CA1276439C - Dimensionally stable carpet tiles - Google Patents

Dimensionally stable carpet tiles

Info

Publication number
CA1276439C
CA1276439C CA000525291A CA525291A CA1276439C CA 1276439 C CA1276439 C CA 1276439C CA 000525291 A CA000525291 A CA 000525291A CA 525291 A CA525291 A CA 525291A CA 1276439 C CA1276439 C CA 1276439C
Authority
CA
Canada
Prior art keywords
composite sheet
percent
dimensionally stable
carpet tile
carpet
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Fee Related
Application number
CA000525291A
Other languages
French (fr)
Inventor
John M. Kernstock
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Dow Chemical Co
Original Assignee
Dow Chemical Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Dow Chemical Co filed Critical Dow Chemical Co
Priority to CA000525291A priority Critical patent/CA1276439C/en
Application granted granted Critical
Publication of CA1276439C publication Critical patent/CA1276439C/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

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  • Carpets (AREA)

Abstract

ABSTRACT

A dimensionally stable carpet tile having a greige good adhered to an aqueous wet-laid composite sheet comprising dimensionally stable reinforcing fiber in an amount sufficient to provide less than a 0.1 percent dimensional change of the carpet on an Aachen Test. Typical dimensionally stable reinforcing fibers are glass fibers and/or polyester fibers employed in amounts from 2 to 15 percent by weight based on the total composite sheet. The other main ingredients of the composite sheet comprise from 1 to 30 percent cellulose fibers, 2 to 30 percent organic polymer binder material and 60 to 95 percent inorganic filler based on the total weight composite sheet. The composite sheet has an internal bond strength of at least 50 grams per inch (19.68 g/cm).

Description

~ ~7~ 3 , DIMENSIONALLY STABLE CARPET TILES

Dimensional stability is one of the most important characteristics for carpet tile. Without a fully stabilized backing, problems of edge curling, buckling, bubbling or shrinkage of the title can occur.
Generally, a carpet tile is manufactured by adhering or otherwise attaching a secondary backing to the underside of the carpet. This secondary backing can be woven scrim, composition material, or a combination of both. Typical secondary backings can be prepared with a woven reinforcement material prepared from jute, nylon, polypropylene or fiberglass. The woven reinforcement can then be covered with an adhesive or other backing material such as polyvinyl chloride urethane foams, polyethylene, ethylene vinyl acetate or an asphalt material.
Attempts to increase dimensional stability have led to the use of many materials, most common is the use of polyvinyl chloride (PVC). In such attempts~
carpet tiles are manufactured by pressing a tufted or woven greige good into a molten PVC case onto a release belt. At this time, a stabili~ing scrim may be added.

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~2--Problems associated with this form of secondary backing are uniformity in the application of the PVC, high energy and raw material costs, and inability to employ solvent adhesives for installation of` the tiles.

Of additional concern in the preparation of carpet tiles is prevention of combustion hazards.
Naturally, the incorporation of large amounts of polymeric materials into the carpet tiles increases the likelihood of smoke hazards when b~rned. It therefore is desirable to find better and alternative methods for providing dimensional stability to carpet tiles.
In one aspect, the present in~ention is directed toward a dimensionally stable carpet tile having a greige good adhered to an aqueous wet-laid composite sheet. The composite sheet characteristic-ally comprises a dimensionally stable reinforcing fiber in an amount sufficient to provide less than a 0.10 percent dimensional change of the carpet tile on an Aachen Test. The dimensionally stable reinforcing fiber is present from 2 to 15 percent by weight based on the total composite sheet. Generally, the composite sheet comprises, based on the total weight composite sheet, from 1 to 30 percent cellulose fibers, from 2 to 30 percent organic polymer binder material and from 60 to 95 percent inorganic filler. The composite sheet has an internal bond strength of at least 50 g per inch (19.68).
Generally, the carpet title is constructed from a greige good adhered to a composite sheet from 0.1 to 2.5 mm in gauge. Typically, the dimensionally stable reinforcing fiber is a glass fiber and the glass fiber is present from 2 to 10 percent by weight based on the total composite sheet and from 2 to 15 percent by weight cellulose fibers based on the total weight of the composite sheet.
The present invention provides for the manufacture of a dimensionally stable piece of carpet Which can ~e die Cut into ~iles. These tiles have the usability Of conventional polyvinyl chloride backed carpets but at an economiC advantage. Further, the tiles prepared by the subject invention can have low polymer content and high inert filler content which is desirable for fire safety.
The present invention is directed toward a carpet which can be die cut into tiles having very good dimensional stability through the use of an aqueous wet-laid sheet as the secondary backing. The wet-laid sheet comprises in pertinent part a filler material, latex binder, and fiber material wherein at least a portion of the fibrous material comprises dimensionally stable reinforcing fiber-s in an amount sufficient to provide dimensional stability.

Typically, the secondary backing material is prepared by an aqueous wet-laid process such as is disclosed in U.S. Patent 4,225,383. All percent weights are based on total composite sheet weight unless otherwise indicated. Sheets prepared in the wet-laid process are generally described as having from l to 30 percent total weight of a water-dispersible fiber such as cellulose fibers, from 2 to 30 percent total weight of a film-forming, water-insoluble~
organic polymer as a binder material and from 60 to 95 percent total weight of a finely divided, substantially water-insoluble, non-fibrous, inorganic filler material. Less critical to the subject application as a carpet backing, however, is the inorganic filler content and, therefore, composite sheets having less t,han 60 percent total weight inorganic filler are acceptable. Alsos cellulose fibers in an excess of 20 percent by weight tend to adversely a~fect the internal bond strength of the composite; there~ore, pre~erably the cellulose fiber content is less than the 30 percent level, more preferred is a cellulose fiber level of from 2 to 15 percent by total weight. More c~itical to the subject application as a carpet backing material is that at least a portion o~ the fibrous content of the composite sheet must be of a dimensionally stable reinforcing material, such as glass fibers. Generally, at least 2 to 15 percent based on the total weight of the subject composite comprises the dimensionally stable reinforcing fibers.

It has been discovered that the incorporation of a minor amount of a dimensionally stabilizing reinforcing fiber to the composite sheet give a balance of physical properties acceptable for use in carpet backing, especially carpet tile backing. Therefore, an aqueous wet-laid composite sheet having from 2 to 15 percent, preferably 2 to 10 percent based on the total weight of the composite sheet is suitable for the subject dimensionally stable carpet tiles.
The subject composite sheets are adhered to the greige goo`ds (carpet woven fabric or looped fabric) by a latex adhesive, hot melt adhesive or other adhesive means. What is meant by greige goods is the cut or uncut loops of fabric filaments, or unwoven or woven fabric filaments which form all or part of the carpet surface. The fabric filaments can be woven, stitched ~ 3'~

or otherwise affixed to a primary backing. It is the underside of this primary backing, if present, to which the present composite sheet is affixed.
A latex or other adhesive material is applied by conventional ~eans, i.e., blade coater, sprayer or hot melt extrusion to the underside of the greige good and the composite sheet is brought into contact with the latex adhesive. The entire assembly is then pressed and dried to permit intimate adhesion of the greige good to the composite sheet. The dried carpet assembly can then be die cut into appropriately sized tiles. The foregoing procedure can be conveniently carried out on a drum ]aminator or other application systems where the composite sheet and greige goods are not separated from each other while curing.
The dimensionally stable reinforcing fibers are meant to define fibrous materials which are resistant to change in dimension after being subjected to changes in conditions such as temperature and moisture.
Sometimes this characteristic is referred to as "memory". For example, glass fibers are fibrous materials having very good dimensional stability.
Whereas, nylon has a tendency to shrink upon being subjected to a heat treatment which makes nylon an undesirable fibrous material for purposes of this invention.
3o The preferred dimensionally stable reinforcing fibrous material employed in the subject composite sheets are generally glass fibers having a length of from 0.01 to 1.5 inches (0.25 to 38 mm) in length with a diameter of from 0.0045 to 0.0133 mm. While glass fibers are preferred, other comparable dimensionally stable fibrous materials can be employed. For examp]e, mineral fibers such as graphite, carbon and sllica or synthetic fibers such as polyester and aramid fibers can be employed.

Typically, polyester fibers having a length of 0.04 to 0.4 inch (1 to 10 mm), preferably 0.1Z5 inch (3 mm), and a diameter of 6 denier are preferred.
Furthermore, combinations of various dimensionally stable fibers can be employed such as polyester and glass fibers.
While all fibers which have dimensional stability equivalent to g]ass fibers or better cannot be listed, it is generally recognized that those skilled in the art can readily determine if a particular reinforcing fiber would meet this requirement.
The dimensionally stable reinforcing fibers are employed in an amount sufficient to provide dimensional stability and internal strength to the backing. Dimen-sional stability is defined as an amount sufficient to give less than a 0.10 percent change on the Aachen Test and internal bond strength is defined as at least 50 gm/in (19.68 g/cm). The Aachen Test is a standardized carpet backing stability test defined by the Aachen Institute in Europe for dimensional stability. The Aachen Test consists of dimensionally measuring a section of carpet which has been at room temperature for 24 hours. Then 9 the carpet is heated for 2 hours at 140F (60C), immersed in water for 2 hours at room temperature, removed from the water and heated for 24 hours at 140F (60C). then left at room temperature for 48 hours. After completing this sequence of conditions, the carpet section is again dimensionally measured and the change calculated.
Other additives can7 of course, be employed in the composite sheet. These additives can include processing aids for the wet-laid process such as stabilizers, flocculating agents, and anti-foaming agents. Also, other additives can be added such as antioxidants, co~orants, antistatic agents, plasti-ci~ers, and waxes.
Generally, the present composite sheet is from0.1 to 2.5 mm in thickness, preferably 0.5 to 1.27 mm in thickness. The gauge or thickness is important to the necessary amount of material per unit area to provide dimensional stability. Therefore a minimum gauge of 0.25 mm is desirable. Gauges above this minimum add additional stability and body to the greige good. However, it is understood that varying percent composition of dimensionally stable reinforcing fibers with gauge can provide equal results but the ranges specified herein are deemed to be most applicable for providing the necessary stability, hand, and appearance for a commercially acceptable carpet tile. Also, the preferred gauges are most compatible with current engineering requirements for installation and maintenance of carpet tiles.
Carpet tiles according to the subject invention are further illustrated by the following examples. All percentages are based on the total weight of the composite sheet unless ot~erwise indicated.

Exa~ple 1 A composite sheet having 15 percent latex (60.5 styrene/37.4 butadiene), 7.0 percent cellulose fibers, 74.5 percent talc and 3 percent dimensionally stable glass fibers was obtained having a gauge of 0~76 mm.
Various composite sheets were prepared to demonstrate the superiority of the subject composite sheet employed as a backing material. The compositions of the composite sheets tested are shown in Table I
below.
Table I

15 Backinp. Latex (~) Fiber (%) Fiber (%) Gau~e (mm~
A1 15 0 7.5 polyester 3.0 0.76 B1 13.0 12.0 polyethylene 5.0 0.76 C 15.0 7.0 glass 3.0 0.76 D 15.0 7.0 gLass 3.0 o.89 El Actlon Ba~k - Woven Polypropylene2 1 not examples of the subJect invention 2 manufactured by the Amoco Company Each of the backings were laminated with a latex adhesive to a standard greige good to form 9-by-9 and 8-by-8 inch (22.8-by-22.8 and 20-by-20 cm) carpet 3 tile samples. The laminating technique employed was to hand coat the greige goods with a blade coater, apply the backing and allow to dry for seven minutes on a drum at 280F (137.78C) under sufficient pressure to maintain contact between the layers. The prepared tiles were then tested for percent dimensional change, i.e., Aachen Test. Each of the backing materials was _9_ evaluated using two different adhesives to see if this changed the dimensional stability. The first latex adhesive "X" had a viscosity of 7,000 centipoise (7 Pas) and a polymer ratio of 26 styrene/36 butadiene/2 itaconic acid/36 vinylidene chloride) and the second latex adhesive "Y" had a viscosity of' 207000 centipoise (20 Pa-s) and a polymer ratio of` 33 styrene/65 butadiene/2 itaconic acid. The results are listed in Table II.
Table II
% dimensional change Backing "X" Adhesive "Y" Adhesive 1~
A1 -0.28/-0.18 -0.41/-0.19 g1 0.19/-0.14 -0.13/-0.12 C -0.09/-0.04 -0.03/-0.01 D not tested -0.01/zero E1 -0.49/~0.05 -0.71/-0-36 The data show that backings "C" and "D" were superior to all others. "C" and "D" each met the dimensional stability standard of less than a 0.1 percent change on the Aachen Test. All other samples failed this dimensional stability test.

3o

Claims (8)

1. A dimensionally stable carpet tile having a greige good adhered to an aqueous wet-laid composite sheet comprising a dimensionally stable reinforcing fiber in an amount sufficient to provide less than a 0.10 percent dimensional change of said carpet tile on an Aachen Test.
2. The carpet tile of Claim 1 wherein said dimensionally stable reinforcing fiber is present from 2 to 15 percent by weight based on total composite sheet.
3. The carpet tile of Claim 1 wherein said composite sheet comprises, based on total weight composite sheet, from 1 to 30 percent cellulose fibers, from 2 to 30 percent organic polymer binder material, and from 60 to 95 percent inorganic filler.
4. The carpet tile of Claim 1 where said composite sheet has an internal bond strength of at least 50 g/in (19.68 g/cm).
5. The carpet tile of Claim 3 where said composite sheet has an internal bond strength of at least 50 g/in (19.68 g/cm).
6. The carpet tile of Claim 1 where said composite sheet is from 0.1 to 2.5 mm in guage.
7. The carpet tile of Claim 1 where said dimensionally stable reinforcing fiber is a glass, polyester fiber or mixture thereof.
8. The carpet tile of Claim 3 where said composite sheet has from 2 to 15 percent by weight cellulose fibers and from 2 to 10 percent by weight of glass fibers.
CA000525291A 1986-12-15 1986-12-15 Dimensionally stable carpet tiles Expired - Fee Related CA1276439C (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
CA000525291A CA1276439C (en) 1986-12-15 1986-12-15 Dimensionally stable carpet tiles

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
CA000525291A CA1276439C (en) 1986-12-15 1986-12-15 Dimensionally stable carpet tiles

Publications (1)

Publication Number Publication Date
CA1276439C true CA1276439C (en) 1990-11-20

Family

ID=4134551

Family Applications (1)

Application Number Title Priority Date Filing Date
CA000525291A Expired - Fee Related CA1276439C (en) 1986-12-15 1986-12-15 Dimensionally stable carpet tiles

Country Status (1)

Country Link
CA (1) CA1276439C (en)

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