yarns is done at low shear to minimize damage to the yarns. The nylon 
yarns consist of pink eighteen denier per filament (18 dpf) yarns cut to 
nine (9) mm lengths and seven (7) with range of seventeen to twenty-three 
denier per filament (17 to 23 dpf) yarns each with different colors--light 
green, charcoal, pink, tan, blue, purple and white--with cut lengths 
between nine and twenty-five millimeters (9 and 25 mm.). Total denier of 
the yarns is between 1100 and 1750. 
The PVC plastisol/yarn mixture is spread upon a Teflon.RTM. film and heated 
in an oven at 320.degree. F. for five (5) minutes to solidify the 
plastisol. The yarns and separated filaments are easily seen in the clear, 
flexible PVC matrix. 
The PVC matrix is stripped from the Teflon.RTM. film and cut into pieces 
approximately twenty-five millimeters square (25 mm.times.25 mm) in size. 
These pieces are distributed randomly on a solid, opaque, filled 
poly(vinyl chloride) composition to cover about fifty percent (50%) of the 
surface area of the decorative layer. This decorative layer comprising a 
plastic matrix having discrete fibrous structures embedded therein was 
placed over a 3.3 oz./yd.sup.2, PVC-coated polyester open mesh backing 
which acts as a fabric base and as a stabilizing layer. The composite 
structure was then compressed at approximately one thousand pounds per 
square inch (1000 psi) for five (5) minutes at 350.degree. F. This causes 
the matrix to fuse together in which the fabric base/stabilizing layer 
gets embedded into the matrix. The fabric base/stabilizing layer remains 
intact. The fibrous structures in the form of yarn and randomly disposed 
group of its individual filaments also stays intact and are easily seen in 
the clear layer contrasted against the opaque PVC base layer. The 
composite structure was used as a floorcovering and was placed over a 
one-quarter inch thick, eighteen pounds per cubic foot density (18 
lbs/ft.sup.3) rubber cushion. 
EXAMPLE 2 
The process of Example 1 is repeated except that the yarns are replaced by 
five percent (5%) weight of the cut fragments of fabric. Approximately 
half of the fabric fragments are four colors of cotton/rayon apparel 
fabric in which the yarns are approximately seventy (70) denier. The 
colors are orange, beige, green, and blue. The remainder of the fabric 
fragments are green/black, nylon/Lycra.RTM. spandex apparel fabrics in 
which the yarns are approximately seventy (70) denier. These cut fragments 
of fabric are in different shapes and sizes up to maximum of about 
one-and-one-half (1.5) inch in any direction. The resulting fragments are 
mixed with the PVC plastisol of Example 1 and processed as in Example 1. 
In the final product the stabilizing layer/fabric base stays substantially 
intact and the fabric fragments are visible against the opaque PVC layer. 
A bottom cushioning layer of one-quarter inch thick, eighteen pounds per 
cubic foot density (18 lbs/ft.sup.3) rubber cushion was used to construct 
a composite floor covering. 
EXAMPLE 3 
In this Example, 2.5% by weight of the fibrous material are the yarns of 
Example 1 and 2.5% by weight are the fabric fragments of Example 2 for a 
total of 5% by weight of fibrous material. These are mixed with the clear 
PVC plastisol at low shear. The final product has a combination of the 
features of Examples 1 and 2. 
EXAMPLE 4 
In this Example, a dyed, 10.7 oz/yd.sup.2, polyester/cotton, woven textured 
fabric (decorative fabric) was used as a stabilizing layer in place of a 
PVC-coated polyester backing. The PVC plastisol/fibrous structure compound 
as prepared in Example 3 is spread upon a Teflon.RTM. film and heated in 
an oven at 320.degree. F. for five (5) minutes to solidify the plastisol. 
The fibrous structures are easily seen in the clear, flexible PVC matrix. 
This decorative PVC matrix is stripped from the Teflon.RTM. film and cut 
into pieces approximately ten millimeters square (10 mm.times.10 mm) in 
size. These pieces are distributed randomly over the decorative, textured 
fabric base to cover about five percent (5%) of the surface area of the 
decorative layer. 
The composite structure was then compressed at approximately one thousand 
pounds per square inch (1000 psi) for five (5) minutes at 350.degree. F. 
This causes the matrix to fuse together. The composite product is thus 
formed with a top layer of a decorative plastic matrix layer which 
contains the fibrous structures supported underneath with a decorative 
fabric base which stays intact. The product displays the base fabric 
design with clear PVC layer on the facing of the fabric in which the 
discrete fibrous structures are also seen. Since the yarn components of 
the decorative woven fabric base had the melt temperature higher than 
350.degree. F., the final product had an interesting three-dimensional 
effect with the decorative fabric showing through the discrete fibrous 
structures. The composite structure was used as a floorcovering and was 
placed over a one-quarter inch thick, eighteen pounds per cubic foot 
density (18 lbs/ft.sup.3) rubber cushion. 
EXAMPLE 5 
A compound with the following composition was prepared: 
______________________________________ 
Parts by Weight 
______________________________________ 
Poly(vinyl chloride) 100 
Ethylene/ester/carbon monoxide terpolymer 
100 
Mark 4737 (b) 5 
Epoxidized soybean oil 8 
Di-Lauryl Thiodipropionate 
1.5 
Irganox 1010 (c) 0.5 
Calcium carbonate 5 
______________________________________ 
(c) Manufactured by CibaGeigy Corporation 
Ninety-five percent (95%) by weight of this composition and five percent 
(5%) by weight of the yarns of Example 1 are mixed and fed to a 
one-and-one-half inch (1.5 in) single screw extruder with the screen pack 
and breaker plate removed to minimize shear. The cylindrical extrudate is 
converted to pellets approximately nine to thirteen millimeters (9 to 13 
mm) in diameter and approximately nine millimeters (9 mm) in length. 
The pellets are distributed randomly on the surface of a solid, opaque, 
filled poly(vinyl chloride) composition to cover about fifty percent (50%) 
of the surface area. This decorative layer comprising a plastic matrix 
having discrete fibrous structures embedded therein was placed over a 3.3 
oz./yd.sup.2, PVC-coated polyester open mesh backing which acts as a 
fabric base and as a stabilizing layer. The composite structure was then 
placed in a press at one thousand pounds per square inch (1000 psi) for 
five (5) minutes at 350.degree. F. This causes the matrix to fuse together 
in which the fabric base/stabilizing layer stays intact. The fibrous 
structures which are embedded in the clear plastic matrix are visible 
against the opaque PVC layer giving the visual appearance similar to the 
product as described in Example 1. The final composite floorcovering was 
prepared with the above-described product having a bottom cushioning layer 
of a one-quarter inch thick, eighteen pounds per cubic foot density (18 
lbs/ft.sup.3) rubber cushion. 
EXAMPLE 6 
The process of Example 5 is repeated with five (5%) by weight of the cut 
fabrics of Example 2 replacing the yarns of Example 5. The final product 
resembles the appearance of the Example 2. 
EXAMPLE 7 
The process of Example 5 is repeated except that the 2.5% by weight of the 
fibrous material are the yarns of Example 1 and 2.5% by weight are the 
fabric fragments of Example 2 for a total of 5% by weight of fibrous 
material. The final product is comparable to the product of Example 3. 
EXAMPLE 8 
In this Example, the decorative woven fabric of Example 4 is used in place 
of a PVC-coated polyester backing as a stabilizing layer. The fibrous 
material consisted of 2.5% by weight of colored yarns as in Example 1 and 
2.5% by weight of colored fabric fragments of Example 2. A clear plastic 
matrix containing these fibrous materials in the form of pellets were 
prepared as the above Example 5 and sprinkled randomly over the decorative 
textured fabric base to cover about five percent (5%) of its surface area. 
The composite structure was then compressed at approximately one thousand 
pounds per square inch (1000 psi) for five (5) minutes at 350.degree. F. 
The final product characteristics had similar three-dimensional features 
as described in Example 4. 
EXAMPLE 9 
In this case, the sample was prepared as in Example 1, except that the 
stabilizing layer was a brushed knit nylon fabric weighing about 2.2 
oz./yd.sup.2. The lower surface of the stabilizing layer was in the form 
of a loop-covered surface. The stabilizing fabric base was not embedded in 
the plastic matrix as in Example 1, but rather it was underneath the 
decorative top layer which consisted of clear plastic matrix having 
fibrous material over an opaque PVC layer. The hook portion of a 
Velcro.RTM.-type mechanical fastener was adhered to the floor and in the 
other case on to a one-quarter inch (1/4") thick rubber cushion having a 
density of eighteen pounds per cubic foot (18 lbs/ft.sup.3). The floor 
covering product was then assembled by simply pressing the loop covered 
lower surface of the stabilizing layer on to the hook portion of the upper 
surface of the floor or the cushioning layer. 
The upper decorative top layer with the stabilizing layer was able to be 
detached (as for repair, or replacement, etc.) and re-attached for further 
use. 
EXAMPLE 10 
In this case, the sample was prepared as in Example 9, except that the top 
decorative layer had a thin layer of protective polyurethane coating on 
its surface.