CA1066834A - High performance hot melt adhesive backsizing compositions and carpet made therewith - Google Patents

Abstract

ABSTRACT OF THE DISCLOSURE
Hot melt backsize compositions ha ?ng high tensile elongation which result in tufted carpets having improved tuft bind comprise a blend of ethylene/vinyl ester copolymer, hydrocarnon resin, and, optionally, low molecular weight polyethylene, paraffin wax, anti-oxidant and filler.

Description

1 ~16683~ `
;
B ~ KCR ~ D OF TUE I~ 'TION
Field of the Inventior:
- This invention relates to carpe~ backsizing, and more particularly it relates to hot melt baoksizing ~ompositions which result in c~xpets havi.ng high tuft - biDa.
Description of the Prior Art . .
~ Backsizing of tuftea carpets with hot melt backsize adhesi~es has been known now f~r some years. - .
lo ~o s. Patent 3,551,231 discloses a process for-app1yi~g a hot melt backsiæe adhesive blend of ethylene/vinyl es~x copol~merr petroleum wax~ a~d a thermoplastic resin. -.
~ Satisfactory carpets are mad~ by applying a crltical ., - - . ., pressure on the tufted structure while it is in contact with the hot melt adhesive applicator ro~l. The necessi~y of maintaining such critical pressure aurin~ ~ .
. t~he adhesive a.pp.tica~io~ detrac~s ~rom process f~e~
.. . .
~ ~ility~
~ , . .
. ` ~. 5. Patent 3,684,600 discloses the ~pplica- ~
.:
2a tion of a low viscosity precoat.adhesiYe to the back-~ide o~ the tuf~ed structure prior to the applic~tion of ~he hot melt backsize adhesive c~mpvsition. By ùsing e precoat adhesive, the necessity of maint ining à
:: . . - .
cri~ical pressure on the carpet during the hot melt adhesive ~pplication can be eliminated. The backsize . - ~ -: adhesive composition con~ains e~hylene/vinyl ester co-; ~: polymer, low molecular weight, low density polyethylene, : microcrystal1ine wax, aliphatic thermoplastic hydrocar~on resi~, dicyclope~tadienP alkylation polymer, antioxidant : 3Q and filler. :
:: :

, ~ 6~3~ .
~ . . .
U. S~ Patent 3,583~936 discl~ses a hot melt backsize adhesive composition comprising an ethylene~
~inyl ester or acrylate polymer, a wax of sufficiently high melting point to yield a blend softening point o~
~t least 190F., a blend of ~iphatio thermoplastic hy~rocarbon resin and a dicyclopentadiene alkylation pol~mer, a~d optionally a iller.
. SO Patent 3,745,054 relates to high filler ;: . - ~ -~ con~ent hot melt backsize adhesive composi~ions comprising . - ~ . : , . . . .
ethyle~eJvinyl ester:copolymerO paraffin wax, micro- . .
cxystalline wax, aliphatic thermoplastic hydxocar~on ~ :`
resin, dicyclopentadiene alkylation po~ymPr, a~tio~i~ant and filler. ; :
... . .
: PreYiously, filler containing hot melt blends ~ha~e been used to produce carp ts having tuft biDds :-. which generally average in the 6 to l~ lb, range~ While .. ..
. ~ ~.his is generally adequate for domesti.G carpet (used in . -.
e ho~e), higher tuft bind values wil~ ensure greatar durability. Considerably higher tuft binds (1~ lb.
average or greater), which up to the present has ~ot~
:~ been attainable, are desired by the carpet industry for contract carpet ~used in schools, hotels, churches, industry, etc.) to:ens~re meeting typically severe ~: ~
~rv~ce requirements. - . ~ :-., - . . : .
: ~ U~MARY OF ~HF I~VENTION
he pr~sen~ invention provid~s hot melt blends ~:
~hich offer:higher strength, as described below, than has ~ .
: ~een obtainable with hot melt blends de~eloped and used ~ :
: hex~tofore. The key to the invention is the application of a novel tackifier resin system, which enhances.the .SI~ ' . ..... ..

. .

~66~3~
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tensile elongation of ~he blends at e~uivalent tackifier cost and quantity. This in turn provides a substantial increase in the tuft bind values attainable for the final ca~pet ~s sold to consumers~
- The new blend has utility in both the domestic carpet and contract carpet markets. Ca~)et for domestic use does not encounter severe wear conditions; hence, , tuft bind ~alues, etc., can be less than is essen~ia~ - :
. .
for carpets for schools, mo~els and hotels,- indus~tria:L
lG buildings, etc, where trafic is severe. It is COm~Oli ;
in industry to use higher s~andards, requiring higher - ~ . costs, for contract carpets.~ 'rhe present invention : -recognizes this distinct~on, and is applicable in both . ~ -. . - - - : ~
e~d use areas. .. . ~ .
According to the present inven~ion there is . ::
.
pr~v ded a composi~ion havinq a tensile elongation about 700-1500 percent, prefera~ly at least abo~lt~ ;
900 percent comprising ~A) about 15-30 (preferably : : -~about 18-22) weight per~ent ethylene~vinyl es~er co~
- . . .
0 polymer having a melt index of about 2 to 100 ~preerably : . ab~ut 10-25), a copolymeriz~d ethylene content o about . ~ . .
~ 67 ~o 84 (preferably about 74-77) weight percent,~a .
. copolymerized ~inyl estex content of about 16 to 33.
(preferably about 23-~6~ weight percentO wherein the acid moiety ~f sai~ ~inyl ester contains 1-4 (preferably-

2-3) carbon atoms,~B) ahout 30-70 ~preferably abaut - .
;40-50) weight percent of a hydrocarbon resin or a :
mixture of several hydrocarb~n resins having a ring and , ~ ball ~oftening poi~t of about 50Co 70C~ a~d a viscosity , ~ 30 of ~.5 to 1.5 poise at 135~., and optionally (C~ 0 to : . , .

~ 4 .:
. ~ ~ . . . . .

1~66~3~ .
about S weight percent of a low molecular weight ethylene homopolymer having ~ molecular weight of about ~500-4000, density of 0.91-0.9~ g./cm.3 and a melting point of abou~ 220F.-270F., ~D) 0 to about 5 weight pe~ent of a paraffin wax, ~E) an effective amount of an antioxidant~ and (F) 0 to about 40 weight pexcent ~iller~ This composition is~intended for lamination .
of contract carpets, however, it is technicall~ suited to lamination of domestic carpets a~so,~ but i5 too ~ . :
10 costly for this market-..................................... ~ ~
.
According to the present invention~there axe further provided co~tract-type carpets having improvea .
tuft bind, at least an average of 18 pounds 7 o~ained ~ -b~ the use of the above compositions and carrying out : :
the backsizing accordlng to the process of U. S n Patent

3,551,231. ~
. ~ .
- ~ccording to the present inventio~ there is . :
~urther provided a composition having a tensile . :
elongatio~ o~ about 50 to 400 perce~t~ preferably at ~:
.
least about 200 perceQt~ comprising ~1 about 3 to 15 : . ~preferably about 5 to 10) weight percent ethylene/
vinyl ester copolymer having.a mel~ index of about 2 : to 100 (preferably about 10-25), a copolymerized et~ylene content of abou~ 67 ~o ~Q (preferably abou~
.. . .
~ 74-77~ weight percenk, a copolymerized vinyl ester conten~
; ~: ` of a~ou~ 10 to 33 ~prefera~ly about 23-26j weight percent, .. ..
. wherein the acid moiety of said vinyl ester contains 1-4 (preferably 2-3) carbon atoms, ~B) about 15 to 40 (pre-ferably about 25 to 35) wei~ht percent of a hydrocarbon resin or a mixture of several hydrocarbo~ resins ~aving , _5_ - .
- ~ .

~LC3 661~39~ .

xing and ball softening point of a~out 50C.~70C. and a ~iscosity of 0.5 to 1.5 poise at 135C., and optionally ~C) 0 to about 3 weight percent of a low molecular weight ethylene homopolymer having a molecular wleight of a~out 1500-4000, density of ~o91~0~9~ gOJcm.3 and a melting point of about 220Fo~270Fo 7 (D) 0 ~ about 3 weight percent of a paraffin wax, (E3 an effective amount n~ a~
an~ioxidant, and (F~ about 40 to 75 wei~ht pexcent ~iller. ~his composition is intended for lamination lD of domestic carpets. . . .
Aceording to the present in~ention there ar~
~urther provided carpets f~r domestic uses having Lm- .
proved tu~t bind, at least an average o~ 10 poundsj ob- .
tainëd by ~he use of the compositions of ~he preceding paragraph and carrying out the backsizing accoxdin~ to the process of U. S. Patent 3,551,231.:-DETAILÉD DESCRIPTI,ON OF T~IE. I~NTION - ~ - .
~ _ . . . _ . . . _ . . . _ . ._ ._ . -- ~ . . .
- , .
It has be~n discovere~ that-a hot melt formati~n a~ aescribed a~ove wîll produce contract-typ~ carpets .
Z0 having high tuft bînds which have not been possible with the ~ype of hot melt blends previously avaîlable for ca~pet backsizing. When more filler is added and the.
;blend ingredient levels are adjusted to a serviceable.
viscosity range, a domestic carpet with tuft binds superior to those currently being sold îs attainea. The higher . pexformance:is attributed to the t~pe of hydrocarbon resin [Component (B)] used and the resultant higher -~e~siIè elongatîon ~f the ho~ meLt compositîon.
.: , .
ydrocarbon xesîns suitable for use in the high performance hot melt backsize compositions are ~ ~ ' " ' , ' ~ . ' , .
. ~6- -. . .

~6~33~
, ~lassified as low molecular weight alkyl-aromatic hydrocarbon resins of ~e non-reactive, thermoplastic hydrocarbon types. Generally~ they range in ring ana ~all softening point, as measured by ASTM E 28-67, from about 10C.-120C. and have viscositi.es measurea at 135C. o~ about ~.5-105 polses~ Certai.n of these are low molecular weigh~ dicyclopentadiene alk:ylation polymers .
~nd may-be prepared according to U. S~ Patent 3,023,2G0 Included in this type are the ~Pi~covar~ resins. The so~tening point of the resin,-or of th~ mixtur~ of res~s, if more than one is employed, has ~o be betwee~

- abou~ 50~C.-70C~ If the softening point of the resin~s) - - :~

. . ~8 less than about 50C. the blend viscosity and tensile . ..
streny~h are too low. If the softening point is higher than about 7~C. the blend viscosity is too high and . .
- ~he ble~d tensile elo~gation is too low to yield ~e.
d~sired high ~uft bind. ` ~
a~l~s A and B list some of the commercialIy . . . .
.
aYailable hydrocarbon resins whic~, when used i~ the ho~ :

~elt blend, yield the desired specifications ~or a high , perfoxmance hot melt blend. The resins shown in Table A

.
can be used alone, while others (Table B~ must be used .
~n aamixture with one or more of the resins to obtain ~ -he desired physical properties in the final hot melt ~ .

blend.. .
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In Table I are presented data showing t~nsile elonga~ion and other physical properties of hot melt adhesive compositions prepared with the indicated hydrocarbon resins.
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', ' ' :~, ~'-, ~066~34 - Ethylene copolymers most useful in th~ present invention are copolyrners of ethylene with vinyl esters o~
lower carboxylic acids. Such ethylene/vinyl ester copolymers can be prepared by known.tec~iques, such as i~lustrated in U. S. Patent 2,200,4~9 and U. S. Patent :
2,703,794. Whîle an ethylene~vinyl acetate copol~mer ~ s preferred, other ethylene c:opolymers ~ such as those o~ ~Lnyl formate, v;nyl propionate, and v;nyl butyrate, ~ ~ are usaful as wel~
10 - ~he ethylene copolymers~have mel~ indexes, as - . . . ~ . ~ .................................................. ..
measured by ASTM 123~52T~ of about 2-100 (preferably : 10-2~ with polymerized ethylene content of ~bout~67 84 - ~ (preferably 74-77) weight percent.: Coxrespondingly,: ~
the pol~nerized ester content of useful et~ylene co~ :
polymers is a~out 16-23 (preferably ~3-26) wei ght percentO
.
Additionally, ethylene copolymers containing minor. amounts i.eu ~ up to about 3 weight percent~ of polymerizable copolymers, such as acrylic acid, methacrylic acid, itaconic acid, acrylamide, isobutyl acrylate, beta -~ .
20 ~ dimethylaminoethyl methacrylate, beta hydroxyethyl - acrylate, diallyl maleate, diallyl phthalate, diallyl ~: ether~ or ethylene glycol dimethacrylate, are useful ~ .
;~ as:well.
:For~contract ~arpet use the ethylene~cQpolymer should be;~present in the ho~ melt blena in about 15-30 ; we~ght perce~t,;preferably a ~ ut 18-2~ weigh~ percent.
;Blends intended for domestic~carpet applicatlon should ~ .
contain about 3 to~l5~weight percent, preferably about 5 to lO weight percent, of the ethylene copolymerO

The optional low molecular weight polyethylen~
i8 present in the compositions of the present invention in sufficien~ amount to raise ~he softening point to a desired level. Thus a higher softening point, e.g. t i350F~-2400F., is of beneit to the car~pet inst~lle~
i~ it becomes necessary to heat-seam two adjacent carpet seetions. This ingredient does not appreciably aff~ct th~ elongation of the composition nor the tuft bind of ~he finished carpet ~ ~-Optionally,;an additional ingredient of suitable backsize adhesi~e compositlons of this in~ention ~s paraffin wax. Paraffin waxes having a melting point of about 146F. to 158F., low needle point penetration .. .
24 at 77F.) and low oil content (0~1 to 0.~5 percentj are preferred. Generally,~their presence up to about -5 weight percent for contract carpet use and up to about : : :
3 weight percent for~domestic carpet use is ~uitable to .
facllitatP ? plication of~the blend to the carpe~by -~ .
adjusting the melt~viscosity of the composition ~o ~he : :
required level. -. The bse of an antioxidant, such as butyla~ea : -hydroxytoluene, in about 0.1-0.3:weight percent is ~ :
advantageou~
Filiers, such as calc;um oarbonate, aluminum .:
hyarat~,~etc~, i~ about 0-75 weight percent concentration ::
may optionally be incorporated into the compositions ~:
of~the present;invention as a low-cos~ extender which improves caxpet hand by providing additional bulk to the carpet~ ~hen compounding blends for contract -.
:: , carpet backsizing, care must be taken not to add more than . -12- .
:: . . . .
. -. .

~ ~ 6 ~3 4 a~out 40 weight percent fillex so as not to reduce ~he elongation o the bac~size adhesive composition or the tuft bind of the carpèt below the req~ired levels.
The particulax manner in which the ingredients are added to formulate the composition of the present invention is not critical and can be accomplished by any of the well-known techniques.
. . . The high strength of the carpet (in terms of ~uft bind~ made with compositions of the present . 10 Inven~ion is~ a significant advantage since in many u~es - ~such as contrac~ carpet) it is important to have a very .
high resistance to tuft pull out. ~ small child can - readily damage a carpet having only a 5-10 pound tuft bLnd but would find it difficult or impossible to pull :
o~t tuf~s from a carpet having a l5 to 20 pound tuft bind. Quite likely the yaxn would break before more .::
. . . . . . .
tha~ one or two tufts could be pulled out. Similaxly, - -: .
ln applications such ~s hotel.lo~bi2s, t~eatel~s, e~
wh2r~ a single tuft might readily be caught accidentally 20 by users of the carpet, the high strength hot melt ~ ~
.
blend of the present invention would be of advantage.
- Tuft bind, expressed in pounds, is measured by ASTM p 1335 or in some-cases by a minor modification ~:
: . . ; .
hich gives comparable results~ Values reported herein ~ :
are the a~erage of about 8~10 determinations. It will ; ;
be appreciated:that prepara~ion of the carpe~ samples, :
following the teachings of U. S. Patent 3,551,231, may :~
:` : lead to some variability in the tu~t bind ~alues because o~ the many ~ariables ~hat ca~ affect the evenness : 30 ~f ~he coating and the uni~ormity of penetxation of the.

~ -13 6~3~

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ho~ mel~ i~to the carp~t tufts. For prior art carpets, th~ spre~d is usually about 5-7 pounds while for ~arpets of the present invention the spxead is usually about 3-4 pounds.
The following examples, wherein all parts a~d percentages are by weight, except where otherwise specified, further illustrate the advanl:ages of the presen~ i~ventionr Two.separate series of examples , - . . : :
are given belowO Series I covers blends intended p~marily for contract ~arpet types. Series II covers : blends intended primarily for domestic càrpet use.

SERIES I - COWTRACT~CARPETS .~

:~ COMPARATIVE EXAMP~ES Cl.TO C4 .......
Refer~nce Blend B, which is representative of the more successful filled prior:art blends, was pre .
pared~

re~ Ble~d ~ - Contract Carpets .
. .: 15.0% ethylene/vinyl acetate copolymer, melt index ~:
-L-~7-2.3, 25~ ~inyl acetate, ~

~ 1~8~ low molecular weight polyethylene, 3500 ~olecular weight, 240F. melting point, AC" 8, available from Allied Chemical :
- Company, , :~ 10.2% microcrystalline wax, melting point 160F., . nShellmax" 400, available from Shell Chemical . , Company,~

17.2~unsaturated~aliphatic thermoplastic hydro- : :
.carbon xesin, melting point 100C. ~- -~ nPiccopale" lOOSF, available from Hercules ~ .
.: : : 30:: ~ : Inc.)., :~ -: . : . .
~ , . ., , : . . , ................................. . . : :.. ~
: 25.6~ di~ycl~pentadiene alkylation polymer, melting point:77F~ (I'Picco~ar" AP 25, available from : Hercules Inc.), 002~ butylated hydroxytoluene ~BHT), ~ ~ ~

30.0~ calcium carbonate filler (No~ 9 "Whiting").

' 4 . , ~ ~ - - , . ~ :

.

6683~
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~lend A had the following proper~ies~ .
Ring and ball softening point, ~F. 210 Viscosity, cps. at 310F. 14,000 Tensile, lb~Jin.2 400-500 Tensile Elongation, % 10 15 Strengt~ characteristics vf the carpet back-~ized with the absve blend according to the process o . S. Patent 3,551,231 are given in Table II~
- . . ~ , - .
: ~ABLE ~
: - ~ , , Properties of Contract-Type Carpe~s Made -: : .
~sin~ Reference Blend A - .. :
.
Carpe~ Back~lze Tuft ~crim Bond, . ~ - :
: No. oz-/yd-2 Bind, lb. lb.~3~(1) , .
-- - -- . . . .
- Cl 27.0~ 13.0 2~o~ , ~
~,, . : , .
C2 18.0 .10.0 16.0 . . ~:-- ~
etermined ~y ASTM D-2724~13.
Data in Table~I~ show that tuft bind values : :
ar~ good for many use~ but are below~the ultimate ~ :
goal - a carpet which cannot readily be hanmed by ~ .
accident, heavy w~ar, or a mischie~ous child.
, ~ . . ., . : . ~
: ~ ~n unfilled prior art blen~, wherein the filler was omitted to maximize the amount of resinous bi~der and to Lmprove the tu~t ~ind thereby, was pr pared. This composition is designated Reference Blend B~ :

:
. 31.5% e~hylene/vinyl acetate copolymer (10~25 melt index, 25~ vinyl acetate ~ 9 : 3.5~ parafin wax~ melting poi~t 146F.
"Pacemaker" 53, available from Ci$ies ~ :
: 30 : : Service Oil Company)~ . . :
.6%~ low molecular weight polyethylene (2000 - :
: m~lecular wei~ht, 0.96 gm./cm.3 density) :: ~: (nPolywax" 2000, available from Petrolite : Corp~ Bareco Div.]~ .
.

~ 15- :

.

`- ~O~ il341~ -11.5~ microcrys~alline wax, 160F. melting point

4% unsaturated aliphatic thermoplastic hydro-carbon resin, melting point 100C.
~5.4~ dicyclopentadiene alkylation polymer, melt-ing point 77Fo ~
0.1% butyla~ed hydroxytoluene. :.
-. . Blen~ B ~ad the following properties: ~
Ri~g and ball so~tening point, F. 20~ : :
iscosity, cps. a~ 3laoF~ 1~,3ao lO; Tensile, lb./in.2 ~ 400-500 Ten~ile elongation, ~ 20-25 Strength characteristics of the carpet back-oized with the above blend ~ccording to the process . `
: ~ of ~ S; Patent 3,551,231 are given in Table I~
-::;.: TABLE III

Pxoperties of~ Contrac~-Type Carpét5 Made -Usin~ Unfilled:Reference Blend B

arpe~ gacksize ~ Tuft ~ Scrim Bond, ;
o.. ~ ~ind, 1~. lb. ~3 n 20~;C3 - ~18.7 : 14:.5 ~ :26.2 C4 25,~ : 14.6 Da~a in~Table IIX show a modest Lmprovement in --:~ ~ properties:compared to.the~fillèd, Iess costly blend A ~ .
; ~hiC~ was used for the sampL~s in Table II. However, the 11 Lmpro~ement is no~ adequate to justly the hig~er cost for~most users.
The higher~strength hot melt ~lends o~ th~ . ~ . .-.
present~ invention are Lllustrated in Examples 1 and 2, ~ ~:
intended ~or contract carpet lse, which ~ollow~

-: - , , , ~. , . ~, .. . .. . . . . .. .. .

"~ ", " ~ ,;, " ;, "~ ,~,","~ " ,~ , . ~3~ ~

EX~MPLE 1 ~igh-Strength Blend - 30% Filled - For 19.8~ ethylene/vinyl acetate copoiymer, melt index 17-21, vinyl acetate content 2$%, 2.2~ para~fin wax, mel~ing point o~ iabou~ 146~F~
2.9% low molecular weight ~2000) polyethylene, .density 0O96 g./cm.3, ring and ball so~ten-. ~ng point (ASTM-E28) 257F.~
.10 .4$.0%-hydrocarbon resin, 60C. ring and ball æoftening point,. ~iscosity.of l~0 poise : :
: at 135C~ ("Piccovar" L60, a~ailable from ~ ~ercules Inc.), .- O.l~ butylated hydroxytoluene, - . : . . .
30.0g calcium c~rbonate.
:: :
Physical properties~o this blen~ are given under Blend No. 1 in Table I. The ~ey physical proper~y - -: tensile.elongation - was ~50 percent~
. - - :: .
Table IV shows the typical ca~pet properties :
attained b~ ùse o~Blend No. l~
. TABLE rv ~ : Proper~ies of Contrac~-Type Carpe~s Mad~
Usinq Blend No. 1 . :
. . _ _ _ , _ _ _ _ _ . . . . _ ~ _ _ . . . . . . . . . .
!
Carpet Backsize Tuft Scrim Bond, ~oO oz.~ Bind, 1~. lb./~' .
202 . .18~5 27.8 2 : ~7.6 . 2103 31.8 .
. : 3 25,7 .18.9 :29.3 ~ . -- ~ All tuft bind values:were in Rxcess of 18 . .
lb~., a marked~improvement over the 10~13 lbs~
values obtained with the corresponding filled prior art :
blend (cf. Table II). In many cases, ~his level of~
tut bind will be near the breaking strength of ~he~
: ea~pet yarn. In a few cases, where the ultimate in : . :

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~g;16683~ ` ~
tuft bind value is desired, further improvement (at added cost~ can be secured by elimination of ~iller, as shown in Example 2. The tuft bind value is above ~7 }bs.Jtuft.

~nfilled High Strength Blend For Contract CarPet . . .
28.3% ethylene~vinyl acetate copoly~er~ melt index of~l7-21, vinyl acetate content 25%, lQ 3.1% paraf~in wax~ melting point of a~out 1~F~, .. ~ - .
: 4.0~ low molecular weigh~ t2000) polyethylen~, -~ensity 0.95 g./cm.3, ri~g and ball soten- .
- i~g point (ASTM-E28) 257F., . . ~ ~ -64.S% hydrocarbon recin~ 60C. ring and ball . softening point; viscosity of 1.0 poise at 135C., .
.. 0.1% butylated hydroxytoluene. :-Ph~sical properties of this blend ~re as .
: ~ follows: . -20 ~ ~ Ring and ball softening point, F. 238 . Viscosity, cps. at 310F. 5~337 ~ ~ -~ensiie, lb.~in.2 ~ 33 Tensile elongation, ~ ~ 1090 Typical properties of carpet backsi~ed by the above hot melt bl2nd are shown in Table V.
.
. : TABLE V ~ .
Propertieg ~f ~ontract-Type Carpet Carpet Backsize~ Tuft Bind Scrim Bond ~:
30: ; No. ~ z,~yd~2 lb~ /3 4 ~ 25.7: 27.6 ~ 36.B
This value is above the breaking strength for the~ yarns~used in many.carpets sold in today's markets, ~;
and is almost double the value obtained by ~he use of a~
~ , . . ~ . .
:: - - -- . . . .

.' ' ," ~66813~ ,. '' ~he corresponding un~.illed p~ior art blend ~i.e., ~4.5-1~.6 lbs. c~. Table ~II)~
SERIES II - DOMESTIC CARPETS
Blends described heretofore, intended prImarily ~r c~ntract carpet, are also technically highly desirable for use in domestic carpet bclcksizing, but costs : are pro~ibiti~e. However, these blends can be modi~ie~
~ ~o include substantial amounts of inert filler ~o render ~he cost more attractive and still retai~ the Lmprovement . 10 in-tuft bind. Accordingly, the highly filled blend o - ~ , . . - .
~he present invention employing the novel ~ackifier re~in .
æystem yie~ds considerably higher tuft bind than a . ~ c~rresponding~highly ~illed blend employing a widely-used prio~ art tackiier resin, althou~h; of c~urse, absolute lues for both .the blends of the~present invention and of the prior art will be lower than for les~-hig~ly- :
. .
illed blends of sLmilar composition.
o ~llustrate the benefits of the inve~tion~ :
when-applied to highly-filled systems, Re~erence Blend C, . 20 and the blends of Exc~mples 3 and 4 were prepared, all at .
60% filIer level:
~ference Blend C - Domestic Car~ets ~Widely-Used Good Qua~ Prior Art Blend~ .
(Reference: U. S. Patent 3,745,0S4~ :
8.1~ ethylene/vinyl acetate copolymer, melt index :~: - 17-21~ vinyl acetate content 25~
0~9% paraffin wax, melting point o~ a~out 146~. -3% low molecular weight polyeth~'ene ~3500 molecular weight, 240Fo melting point, :::
~ 3~: 0.93 gm.!cm. 3 density~.
. ~ .
~ : 5,4~ microcrystalline wax, melting point 16DF.
:: :
.

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~6~

12.l~ unsaturated aliphatic thermoE~last:ic hydrocarbon resin, melting point 100C.
12.l~ dicyclopentadiene alkylation polymer, melting poin~ 77F.
0.1% butylated hydxoxytoluene~
S0~0% calcium carbonate.

Domestic Carpet Blend - 60~ Filled - Based on Im~roved Tackifier Resin S~stem 8~1% ethylenejvinyl ace~ate copol~mer, m~lt index 17 2l~vinyl acetate content 25%o 00~ paraffin wax, melting point of abou~ 146~F.
-, , . :. , 1.8% low molecular-weight polyethylelle (3500 molecular weight, 240F. melting point, - - 0~93 ym./cm.3 density3.
29.0~ hydrocarbon xesin, 60C. ~ing and ball soften-~g point, viscosity of 1.0 poise at 135~C.
0. 2% butylated hydroxytoluene .
.
60.0% calciwm carbonate.
. -. .
- 20E~AMP~E 4 Domastic Ca~pet Blend -- 6G~ Filled - Ease~
o~ Alternate Im~roved Tackifier Resin Svstem : 7~2~ ethyleneivinyl acetate copolymer, melt index 17-21, vinyl acetate content 25%.
0.8~ paraffin ~Yax~ melting point of about 146F. . ~ -1.9~ low molecular weigh~ polyethyl~ne (2000 - molecular weight, 0.96 gm~/cm. density, r~ng and ball softening point 257F.). - :
: : 29~6~ hydrocar~on resin, 64C. ring and ball :
30 : ~ softening point,:viscosity of l.0 poise a~ . :
: 135C.
- . ~ . .
. . ~0,5% calcium carbonate~
The relative merits of the prior art blend and the Improved blends of the present invention gixen i~
Examples 3 a~d 4 are exhibi~ed in two ways. Table VI

~: provides comparative physical properties for the three .
. ' .
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blends; the reference blend clearly has a far lowe~
tensil~ elongation percentage than does the Example 3 - or Example 4 blend. The tensile strength for the reference blend is highest~ but, as shown below, this does not result in good tuft bind performance.
Table VII shows c~early that the benefit o .
the high ~ensile elongation percentage noted in Table VI

. ~arry through, and confer a defin7te ben,efit on carpets ~ade with ~he improved blends. Both tuft bind values 10 : ana scrim bond values for the carpets m ae using Example 3 : and ~xample 4 blends are clearly superior to comparable - . values ~or the reference blend, even though the carpet .
tyle is common and the~backsize coating weights are e~sential~y equaL. .
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The appl:ication i~ a d~vi~ion o:E copending appli-cation Serial No. 236~286J ~iled ~eptember 24, 19'~5.

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Claims (10)

The embodiments of the invention in which an exclu-sive property or privilege is claimed are defined as follows:

1. A composition having a tensile elongation of about 50 to 400 percent comprising (A) about 3 to 15 weight percent ethylene/vinyl ester copolymer having a melt index of about 2 to 100, a copolymerized ethylene content of about 67 to 90 weight percent, a copolymerized vinyl ester content of about 10 to 33 weight percent, wherein the acid moiety of said vinyl ester contains 1-4 carbon atoms, (B) about 15 to 40 weight percent of a hydrocarbon resin or a mixture of several hydrocarbon resins having a ring and ball softening point of about 50°C.-70°C. and a viscosity of 0.5 to 1.5 poise at 135°C., (C) 0 to about 3 weight percent of a low molecular weight ethylene homopolymer having a molecular weight of about 1500-4000, density of 0.91-0796 g./cm.3 and a melting point of about 220°C.-270°C., (D) 0 to about 3 weight percent of a paraffin wax, (E) 0 to about 0.3 weight percent of an antioxidant, and (F) about 40 to 75 weight percent filler.

2. The composition of Claim 1 having a tensile elongation of at least about 200 percent.

3. The compositon of Claim 1 wherein said ethylene/vinyl ester copolymer is present in about 5 to 10 weight percent and has a melt index of about 10 to 25.

4. The composition of claim 3 wherein said copolymerized vinyl ester content 13 about 23 to 26 weight percent and the acid moiety thereof contains 2 to 3 carbon atoms.

5. The composition of Claim 4 wherein said hydrocarbon resin Is present in about 25 to 35 weight percent.

6. The composition of Claim 5 having a tensile elongation of at least about 200 percent.

7. The composition of Claim 6 wherein said vinyl ester is vinyl acetate.

8. A carpet comprised of a primary backing material stitched with closely spaced erect loops of yarn to form a tufted structure, the bottom surface of the tufted structure having as a tuft bonding backsize adhesive coating the composition of Claim 1, said carpet having an average tuft bind of at least 10 pounds.

9. A carpet comprised of a primary backing material stitched with closely spaced erect loops of yarn to form a tufted structure, the bottom surface of the tufted structure having as a tuft bonding backsize adhesive coating the composition of Claim 4, said carpet having an average tuft bind of at least 10 pounds.

10. A carpet comprised of a primary backing material stitched with closely spaced erect loops of yarn to form a tufted structure, the bottom surface of the tufted structure having as a tuft bonding backsize adhesive coating the composition of Claim 7, said carpet having an average tuft bind of at least 10 pounds.