CA2127821A1 - Polyurethane backed textiles having improved flame retardancy and method for the preparation thereof - Google Patents
Polyurethane backed textiles having improved flame retardancy and method for the preparation thereofInfo
- Publication number
- CA2127821A1 CA2127821A1 CA 2127821 CA2127821A CA2127821A1 CA 2127821 A1 CA2127821 A1 CA 2127821A1 CA 2127821 CA2127821 CA 2127821 CA 2127821 A CA2127821 A CA 2127821A CA 2127821 A1 CA2127821 A1 CA 2127821A1
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- Canada
- Prior art keywords
- polyurethane
- textile
- formulation
- polyol
- polyisocyanate
- 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.)
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Abstract
ABSTRACT
Polyurethane backed textiles, particularly polyurethane backed carpets and carpet tiles can be prepared having a critical radiant flux of greater than or equal to 0.45 watts/cm2. The improved flammability performance is achieved by using ZnCO3 or MgCO3 as flame retardants. The use of the flame retardants of the present invention allows for improved flammability properties compared to otherwise similar backed textiles prepared with conventional flame retardants. The flame retardants of the present invention can have no substantial affect on polyisocyanate reactivity which can minimize reformulation experimentation.
Polyurethane backed textiles, particularly polyurethane backed carpets and carpet tiles can be prepared having a critical radiant flux of greater than or equal to 0.45 watts/cm2. The improved flammability performance is achieved by using ZnCO3 or MgCO3 as flame retardants. The use of the flame retardants of the present invention allows for improved flammability properties compared to otherwise similar backed textiles prepared with conventional flame retardants. The flame retardants of the present invention can have no substantial affect on polyisocyanate reactivity which can minimize reformulation experimentation.
Description
41,~43-F
POLYURETHANE BACKED TEXTILES HAVING IMPROVED FLAME 2~7~21.
RETARDANCY AND METHOD FOR THE PREPARATION THEREOF
The present invention relates to polyurethane backed textiles having improved flame retardancy. The present invention particularly relates to polyurethane backed carpets and carpet tiles having improved flame retardancy.
It is known in the art of preparing textile articles to use polyurethanes in various forms. For example, U.S. Patent No. 4,296,159 to Jenkines, et al. discloses preparing a tufted or woven article having a unitary backing prepared by applying a polyurethane forming composition to the underside of the tufted or woven article. A different form of polyurethane backing is disclosed in U.S. Patent No. 5,102,714 to Mobley, et al. wherein the polyurethane backing is a tacky adhesive. It is also known to use polyurethane foam as a cushioning textile backing.
But preparing polyurethane backed textile articles is not always trouble free. Preparing new articles can be particularly troubling. For example, U.S. Patent No. 4,689,256 discloses that preparing a carpet from nylon and poly vinyl chloride, each of which alone are ~low smoke~
materials can result in a carpet which is not low smoke. As in this example, using new materials to prepare polyurethane backed textiles to improve one property of the backed textile can result in another property being degraded. When this occurs, it is sometimes necessary to modify formulations to accommodate the new materials and yet maintain desirable physical properties.
In order to meet contingencies such as the use of new textile materials having high smoke values or just to comply with increasingly stringent fire retardant requirements, it is desirable in the art to prepare flame retardant polyurethane backed textile articles. It is also desirable in the art to prepare polyurethane backed textile articles with flame retardant polyurethane backings. And it is particularly desirable in the art that the flame retardant polyurethane backings be useful in textile applications having rigorous physical property requirements such as carpet and carpet tiles.
41,443-F
X~278~1.
In one aspect, the present invention is a polyurethane backed textile having improved flame retardancy comprising (A) a top-most textile facing layer, (B) a polymeric textile backing prepared from a polyurethane formulation including (lj a polyisocyanate, (2) a polyol, (3) a catalyst, (4) a flame retardant selected from the group consisting of ZnC03, MgCO3 and mixtures thereof and, optionally, (5) a blowing agent.
In another aspect, the present invention is a polyurethane textile backing comprising a polyurethane prepared from a formulation including (1) a polyisocyanate, (2) a polyol, (3) a catalyst, (4) a flame retardant selected from the group consisting of ZnC03, MgC03 and mixtures thereof and, optionally, (5) a blowing agent.
Another aspect of the present invention is a method for preparing a polyurethane backed textile having improved flame retardancy comprising applying to a textile facing layer one or more polyurethane backing layers prepared from a formulation including (1) a polyisocyanate, (2) a polyol, (3) a catalyst, (4) a flame retardant selected from the group consisting of ZnCO3, MgCO3 and mixtures thereof and, optionally, (5)a blowing agent.
In yet another aspect, the present invention is a polyurethane formulation useful for preparing a polyurethane backed textile having improved flame retardancy comprising (1) a polyisocyanate, (2) a polyol, (3) a catalyst, (4) a flame retardant selected from the group consisting of ZnCO3, MgCO3 and mixtures thereof and, optionally, (5) a blowing agent.
In one embodiment, the present invention is a polyurethane backed textile having improved flame retardancy. Preferably the polyurethane backed textile is a carpet or carpet tile. The polyurethane layer can take several forms. In one form, it is a cellular polyurethane foam which acts as an integral pad. This application of a polyurethane layer in a carpet is disclosed in, for example, U. S. Patent No. 4,853,054, to Turner, et al., which is incorporated herein by reference, and U.S. Patent No.
5,104,693 to Jenkines, et al., also incorporated herein by reference.
-` 2~27821.
In another form, the polyurethane layer of the present invention is a microcellular polyurethane textile backing which, when applied to the primary textile backing, can provide dimensional stability and serve to anchor the textile tufts, also known as the face, to the textile primary backing. The microcellular polyurethane of the present invention is useful in the form of a layer adherent to the primary or secondary textile backing serving to provide a suitable surface for the application of a polyurethane foam wherein it is known as a precoat. This application of a polyurethane backing layer in a carpet is disclosed in, for example, V.S. Patent No.
4,696,849 to Mobley, et al., which is incorporated herein by reference.
In yet another form, the polyurethane layer is a removable adhesive such as that which is disclosed in U.S. Patent No. 5,102,714, also to Mobley, et al, which is also incorporated herein by reference. In this form the polyurethane adhesive can function to anchor floor coverings or to anchor protective coverings such as a painter's drop cloth in place.
However, the removable character of the adhesive can allow the textile to be removed easily.
When the polyurethane is in the form of a foamed polyurethane pad, it can be prepared from a formulation including: (l) a polyisocyanate, (2) a polyol, (3) a catalyst, and (4) a flame retardant, and additionally including such materials as a filler; a catalyst, a surfactant, pigments, molecular sieves, other flame retardants, antimicrobial materials and blowing agents. The foamed polyurethane layer functions as an integral foam pad thereby eliminating the need for a separate foam pad. The formulation can be any foam formulation known to those skilled in the art of preparing polyurethane foam for carpet applications to be useful. For example, the formulation can be one of those disclosed U.S. Patent No. 4,853,05~ to Turner, et al. additionally containing the flame retardant of the present invention.
In the '054 patent to Turner, it is disclosed that the polyisocyanate can be toluene diisocyanate or a prepolymer thereof with glycerine or -trimethylolpropane or mixture thereof with an alkylene glycol or glycol ether, the prepolymer having an average functionality of 2.03 to 2.2.
Preferably, the polyisocyanate is a mixture of a liquid methylene - . . : , - : -L ' . , ~ "
41,443-F
~ 21Z7821 diphenyldiisocyanate (MDI) having an equivalent weight of 130 to 200 and polyphenyl polymethylene polyisocyanate (also known as polymeric MDI and hereinafter PMDI), the mixture having an average functionality of 2.03 to 2.2.
The polyol component of the foam formulation can be any polyol or polyol mixture which can be used to prepare a foam which can withstand the rigorous physical property and handling requirements of foams used in carpet applications. The foamed polyurethane polyol component of a Turner '054 type foam is preferably a polyol mixture h~ving as one part of the mixture a polyol based on a C3-Cg alkylene oxide, which has an equivalent weight of 1000 to 5000, and an internal poly(ethylene oxide) block or a terminal ethylene oxide cap constituting 15 to 30 percent of the weight of the polyol, or mixture of such polyols wherein the polyol or mixture thereof has an average functionality of 1.8 to 2.2. The other portion of the polyol mixture is preferably a minor amount of a low equivalent weight compound having 2 active hydrogen containing groups per molecule.
Another example of the foamed form of the present invention is a polyurethane foam prepared from a formulation such as those disclosed by U.S. Patent No. 5,104,693 to Jenkines additionally including the flame retardant of the present invention. In formulations of this type, the polyol component can be at least one isocyanate reactive material having an average equivalent weight of 1,000 to 5,000. The polyisocyanate can be any polyisocyanate in an amount to provide an isocyanate index of 90 to 130, wherein at least 30 percent by weight of the polyisocyanate is a soft segment prepolymer which is the reaction product of a stoichiometric excess of MDI or a MDI derivative and an isocyanate reactive organic polymer having an equivalent weight from 500 to 5,000, the prepolymer having an isocyanate group content of 10 to 30 percent by weight.
With either type of foam, the blowing agent is preferably air, however, other gasses, such as carbon dioxide, and nitrogen can be used.
It is preferably injected into the polymer by frothing. The fillers can be aluminum oxide trihydrate (alumina), calcium carbonate, barium sulfate or mixtures thereof.
.:
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:. . . . . :, . , 41,443-F
21~7821.
When the polyurethane is in the form of a microcellular polyurethane, it can be prepared from a formulation including: (1) a polyisocyanate, (2) a polyol, (3) a catalyst and (4~ a flame retardant, and additionally including such materials as a filler, a surfactant, pigments, molecular sieves, other flame retardants, antimicrobial materials and blowing agents.
Any formulation known to those skilled in the art of preparing polyurethanes for carpet applications can be used to prepare the polymers of the present invention except that they will additionally have a flame retardant of the present invention. Polymers of this type are generally applied to textiles as an unfoamed, non cellular layer which functions to stiffen a textile and to adhere the tufts of the textile to the primary backing. Particularly when the polyurethane layer is a precoat, the polyisocyanate can be, for example, MDI, an MVI prepolymer or a modified MDI material.
For example, the polyol component of a microcellular polyurethane can include a first polyol which comprises a relatively high equivalent weight polyol containing an average of 1.4-1.95 hydroxyl groups per molecule, of which hydroxyl groups at least 30 percent are primary hydroxyls or a mixture thereof with at least one additional relatively high equivalent weight polyol containing at least 2.05 hydroxyl groups per molecule, of -which at least 30 percent are primary hydroxyls. Additionally the polyol component can include a relatively low equivalent weight compound having 2 active hydrogen containing moieties per molecule. Desirably, the polyol component has an average functionality of 0.97 - 2.03. The polyurethane is preferably prepared such that the polyisocyanate and the polyol component has an isocyanate index of 85-125.
When the polyurethane polymer of the present invention is prepared in ~ ~
the form of a removable adhesive, it can be prepared from a formulation - ~-including: (l) a polyisocyanate; (2) a polyol; (3) a catalyst and (4) a flame retardant. The formulation is applied in the form of a tacky adhesive, preferably to a precoat layer. The polyisocyanate can have an average functionality of 2.2 or less.
The polyol component of the removable adhesive can be a complex admixture. It can have, as a first component, a mixture of a monoalcohol : :~ ,.,; .~.-: ., : - .
41,443-F
21;;~7~32~.
and a polyether or polyester polyol, the mixture having an average actual funct-onality of 2.2 or less, an equivalent weight of at least 50V and containing from 10 to 70 mole percent monoalcohol. As a second component, the polyol can have less than 10 weight percent, based on the weight of the first polyol component of a compound or mixture of compounds having at least two active hydrogen containing groups per molecule and an equivalent weight from 30 to 500.
The polyurethane polymer adhesive, when prepared by the method of U.S. Patent 5,102,70q to Mobley, is prepared with no more than 0.1 percent water present. The polyurethane adhesive is prepared at an isocyanate index of from 85 to 115. The adhesive can contain other additives such as catalysts, and fillers. However, preferably, it contains no blowing agent.
If a blowing agent is used, the blowing agent is selected such that the proscription of 0.1 percent water is not exceeded.
Polyurethane catalysts can be suitably used with all forms of the present invention. The catalyst is preferably incorporated into the formulation in an amount suitable to increase the rate of reaction between the polyisocyanate and the polyol components of the present invention.
Although a wide variety of materials is known to be useful for this purpose, the most widely used and preferred catalysts are the tertiary amine catalysts and the organotin catalysts.
Examples of the tertiary amine catalysts include, for example, triethylenediamine, N-methyl morpholine, N-ethyl morpholine, diethyl ethanolamine, N-coco morpholine, l-methyl-4-dimethylaminoethyl piperazine, 3-methoxy-N-dimethylpropylamine, N,N-diethyl-3-diethyl aminopropylamine, :
and dimethylbenzyl amine. Tertiary amine catalysts are advantageously ~;
employed in an amount from 0.01 to 2 percent by weight of the polyol formulation.
Examples of organotin catalysts include dimethyltin dilaurate, dibutyltin dilaurate, dioctyltin dilaurate, and stannous octoate. Other examples of effective catalysts include those taught in, for example, U.S.
Patent No. 2,846,408. Preferably the organotin catalyst is employed in an amount from 0.001 to 0.5 percent by weight of the polyol formulation.
41,443-F
Z~7821 The flame retardants of the present invention are selected from the group consisting of ZnCO3, MgCO3 and mixtures thereof. Preferably the agent is ZnCO3. Either the ZnCO3 or the MgCO3 can include other materials.
For example, MgCO3 commonly includes minor amounts of Mg(OH)2 and is often hydrated with the pentahydrate often predominating. Where other materials are present in the ZnCO3 or MgCO3, preferably they are materials which are low in iron and chloride salts as these species can interfere with urethane reactions. The ZnCO3 and MgCO3 materials are solids and have particle sizes sufficiently large to facilitate handling yet not so large as to make it too difficult to admix them with the polyurethane backing formulation.
Preferably, the particle size distribution of the ZnCO3 and MgCO3 is such that little dust is generated during handling but 99 percent will pass through a 325 mesh screen.
Use of the flame retardants of the present invention is advantageous for several reasons. Firstly, ZnCO3 and MgCO3 decompose at advantageous temperature. ZnCO3 decomposes at 300C to produce CO2 which is believed to be one mechanism whereby it retards flammability. MgCO3 similarly decomposes at 800C. However MgCO3 dehydrates at 230C and Mg(oH12 decomposes to produce water at 350C. Polyurethane textiles can be subject to temperatures of up to 160C during processing. Polyurethane backings such as those used with the present invention begin to decompose at 180C.
A standard test for textiles, particularly for carpets and carpet tiles is ASTM E 6~8-9la UStandard Test Method for Critical Radiant Flux of Floor-Covering Systems Using a Radiant Heat Energy Source~. During this test, the textile is exposed to temperatures of 600C and greater. The 230C
temperature where the flame retardants of the present invention can begin decomposition is greater than the processing temperature of the textile, so that the retardant does not decompose releasing CO2 prematurely. These temperatures are near the polyurethane decomposition and testing temperatures so that the flammability retarding agents can decompose in time to improve flammability performance of the polyurethane backed textiles. -~
Another reason that the flame retardants of the present invention are advantageously used with polyurethane backed textiles is that as well as 41,443-F
-`` 21;~7821 being very economical, they can have minimal effect upon the curing times of polyurethane formulations. The retardants will generally neither substantially accelerate nor substantially slow polyurethane cure. This is particularly important in polyurethane foam backed textile production. In commercial carpet manufacturing operations, production equipment is often sized based upon the cure time of the foam. For example, if it is desirable to xun the textile through the foam backing application device at a rate of x feet per second, and it is known that the foam will cure in y seconds, then there needs to be x times y feet of carpet between the point of foam application and the point at which the foam must be cured. If a flame retardant were to significantly affect the cure time of a polyurethane, it could result in undesirable quick cures wherein the polymer might delaminate from the textile, or in a too slow cure wherein the foam layer might be deformed or be squeezed out of the carpet and damage the carpet facing.
The flame retardants of the present invention can be used alone, but in some applications, they can also be used with other flame retardants.
For example, the flame retardants can be used with materials such as -alumina. The primary reason that this can be desirable is that it allows for minimal reformulation of the polyurethane backings. In a polyurethane backed textile application which was adequate with only alumina, a change in textile to one with poorer flammability can require that the polyurethane backing be modified to supply additional flame retardancy to compensate. Since the present invention can be used in conjunction with alumina, a minor change to the formulation, adding an effective amount of the retardants of the present invention, can be easily made.
The amount of flame retardants of the present invention used will vary with the polyurethane formulations and choice of textiles for the particular polyurethane backed textile application. However, generally, where ZnC03 and MgC03 are used as sole flame retardants, they are used at from 5 to 500 parts (by weight) per 100 parts of active hydrogen containing materials. Preferably, they are used at from 10 to 300 parts ~by weight) per 100 parts of active hydrogen containing materials. And more preferably, they are used at from 50 to 225 parts (by weight) per 100 parts of active hydrogen containing materials. Where they are used in 41,443-F
Z~7~32~.
conjunction with other flame retardants, they are used in an amount effective to produce a polyurethane backed textile having Class I
flammability which is one having a critical radiant flux greater than or equal to 0.4S watts/cm2. While this level of fire retardant will vary with the textile and amount of flame retardant already present, it will preferably be from 1 to 250, more preferably from 5 to 100, and even more preferably from 5 to 50 parts (by weight) per 100 parts of active hydrogen containing materials.
Alth~ugh they can be admixed with polyisocyanates, the flame retardants of the present invention are desirably added to the non-polyisocyanate component of the formulations of the present invention. For example, when preparing a foam backed textile, the individual components of the polyurethane formulation are admixed and added as a layer of preferably uniform thickness on the textile. ~hile the flame retardants of the present invention desirably do not substantially negatively affect the physically properties of the polymers prepared therewith, they can increase the viscosity of the polymer formulations in which they are included.
Often, this viscosity increase does not adversely affect handling, but where it does, a surfactant can be used to alleviate the problem. Any surfactant which does not adversely affect the polymer formulation can be used for this purpose. Preferably the surfactant is an anionic/nonionic surfactant. Care should be taken to use no more surfactant than is necessary to avoid degrading polymer physical properties.
It is often preferable to premix all of the components except the polyisocyanate (and the blowing agent when a gas is used) to form a ~B~
component. The polyisocyanate and the B component are admixed and then the gas is blended in using, for example, an OAKES FROTHER* (*OAKES FROTHER is a trade designation of the E.T. Oakes Corporation). The composition is preferably applied prior to any significant level of curing using equipment such as a doctor knife, air knife, or extruder to apply and gauge the layer. In the alternative, the forming polyurethane can be applied by forming it into a layer using a moving belt, allowing it to partially cure, and then marrying it to the textile using equipment such as a double belt laminator. After application of the foam layer, the polyurethane is cured 41,443-F
-21;~82~.
by applying heat by means of an infrared oven, open flame forced draft convection impingement oven, heated plates or the like.
Textiles useful with the present invention can include broadloom carpet, automotive carpet, fabrics for automotive trim and automotive trunk liners. In addition, the textiles useful with the present invention can include synthetic playing surfaces, woven polymeric scrim, nonwoven polymeric scrim, wall coverings, sheet polymers, and furniture covers. One preferred embodiment of the present invention is carpet tile prepared by incorporating the flame retardants of the present invention into a carpet tile production process such as that disclosed in U.S. Patent No. ~,657,790 to Wing, et al. The '790 Wing, et al. patent is incorporated herein by ~
reference. :
Non-textile materials commonly used to prepare textiles can also be used with the present invention. For example, latex precoats and adhesives can be used with the present invention to prepare carpets. Other adhesives, and coatings can be used with the present invention as long as they do not substantially interfere with the flame retardant character of the components of the carpets of the present invention.
In addition to carpets, the present invention can be used to prepare furniture covers, and wall coverings. Useful applications of the present invention include unusual applications such as a drop cloth having one side coated with a removable adhesive.
The following examples are provided to illustrate the present invention. The examples are not intended to limit the scope of the present invention and they should not be so interpreted. Amounts are in weight parts or weight percentages unless otherwise indicated.
E~ :;
A polyurethane backed textile was prepared with a precoat and a foam backing, the formulations for which are disclosed in the Tables 1 and 2 below, according to the following steps:
41,443-F
21;;~7~321.
a. A Precoat polyol/filler compound was prepared according to the formulation below by placing the indicated amount of polyol(s) in a suitably sized container;
b. The indicated amount of D-~0* calcium carbonate filler (*D-70 was a trade designation of Georgia Marble) was added to the polyol while under high sheer agitation;
c. The indicated amount of H-36U* hydrated alumina (*H-36U is a trade designation of Solem Industries) was added to the polyol while under agitation;
d. The indicated amount of Zinc Carbonate (Mineral Research and Development Corp.) or MagCarb H~ (*MagCarb H is a trade designation of Marine Magnesium Company) was added to the polyol while under agitation;
e. High shear agitation of the polyol/filler compound was continued until a temperature of 50C was reached in order to thoroughly disperse and break up agglomerate filler particles;
f. The polyol/filler compound was cooled to 20C;
g. The indicated amount of the isocyanate component was added to the polyol/filler compound and the two thoroughly mixed;
h. The indicated amount of polyurethane catalyst was added to the reaction mixture with agitation;
i. The reaction mixture was then spread onto the back of the textile by means of a knife coating process and cured by means of heated platens and/or an oven.
j. A foam polyol/filler compound was prepared according to the formulation below and reacted with the isocyanate component using the same procedures in steps a-h, above, except no metal carbonate was used.
k. Air was metered into the reaction mixture which was frothed to a foam of approximately 288 kg/M3 density.
1. The frothed foam reaction mixture was applied to the textile according to step I above.
The textile was tested for radiant heat flux and the results are displayed in Table 3 below. -~:.
41,443-F
21~7~
A polyurethane backed textile was prepared and tested substantially identically to Example 1 except that the formulation components indicated in Tables 1 and 2 were used. Testing results are displayed in Table 3 below.
COMPARATIVE ~XAMPLE 3 A polyurethane backed textile was prepared and tested substantially identically to Example 1 except that the formulation components indicated in Tables 1 and 2 were used. Testing results are displayed in Table 3 below.
. . ... .. , .. ~................. .
I
lDPG2 15 15 15 ¦D-703 61.5 61.5 70 ¦H-36U4 135 135 135 ¦ ZnCO~5 8.5 __ __ ~ __ 10 __ ~ 1.0 0.5 __ ¦Catalyst8 0.2 0.2 0.2 *Not an Example of the present invention.
1. VORANOL 9120* is a 2,000 molecular weight propylene oxide polyether polyol having a nominal functionality of 2 (*VORANOL 9120 is a trade designation of The Dow Chemical Company).
2. Dipropylene glycol .
3. D-70* is a calcium carbonate filler (*D-70 is a trade designation of Georgia Marble).
POLYURETHANE BACKED TEXTILES HAVING IMPROVED FLAME 2~7~21.
RETARDANCY AND METHOD FOR THE PREPARATION THEREOF
The present invention relates to polyurethane backed textiles having improved flame retardancy. The present invention particularly relates to polyurethane backed carpets and carpet tiles having improved flame retardancy.
It is known in the art of preparing textile articles to use polyurethanes in various forms. For example, U.S. Patent No. 4,296,159 to Jenkines, et al. discloses preparing a tufted or woven article having a unitary backing prepared by applying a polyurethane forming composition to the underside of the tufted or woven article. A different form of polyurethane backing is disclosed in U.S. Patent No. 5,102,714 to Mobley, et al. wherein the polyurethane backing is a tacky adhesive. It is also known to use polyurethane foam as a cushioning textile backing.
But preparing polyurethane backed textile articles is not always trouble free. Preparing new articles can be particularly troubling. For example, U.S. Patent No. 4,689,256 discloses that preparing a carpet from nylon and poly vinyl chloride, each of which alone are ~low smoke~
materials can result in a carpet which is not low smoke. As in this example, using new materials to prepare polyurethane backed textiles to improve one property of the backed textile can result in another property being degraded. When this occurs, it is sometimes necessary to modify formulations to accommodate the new materials and yet maintain desirable physical properties.
In order to meet contingencies such as the use of new textile materials having high smoke values or just to comply with increasingly stringent fire retardant requirements, it is desirable in the art to prepare flame retardant polyurethane backed textile articles. It is also desirable in the art to prepare polyurethane backed textile articles with flame retardant polyurethane backings. And it is particularly desirable in the art that the flame retardant polyurethane backings be useful in textile applications having rigorous physical property requirements such as carpet and carpet tiles.
41,443-F
X~278~1.
In one aspect, the present invention is a polyurethane backed textile having improved flame retardancy comprising (A) a top-most textile facing layer, (B) a polymeric textile backing prepared from a polyurethane formulation including (lj a polyisocyanate, (2) a polyol, (3) a catalyst, (4) a flame retardant selected from the group consisting of ZnC03, MgCO3 and mixtures thereof and, optionally, (5) a blowing agent.
In another aspect, the present invention is a polyurethane textile backing comprising a polyurethane prepared from a formulation including (1) a polyisocyanate, (2) a polyol, (3) a catalyst, (4) a flame retardant selected from the group consisting of ZnC03, MgC03 and mixtures thereof and, optionally, (5) a blowing agent.
Another aspect of the present invention is a method for preparing a polyurethane backed textile having improved flame retardancy comprising applying to a textile facing layer one or more polyurethane backing layers prepared from a formulation including (1) a polyisocyanate, (2) a polyol, (3) a catalyst, (4) a flame retardant selected from the group consisting of ZnCO3, MgCO3 and mixtures thereof and, optionally, (5)a blowing agent.
In yet another aspect, the present invention is a polyurethane formulation useful for preparing a polyurethane backed textile having improved flame retardancy comprising (1) a polyisocyanate, (2) a polyol, (3) a catalyst, (4) a flame retardant selected from the group consisting of ZnCO3, MgCO3 and mixtures thereof and, optionally, (5) a blowing agent.
In one embodiment, the present invention is a polyurethane backed textile having improved flame retardancy. Preferably the polyurethane backed textile is a carpet or carpet tile. The polyurethane layer can take several forms. In one form, it is a cellular polyurethane foam which acts as an integral pad. This application of a polyurethane layer in a carpet is disclosed in, for example, U. S. Patent No. 4,853,054, to Turner, et al., which is incorporated herein by reference, and U.S. Patent No.
5,104,693 to Jenkines, et al., also incorporated herein by reference.
-` 2~27821.
In another form, the polyurethane layer of the present invention is a microcellular polyurethane textile backing which, when applied to the primary textile backing, can provide dimensional stability and serve to anchor the textile tufts, also known as the face, to the textile primary backing. The microcellular polyurethane of the present invention is useful in the form of a layer adherent to the primary or secondary textile backing serving to provide a suitable surface for the application of a polyurethane foam wherein it is known as a precoat. This application of a polyurethane backing layer in a carpet is disclosed in, for example, V.S. Patent No.
4,696,849 to Mobley, et al., which is incorporated herein by reference.
In yet another form, the polyurethane layer is a removable adhesive such as that which is disclosed in U.S. Patent No. 5,102,714, also to Mobley, et al, which is also incorporated herein by reference. In this form the polyurethane adhesive can function to anchor floor coverings or to anchor protective coverings such as a painter's drop cloth in place.
However, the removable character of the adhesive can allow the textile to be removed easily.
When the polyurethane is in the form of a foamed polyurethane pad, it can be prepared from a formulation including: (l) a polyisocyanate, (2) a polyol, (3) a catalyst, and (4) a flame retardant, and additionally including such materials as a filler; a catalyst, a surfactant, pigments, molecular sieves, other flame retardants, antimicrobial materials and blowing agents. The foamed polyurethane layer functions as an integral foam pad thereby eliminating the need for a separate foam pad. The formulation can be any foam formulation known to those skilled in the art of preparing polyurethane foam for carpet applications to be useful. For example, the formulation can be one of those disclosed U.S. Patent No. 4,853,05~ to Turner, et al. additionally containing the flame retardant of the present invention.
In the '054 patent to Turner, it is disclosed that the polyisocyanate can be toluene diisocyanate or a prepolymer thereof with glycerine or -trimethylolpropane or mixture thereof with an alkylene glycol or glycol ether, the prepolymer having an average functionality of 2.03 to 2.2.
Preferably, the polyisocyanate is a mixture of a liquid methylene - . . : , - : -L ' . , ~ "
41,443-F
~ 21Z7821 diphenyldiisocyanate (MDI) having an equivalent weight of 130 to 200 and polyphenyl polymethylene polyisocyanate (also known as polymeric MDI and hereinafter PMDI), the mixture having an average functionality of 2.03 to 2.2.
The polyol component of the foam formulation can be any polyol or polyol mixture which can be used to prepare a foam which can withstand the rigorous physical property and handling requirements of foams used in carpet applications. The foamed polyurethane polyol component of a Turner '054 type foam is preferably a polyol mixture h~ving as one part of the mixture a polyol based on a C3-Cg alkylene oxide, which has an equivalent weight of 1000 to 5000, and an internal poly(ethylene oxide) block or a terminal ethylene oxide cap constituting 15 to 30 percent of the weight of the polyol, or mixture of such polyols wherein the polyol or mixture thereof has an average functionality of 1.8 to 2.2. The other portion of the polyol mixture is preferably a minor amount of a low equivalent weight compound having 2 active hydrogen containing groups per molecule.
Another example of the foamed form of the present invention is a polyurethane foam prepared from a formulation such as those disclosed by U.S. Patent No. 5,104,693 to Jenkines additionally including the flame retardant of the present invention. In formulations of this type, the polyol component can be at least one isocyanate reactive material having an average equivalent weight of 1,000 to 5,000. The polyisocyanate can be any polyisocyanate in an amount to provide an isocyanate index of 90 to 130, wherein at least 30 percent by weight of the polyisocyanate is a soft segment prepolymer which is the reaction product of a stoichiometric excess of MDI or a MDI derivative and an isocyanate reactive organic polymer having an equivalent weight from 500 to 5,000, the prepolymer having an isocyanate group content of 10 to 30 percent by weight.
With either type of foam, the blowing agent is preferably air, however, other gasses, such as carbon dioxide, and nitrogen can be used.
It is preferably injected into the polymer by frothing. The fillers can be aluminum oxide trihydrate (alumina), calcium carbonate, barium sulfate or mixtures thereof.
.:
... - ~ ; . ::
:. . . . . :, . , 41,443-F
21~7821.
When the polyurethane is in the form of a microcellular polyurethane, it can be prepared from a formulation including: (1) a polyisocyanate, (2) a polyol, (3) a catalyst and (4~ a flame retardant, and additionally including such materials as a filler, a surfactant, pigments, molecular sieves, other flame retardants, antimicrobial materials and blowing agents.
Any formulation known to those skilled in the art of preparing polyurethanes for carpet applications can be used to prepare the polymers of the present invention except that they will additionally have a flame retardant of the present invention. Polymers of this type are generally applied to textiles as an unfoamed, non cellular layer which functions to stiffen a textile and to adhere the tufts of the textile to the primary backing. Particularly when the polyurethane layer is a precoat, the polyisocyanate can be, for example, MDI, an MVI prepolymer or a modified MDI material.
For example, the polyol component of a microcellular polyurethane can include a first polyol which comprises a relatively high equivalent weight polyol containing an average of 1.4-1.95 hydroxyl groups per molecule, of which hydroxyl groups at least 30 percent are primary hydroxyls or a mixture thereof with at least one additional relatively high equivalent weight polyol containing at least 2.05 hydroxyl groups per molecule, of -which at least 30 percent are primary hydroxyls. Additionally the polyol component can include a relatively low equivalent weight compound having 2 active hydrogen containing moieties per molecule. Desirably, the polyol component has an average functionality of 0.97 - 2.03. The polyurethane is preferably prepared such that the polyisocyanate and the polyol component has an isocyanate index of 85-125.
When the polyurethane polymer of the present invention is prepared in ~ ~
the form of a removable adhesive, it can be prepared from a formulation - ~-including: (l) a polyisocyanate; (2) a polyol; (3) a catalyst and (4) a flame retardant. The formulation is applied in the form of a tacky adhesive, preferably to a precoat layer. The polyisocyanate can have an average functionality of 2.2 or less.
The polyol component of the removable adhesive can be a complex admixture. It can have, as a first component, a mixture of a monoalcohol : :~ ,.,; .~.-: ., : - .
41,443-F
21;;~7~32~.
and a polyether or polyester polyol, the mixture having an average actual funct-onality of 2.2 or less, an equivalent weight of at least 50V and containing from 10 to 70 mole percent monoalcohol. As a second component, the polyol can have less than 10 weight percent, based on the weight of the first polyol component of a compound or mixture of compounds having at least two active hydrogen containing groups per molecule and an equivalent weight from 30 to 500.
The polyurethane polymer adhesive, when prepared by the method of U.S. Patent 5,102,70q to Mobley, is prepared with no more than 0.1 percent water present. The polyurethane adhesive is prepared at an isocyanate index of from 85 to 115. The adhesive can contain other additives such as catalysts, and fillers. However, preferably, it contains no blowing agent.
If a blowing agent is used, the blowing agent is selected such that the proscription of 0.1 percent water is not exceeded.
Polyurethane catalysts can be suitably used with all forms of the present invention. The catalyst is preferably incorporated into the formulation in an amount suitable to increase the rate of reaction between the polyisocyanate and the polyol components of the present invention.
Although a wide variety of materials is known to be useful for this purpose, the most widely used and preferred catalysts are the tertiary amine catalysts and the organotin catalysts.
Examples of the tertiary amine catalysts include, for example, triethylenediamine, N-methyl morpholine, N-ethyl morpholine, diethyl ethanolamine, N-coco morpholine, l-methyl-4-dimethylaminoethyl piperazine, 3-methoxy-N-dimethylpropylamine, N,N-diethyl-3-diethyl aminopropylamine, :
and dimethylbenzyl amine. Tertiary amine catalysts are advantageously ~;
employed in an amount from 0.01 to 2 percent by weight of the polyol formulation.
Examples of organotin catalysts include dimethyltin dilaurate, dibutyltin dilaurate, dioctyltin dilaurate, and stannous octoate. Other examples of effective catalysts include those taught in, for example, U.S.
Patent No. 2,846,408. Preferably the organotin catalyst is employed in an amount from 0.001 to 0.5 percent by weight of the polyol formulation.
41,443-F
Z~7821 The flame retardants of the present invention are selected from the group consisting of ZnCO3, MgCO3 and mixtures thereof. Preferably the agent is ZnCO3. Either the ZnCO3 or the MgCO3 can include other materials.
For example, MgCO3 commonly includes minor amounts of Mg(OH)2 and is often hydrated with the pentahydrate often predominating. Where other materials are present in the ZnCO3 or MgCO3, preferably they are materials which are low in iron and chloride salts as these species can interfere with urethane reactions. The ZnCO3 and MgCO3 materials are solids and have particle sizes sufficiently large to facilitate handling yet not so large as to make it too difficult to admix them with the polyurethane backing formulation.
Preferably, the particle size distribution of the ZnCO3 and MgCO3 is such that little dust is generated during handling but 99 percent will pass through a 325 mesh screen.
Use of the flame retardants of the present invention is advantageous for several reasons. Firstly, ZnCO3 and MgCO3 decompose at advantageous temperature. ZnCO3 decomposes at 300C to produce CO2 which is believed to be one mechanism whereby it retards flammability. MgCO3 similarly decomposes at 800C. However MgCO3 dehydrates at 230C and Mg(oH12 decomposes to produce water at 350C. Polyurethane textiles can be subject to temperatures of up to 160C during processing. Polyurethane backings such as those used with the present invention begin to decompose at 180C.
A standard test for textiles, particularly for carpets and carpet tiles is ASTM E 6~8-9la UStandard Test Method for Critical Radiant Flux of Floor-Covering Systems Using a Radiant Heat Energy Source~. During this test, the textile is exposed to temperatures of 600C and greater. The 230C
temperature where the flame retardants of the present invention can begin decomposition is greater than the processing temperature of the textile, so that the retardant does not decompose releasing CO2 prematurely. These temperatures are near the polyurethane decomposition and testing temperatures so that the flammability retarding agents can decompose in time to improve flammability performance of the polyurethane backed textiles. -~
Another reason that the flame retardants of the present invention are advantageously used with polyurethane backed textiles is that as well as 41,443-F
-`` 21;~7821 being very economical, they can have minimal effect upon the curing times of polyurethane formulations. The retardants will generally neither substantially accelerate nor substantially slow polyurethane cure. This is particularly important in polyurethane foam backed textile production. In commercial carpet manufacturing operations, production equipment is often sized based upon the cure time of the foam. For example, if it is desirable to xun the textile through the foam backing application device at a rate of x feet per second, and it is known that the foam will cure in y seconds, then there needs to be x times y feet of carpet between the point of foam application and the point at which the foam must be cured. If a flame retardant were to significantly affect the cure time of a polyurethane, it could result in undesirable quick cures wherein the polymer might delaminate from the textile, or in a too slow cure wherein the foam layer might be deformed or be squeezed out of the carpet and damage the carpet facing.
The flame retardants of the present invention can be used alone, but in some applications, they can also be used with other flame retardants.
For example, the flame retardants can be used with materials such as -alumina. The primary reason that this can be desirable is that it allows for minimal reformulation of the polyurethane backings. In a polyurethane backed textile application which was adequate with only alumina, a change in textile to one with poorer flammability can require that the polyurethane backing be modified to supply additional flame retardancy to compensate. Since the present invention can be used in conjunction with alumina, a minor change to the formulation, adding an effective amount of the retardants of the present invention, can be easily made.
The amount of flame retardants of the present invention used will vary with the polyurethane formulations and choice of textiles for the particular polyurethane backed textile application. However, generally, where ZnC03 and MgC03 are used as sole flame retardants, they are used at from 5 to 500 parts (by weight) per 100 parts of active hydrogen containing materials. Preferably, they are used at from 10 to 300 parts ~by weight) per 100 parts of active hydrogen containing materials. And more preferably, they are used at from 50 to 225 parts (by weight) per 100 parts of active hydrogen containing materials. Where they are used in 41,443-F
Z~7~32~.
conjunction with other flame retardants, they are used in an amount effective to produce a polyurethane backed textile having Class I
flammability which is one having a critical radiant flux greater than or equal to 0.4S watts/cm2. While this level of fire retardant will vary with the textile and amount of flame retardant already present, it will preferably be from 1 to 250, more preferably from 5 to 100, and even more preferably from 5 to 50 parts (by weight) per 100 parts of active hydrogen containing materials.
Alth~ugh they can be admixed with polyisocyanates, the flame retardants of the present invention are desirably added to the non-polyisocyanate component of the formulations of the present invention. For example, when preparing a foam backed textile, the individual components of the polyurethane formulation are admixed and added as a layer of preferably uniform thickness on the textile. ~hile the flame retardants of the present invention desirably do not substantially negatively affect the physically properties of the polymers prepared therewith, they can increase the viscosity of the polymer formulations in which they are included.
Often, this viscosity increase does not adversely affect handling, but where it does, a surfactant can be used to alleviate the problem. Any surfactant which does not adversely affect the polymer formulation can be used for this purpose. Preferably the surfactant is an anionic/nonionic surfactant. Care should be taken to use no more surfactant than is necessary to avoid degrading polymer physical properties.
It is often preferable to premix all of the components except the polyisocyanate (and the blowing agent when a gas is used) to form a ~B~
component. The polyisocyanate and the B component are admixed and then the gas is blended in using, for example, an OAKES FROTHER* (*OAKES FROTHER is a trade designation of the E.T. Oakes Corporation). The composition is preferably applied prior to any significant level of curing using equipment such as a doctor knife, air knife, or extruder to apply and gauge the layer. In the alternative, the forming polyurethane can be applied by forming it into a layer using a moving belt, allowing it to partially cure, and then marrying it to the textile using equipment such as a double belt laminator. After application of the foam layer, the polyurethane is cured 41,443-F
-21;~82~.
by applying heat by means of an infrared oven, open flame forced draft convection impingement oven, heated plates or the like.
Textiles useful with the present invention can include broadloom carpet, automotive carpet, fabrics for automotive trim and automotive trunk liners. In addition, the textiles useful with the present invention can include synthetic playing surfaces, woven polymeric scrim, nonwoven polymeric scrim, wall coverings, sheet polymers, and furniture covers. One preferred embodiment of the present invention is carpet tile prepared by incorporating the flame retardants of the present invention into a carpet tile production process such as that disclosed in U.S. Patent No. ~,657,790 to Wing, et al. The '790 Wing, et al. patent is incorporated herein by ~
reference. :
Non-textile materials commonly used to prepare textiles can also be used with the present invention. For example, latex precoats and adhesives can be used with the present invention to prepare carpets. Other adhesives, and coatings can be used with the present invention as long as they do not substantially interfere with the flame retardant character of the components of the carpets of the present invention.
In addition to carpets, the present invention can be used to prepare furniture covers, and wall coverings. Useful applications of the present invention include unusual applications such as a drop cloth having one side coated with a removable adhesive.
The following examples are provided to illustrate the present invention. The examples are not intended to limit the scope of the present invention and they should not be so interpreted. Amounts are in weight parts or weight percentages unless otherwise indicated.
E~ :;
A polyurethane backed textile was prepared with a precoat and a foam backing, the formulations for which are disclosed in the Tables 1 and 2 below, according to the following steps:
41,443-F
21;;~7~321.
a. A Precoat polyol/filler compound was prepared according to the formulation below by placing the indicated amount of polyol(s) in a suitably sized container;
b. The indicated amount of D-~0* calcium carbonate filler (*D-70 was a trade designation of Georgia Marble) was added to the polyol while under high sheer agitation;
c. The indicated amount of H-36U* hydrated alumina (*H-36U is a trade designation of Solem Industries) was added to the polyol while under agitation;
d. The indicated amount of Zinc Carbonate (Mineral Research and Development Corp.) or MagCarb H~ (*MagCarb H is a trade designation of Marine Magnesium Company) was added to the polyol while under agitation;
e. High shear agitation of the polyol/filler compound was continued until a temperature of 50C was reached in order to thoroughly disperse and break up agglomerate filler particles;
f. The polyol/filler compound was cooled to 20C;
g. The indicated amount of the isocyanate component was added to the polyol/filler compound and the two thoroughly mixed;
h. The indicated amount of polyurethane catalyst was added to the reaction mixture with agitation;
i. The reaction mixture was then spread onto the back of the textile by means of a knife coating process and cured by means of heated platens and/or an oven.
j. A foam polyol/filler compound was prepared according to the formulation below and reacted with the isocyanate component using the same procedures in steps a-h, above, except no metal carbonate was used.
k. Air was metered into the reaction mixture which was frothed to a foam of approximately 288 kg/M3 density.
1. The frothed foam reaction mixture was applied to the textile according to step I above.
The textile was tested for radiant heat flux and the results are displayed in Table 3 below. -~:.
41,443-F
21~7~
A polyurethane backed textile was prepared and tested substantially identically to Example 1 except that the formulation components indicated in Tables 1 and 2 were used. Testing results are displayed in Table 3 below.
COMPARATIVE ~XAMPLE 3 A polyurethane backed textile was prepared and tested substantially identically to Example 1 except that the formulation components indicated in Tables 1 and 2 were used. Testing results are displayed in Table 3 below.
. . ... .. , .. ~................. .
I
lDPG2 15 15 15 ¦D-703 61.5 61.5 70 ¦H-36U4 135 135 135 ¦ ZnCO~5 8.5 __ __ ~ __ 10 __ ~ 1.0 0.5 __ ¦Catalyst8 0.2 0.2 0.2 *Not an Example of the present invention.
1. VORANOL 9120* is a 2,000 molecular weight propylene oxide polyether polyol having a nominal functionality of 2 (*VORANOL 9120 is a trade designation of The Dow Chemical Company).
2. Dipropylene glycol .
3. D-70* is a calcium carbonate filler (*D-70 is a trade designation of Georgia Marble).
4. H-36U* is a hydrated alumina filler (*H-36U is a trade designation of Solem Industries).
5. Zinc Carbonate is available from Mineral Research and Development Corp.
41,44~-F
21~321 6. MagCarb H* iS an admixture having an approximate formulation of (MgCO3)4 Mg(OH)2 5H2O (~MagCarb H iS a trade de~ignation of Marine Magnesium Company).
41,44~-F
21~321 6. MagCarb H* iS an admixture having an approximate formulation of (MgCO3)4 Mg(OH)2 5H2O (~MagCarb H iS a trade de~ignation of Marine Magnesium Company).
7. Code 5027* is a anionic/nonionic surfactant (*Code 5027 is a trade designation of Fibro Chem, Inc.).
8. Dibutyl tin maleate and ethylene diamine dispersed in a copolymer polyol.
9. Is a polyisocyanate admixture of PMDI and MDI prepolymer having an NCO
percent of 27.6 and an isocyanate equivalent weight of 152.2.
. _ ¦DEG2 10 10 10 1 H-36U4 50 50 50 ¦
L-54405 0.38 0.38 0.38 l Catalyst6 0.15 0.15 0.15 -¦
PMDI7 40.7 40.7 40.7 *Not an Example of the present invention.
1. VORANOL 9741* is a 4,800 molecular weight ethylene oxide capped propylene oxide polyether polyol having a nominal functionality of 3 (*VORANOL 9741 is a trade designation of The Dow Chemical Company). -2. Diethylene glycol 3. D-70* is a calcium carbonate filler (*D-70 is a trade designation of -Georgia Marble).
4. H-36U* is a hydrated alumina filler (*H-36U is a trade designation of Solem Industries).
5. L-5440* is a silicone surfactant (*L-5440 is a trade designation of Union Carbide Corp.). -:~
6. Dioctyl tin diisooctylmercaptoacetate.
7. Is a polyisocyanate admixture of PMDI and an MDI prepolymer having an NCO percent of 27.6 and an isocyanate equivalent weight of 152.2.
~; ~ . ~ ........ ..
: : : ", ~
41, 443-F
r~ 2127821 = r~Mn] 1 E :~LC Z _ ,3,~
Critical .
Radiant 0.70 0.68 0.39 (w/ cnl2 ~ . .. ,.. , .. . .
*Not an Example of the present invention.
percent of 27.6 and an isocyanate equivalent weight of 152.2.
. _ ¦DEG2 10 10 10 1 H-36U4 50 50 50 ¦
L-54405 0.38 0.38 0.38 l Catalyst6 0.15 0.15 0.15 -¦
PMDI7 40.7 40.7 40.7 *Not an Example of the present invention.
1. VORANOL 9741* is a 4,800 molecular weight ethylene oxide capped propylene oxide polyether polyol having a nominal functionality of 3 (*VORANOL 9741 is a trade designation of The Dow Chemical Company). -2. Diethylene glycol 3. D-70* is a calcium carbonate filler (*D-70 is a trade designation of -Georgia Marble).
4. H-36U* is a hydrated alumina filler (*H-36U is a trade designation of Solem Industries).
5. L-5440* is a silicone surfactant (*L-5440 is a trade designation of Union Carbide Corp.). -:~
6. Dioctyl tin diisooctylmercaptoacetate.
7. Is a polyisocyanate admixture of PMDI and an MDI prepolymer having an NCO percent of 27.6 and an isocyanate equivalent weight of 152.2.
~; ~ . ~ ........ ..
: : : ", ~
41, 443-F
r~ 2127821 = r~Mn] 1 E :~LC Z _ ,3,~
Critical .
Radiant 0.70 0.68 0.39 (w/ cnl2 ~ . .. ,.. , .. . .
*Not an Example of the present invention.
Claims (17)
1. A polyurethane backed textile having improved flame retardancy comprising (A) a top-most textile facing layer, and (B) a polymeric textile backing prepared from a polyurethane formulation including:
(1) a polyisocyanate, (2) a polyol, (3) a catalyst, (4) a flame retardant selected from the group consisting of ZnCO3, MgCO3 and mixtures thereof and, optionally, (5) a blowing agent.
(1) a polyisocyanate, (2) a polyol, (3) a catalyst, (4) a flame retardant selected from the group consisting of ZnCO3, MgCO3 and mixtures thereof and, optionally, (5) a blowing agent.
2. The polyurethane backed textile of Claim 1 wherein the polyurethane backed textile is a carpet or carpet tile.
3. The carpet or carpet tile of Claim 2 wherein the backing is a polyurethane precoat, a foamed polyurethane integral pad or a removable polyurethane adhesive.
4. The carpet or carpet tile of Claim 3 wherein the backing is a foamed polyurethane pad and the blowing agent used is air.
5. The carpet or carpet tile of Claim 2 wherein the carpet or carpet tile has a critical radiant flux of greater than or equal to 0.45 watts/cm2.
6. A polyurethane textile backing comprising a polyurethane prepared from a formulation including:
(1) a polyisocyanate, (2) a polyol, (3) a catalyst, (4) a flame retardant selected from the group consisting of ZnCO3, MgCO3 and mixtures thereof and, optionally, (5) a blowing agent.
(1) a polyisocyanate, (2) a polyol, (3) a catalyst, (4) a flame retardant selected from the group consisting of ZnCO3, MgCO3 and mixtures thereof and, optionally, (5) a blowing agent.
7. The polyurethane textile backing of Claim 6 wherein the polyurethane formulation additionally includes one or more materials selected from the group consisting of a filler, a surfactant, pigments, molecular sieves, other flame retardants, and antimicrobial materials.
8. A method for preparing a polyurethane backed textile having improved flame retardancy comprising applying to a textile facing layer one or more polyurethane backing layers prepared from a formulation including:
(1) a polyisocyanate, (2) a polyol, (3) a catalyst, (4) a flame retardant selected from the group consisting of ZnCO3, MgCO3 and mixtures thereof and, optionally, (5) a blowing agent.
(1) a polyisocyanate, (2) a polyol, (3) a catalyst, (4) a flame retardant selected from the group consisting of ZnCO3, MgCO3 and mixtures thereof and, optionally, (5) a blowing agent.
9. The method of Claim 8 wherein the polyurethane backing is applied as a polyurethane precoat, a foamed polyurethane integral pad or a removable polyurethane adhesive.
10. The method of Claim 8 wherein the blowing agent is air.
11. The method of Claim 10 wherein the blowing agent is incorporated into the polyurethane formulation by frothing.
12. The method of Claim 8 wherein the all of the polyurethane formulation components except the polyisocyanate are first admixed together to form a B side.
13. The method of Claim 8 additionally comprising using a surfactant to reduce the B side viscosity.
14. A polyurethane formulation useful for preparing a polyurethane backed textile having improved flame retardancy comprising:
(1) a polyisocyanate, (2) a polyol, (3) a catalyst, (4) a flame retardant selected from the group consisting of ZnCO3, MgCO3 and mixtures thereof and, optionally, (5) a blowing agent.
(1) a polyisocyanate, (2) a polyol, (3) a catalyst, (4) a flame retardant selected from the group consisting of ZnCO3, MgCO3 and mixtures thereof and, optionally, (5) a blowing agent.
15. The polyurethane formulation of Claim 30 wherein the polyisocyanate is methylene diphenyldiisocyanate, polymethylene polyphenyl polyisocyanate, a methylene diphenyldiisocyanate prepolymer, a modified methylene diphenyldiisocyanate or mixtures thereof.
16. The polyurethane formulation of Claim 14 wherein the polyol is a base polyol.
17. The polyurethane formulation of Claim 14 wherein the formulation additionally includes one or more materials selected from the group consisting of a filler, a surfactant, pigments, molecular sieves, other flame retardants, and antimicrobial materials.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US9110293A | 1993-07-13 | 1993-07-13 | |
| US08/091,102 | 1993-07-13 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2127821A1 true CA2127821A1 (en) | 1995-01-14 |
Family
ID=22226132
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2127821 Abandoned CA2127821A1 (en) | 1993-07-13 | 1994-07-12 | Polyurethane backed textiles having improved flame retardancy and method for the preparation thereof |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2127821A1 (en) |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US9670338B2 (en) | 2014-11-18 | 2017-06-06 | International Business Machines Corporation | Polymer comprising mesoporous flame retardant |
| CN106905686A (en) * | 2015-12-22 | 2017-06-30 | 万华化学集团股份有限公司 | A kind of halogen-free fire retardation thermoplastic polyurethane elastic composition and its product and halogen-free flame retardants bag |
-
1994
- 1994-07-12 CA CA 2127821 patent/CA2127821A1/en not_active Abandoned
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US9670338B2 (en) | 2014-11-18 | 2017-06-06 | International Business Machines Corporation | Polymer comprising mesoporous flame retardant |
| US9732205B2 (en) | 2014-11-18 | 2017-08-15 | International Business Machines Corporation | Polymer comprising mesoporous flame retardant |
| CN106905686A (en) * | 2015-12-22 | 2017-06-30 | 万华化学集团股份有限公司 | A kind of halogen-free fire retardation thermoplastic polyurethane elastic composition and its product and halogen-free flame retardants bag |
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