CA2264947C - Rug and carpet underlays substantially impervious to liquids - Google Patents

Abstract

A carpet underlay comprising a fibrous nonwoven substrate composed of natura l or synthetic fibers having in or on it a repellent finish which makes said substrate substantially impervious to liquids, and a carpet having an underlay substantially impervious to liquids affixed to the carpet back rendering said carpet substantially impervious to liquids are disclosed.

Description

l0l5202530W0 98/ 12375CA 02264947 1999-03-05PCT/US96/ 14935IIILERUG AND CARPET UNDERLAYS SUBSTANTIALLYIMPERVIOUS TO LIQUIDSBELAIED_AEELl§AIlQN§This is a Continuation-in—Part of Application08/424,754 filed April 18, 1995.ElELQ_QE_IHE_lN¥ENIlQNThis invention relates to novel rug and carpetunderlays that are substantially impervious to liquids.EACKQRQHND_QE_IHE_lNMENIlQNArea rugs, for instance Oriental rugs, arecommonly laid over wall—to—wall carpeting or othercarpets, or over decorative wood flooring, to achievedesired esthetic effects. When such rugs are laid overcarpets the rug may tend to slip or move in one directiondue to the alternating compression and release of thefibers in the underlying carpet caused by normal traffic.Thus the rug and furnishings placed on it move from theirdesired position. Additionally the rug may becomecreased or wrinkled instead of flat. Such rugs may alsoslip on the polished surfaces of a decorative wood floor.Such movements detract from the esthetics of the room andmay cause slipping and tripping risks.Rug underlays have been proposed as a solutionto such problems, for instance the rug underlaysdisclosed by Mussallem in U.S. Patent. 4,504,538 and U.S.Patent. 4,985,279. The underlay typically consists of alight—weight nonwoven mat, comprised of filamentarySUBSTITUTE SHEET (RULE 26)1015202530W0 98/12375CA 02264947 1999-03-05PCT/‘U S96/ 149352fibers, needle—punched into a coarse thin mat.Needle—punching is commonly used to compress fibrous mats into afelt—like material. Mussallem discloses that any naturalor synthetic fiber may be used in the underlay, but thatsynthetic fibers such as polyolefin, nylon, polyester,acrylic polymers, etc., are preferred. Needle—punchingcan also be used to embed a woven mesh in such a nonwovenmat to strengthen and stiffen the mat. The needle-punched mat is then treated with an emulsion adhesive,such as a synthetic rubber latex, on at least one sideand preferably both sides. The adhesive is then cured.The adhesive properties of the underlay effectivelysecures it to the underlying rug or underlying surfaceand prevents movement. The underlay adhesive coating isselected to provide both the necessary adhesive strengthto prevent slippage or movement and a sufficiently lowpeel strength so that the rug may be easily andreversibly removed from the underlying surface forcleaning or other purposes.If water-based or oil—based liquids are spilledon a rug or carpet placed over a carpet or decorativewood floor, the underlying material may become stainedand deteriorate. Water—based spills may also transferdyes from the rug to the underlying material. Otherwater—based spills may contain colored materials, e.g.,colored drinks or coffee, or contain other undesirablecomponents which can soak through to the underlyingmaterial.Oil—based liquids, e.g.,mineral oil, babyoil, kerosene, or alcohol, may penetrate to theunderlying material with potential undesirable effects.Cleaning aids applied to the rug may similarly passthrough the rug and adversely affect the underlyingSUBSTITUTE SHEET (RULE 26) 1015202530CA 02264947 1999-03-05W0 98/ 12375PCT/U S96/ 149353material. Oil-in-water emulsions,e.g., milk or lotions,and water—in—oil emulsions, e.g.,examples of spills requiring a barrier substantially anddairy spreads, aresimultaneously impervious to both water—based and oil-based spills.Broadloom carpeting, typically used for fittedor wal1—to-wall carpeting, may be laid over substrateswhere the appearance of the substrate is to be preserved.Broadloom carpeting is typically constructed with aprimary backing to which the carpet tufts are attached bymeans of a latex adhesive. Such carpeting with a latexadhesive and single backing is termed "unitary"carpeting. Most broadloom carpeting also has a secondarybacking of an open weave fabric (weave spacing about 0.6— 0.9 cm (0.25 — 0.375 inches), impregnated with thelatex, which provides dimensional stability and afinished appearance to the back of the carpet. While theopen weave of the secondary backing fabric itself cannotbe made impervious to liquids, U.S. Patent 5,348,785discloses a method to render the latex~impregnatedsecondary backing of a carpet substantially impervious toliquids by treatment with repellent compositions, such asfluorochemicals, silicone—based compositions, oils,waxes, and/or hydrophobic acrylate resins. Typically areaand Oriental rugs are not treated by such processes andare therefore permeable to liquidsSimilarly, carpets used for fitted or wall~to—wall carpeting may be laid over substrates where theappearance of the substrate is to be preserved. Whilesuch carpets are not prone to the movement or slippinghazards of rugs, staining of the substrate can resultfrom spills. Such staining is particularly insidiousSUBSTITUTE SHEET (RULE 25)l0l5202530CA 02264947 1999-03-05W0 98/ 12375PCT/U S96/ 149354since detection and prevention of the staining followinga spill is typically impractical with large or fittedcarpets. A spill on broadloom carpeting often puddles onthe padding or subflooring where it can not be removed bycleaning. This spill then accelerates the growth ofmold, mildew and odors. By allowing spills to be morethoroughly cleaned, a water impermeable backing reducesthe growth of mold and mildews which cause odors.The prior art also describes water—impermeablecarpeting constructed using impervious backings such asthose based on poly(vinyl chloride) and polyurethane.However, such backings are expensive and createmanufacturing difficultiesIt is desirable that a treatment be applied tothe underlay which would create a substantiallyimpervious barrier to liquids between the rug or carpetand the underlying material. Such a treatment must notinterfere with the adhesive surfaces of the underlay, andideally would be readily incorporated into themanufacturing process for the underlay. It is alsodesirable to have a carpet backing which is substantiallyimprevious to liquids.The present invention providessuch an underlay and carpet having such a backing.SUMMARY OF THE INVENTIONThis invention relates to rug or carpetunderlays which are substantially impervious to liquids,such as oil and water, and methods of preparing the same.The underlays are also oil—repellent and water—repellent.The present invention comprises a tufted pilecarpet comprising: a) a primary backing having a surfacetufted with pile yarns and an underside to which a waterSUBSTITUTE SHEET (RULE 26)1015202530W0 98/12375CA 02264947 1999-03-05PCT/US96/149355permeable latex has been applied; b)an optional waterpermeable secondary backing having a surface and anunderside, wherein the surface of the secondary backingis adhered to the underside of the primary backing; andc) an underlay having a surface and an underside,wherein the surface of said underlay is affixed with anadhesive to the underside of either the secondary backingor the primary backing, and said underlay comprises anonlatex fabric, said fabric being substantiallyimpervious to liquids, wherein said carpet issubstantially impervious to liquids.DEIAlLED_DESQRIEIlQM_Q£;IHE_lNMENIlQHThis invention provides underlays and carpetbacking with one or more adhesive surfaces havingrepellent finishes, whereby the underlays and backing aresubstantially impervious to oil—based and/or water—basedliquids. The process of this invention for making theunderlay or backing liquid impervious is readilyincorporated into the manufacturing processes forunderlays.The term "repellent finish", as used herein,means a composition containing oil— and/or water-repellent chemicals dispersed, dissolved, or suspended ina solvent such as water or alcohol which will form afilm—like barrier on or in the underlay to render thesame substantially impervious to liquids.The repellentfinish optionally contains surfactants, foaming agents,and other additives. In addition the repellent finishcan contain a mixture of different repellents. Suitablerepellents for use in the repellent finish are selectedfrom the group consisting of fluorochemicals, siliconecompositions, wax emulsions, naturally—occurring oils,SUBSTITUTE SHEET (RULE 26)M ...........-.................. .. ._.1015202530CA 02264947 1999-03-05“'0 93’ 12375 PCT/US96l1493S6hydrophobic alkylacrylate resins, and hydrophobicalkylmethacrylates resins.By the term "liquids" is meant oil—based and/orwater—based liquids.By the phrase "substantially impervious to oil-based liquids" is meant that, in addition to beingsubstantially impervious to water, non—aqueous liquids(e.g., mineral oil or alcohol) will not substantiallypenetrate through the underlay in accordance with theTest Method 1 described below.By the phrase "substantially impervious towater" is meant that water or aqueous solutions oraqueous suspensions (e.g., coffee, wine, soda, fruitjuices, or urine) will not substantially penetratethrough the underlay in accordance with the Test Method 2described below.By the term “substantially impervious toliquids” is meant that 20 ml of liquid poured on theunderlay from a height of 6 cm makes no wet spot after 30minutes, or a wet spot having a diameter of no more than2.54 cm, on a paper towel located directly beneath thelocation of the underlay on which the liquid has beenpoured.By the term “water permeable” is meant thatwhen the above test is performed a wet spot having adiameter of greater than 2.54 cm is obtained.Generally the mat for the underlay of thisinvention is prepared by conventional techniques. Theunderlay typically consists of a light-weight nonwovenmat, comprised of filamentary fibers, and is needle-punched into a coarse thin mat. Any natural or syntheticfiber is used to make the underlay, but fibers such asSUBSTITUTE SHEET (RULE 26)1015202530CA 02264947 1999-03-05W0 98/ 12375PCT/US96l149357polyolefin, nylon, polyester, wool, cotton, jute, acrylicpolymers, and the like are suitable. The fibers arewoven, nonwoven, knitted or stitch—bonded.Optionally awoven mesh is incorporated into the mat. Such methodsand materials are well known to those skilled in the art.While the underlay mat has been described with respect tocertain embodiments, many modifications and changes maybe made by those skilled in the art. Similarly manymethods for the continuous production of underlay and thecoating of the underlay are well known to those skilledin the art. It is intended that all such modificationsand production methods are included in the meaning of theterm "underlay mat" as used herein.The underlay of this invention is sufficientlysubstantial and underlays of less than about 40 to 50g/m2typically will provide repellency but may not beimpervious to oil and water. The underlay of thisinvention may be described as a "tertiary" backing whenaffixed to a carpet, and is applied to unitary carpetingand carpeting with a secondary backing. The underlays ofthis invention are applied to carpets and rugs that donot already have a water-impermeable backing such as thepoly(vinyl chloride) and polyurethane backings describedabove. Typically the underlays of this invention areapplied to carpets having a latex coated primary backingsuch as styrene—butadiene rubber based latex (SBR) orethylene vinyl acetate based latex (EVA), and where theunitary carpet or secondary backing has not been treatedwith oil or water repellant finishes.The underlays of this invention are useful as aseparate underlay under an area rug or affixed to theSUBSTITUTE SHEET (RULE 26)1015202530WO 98/12375CA 02264947 1999-03-05PCT/U S96! 149358backing of a carpet to provide imperviousness to liquids,and provide several advantages over the prior art. Theunderlays provide a more complete, durable, and permanentrepellency and imperviousness to liquids since thefluorocarbon treatment has more affinity for the underlaymaterial than for the latex—treated primary or secondarybacking, where incompatibilities between the fluorocarbontreatment agent and the latex can occur. Thus theuniformity of application eliminates untreated areasthrough which spills can pass. The underlay of thisinvention is applied separately from the carpetmanufacture, eliminating a production holdup for an extradrying step and enabling the underlay to be applied todesired areas of carpet, rather than throughout amanufacturing run. The drying of carpet is typically theproduction—limiting step. The underlay of this inventioncan be applied independantly of the carpet production,for instance, at the installation site.Furthermore, theapplied underlay improves the cushioning of the carpet,contributing to reduced wear and improved feel andesthetics.Suitable fluorochemicals for use hereininclude, but are not limited to, polymers or othercompounds with molecular weight greater than 500 havingpendent or terminal groups of perfluoroalkyl moieties.Examples of some suitable fluorochemicals include:polymers and copolymers of vinylidene fluoride,tetrafluoroethylene, perfluoroalkylethyl acrylates,perfluoroalkylethyl methacrylates, mixtures of the same;blends of the foregoing polymers and copolymers withpolymers and copolymers of alkyl acrylates andalkylmethacrylates, copolymers of vinylidene chloride,SUBSTITUTE SHEET (RULE 26)1015202530WO 98/12375CA 02264947 1999-03-05PCT/U S96/ 149359vinylidene fluoride, tetrafluoroethylene,perfluoroalkylethyl acrylates and perfluoroalkylethylmethacrylates and wax emulsions.Many commercially available fluorochemicals areused both as repellent finishes and as effective oil-repellents and water—repellents. These include forexample, commercially available proprietary products soldunder the tradenames of "TEFLON" and "ZONYL” from E. I.du Pont de Nemours and Company, Wilmington, DE; "MILEASE"from ICI, Wilmington, DE; "ASAHIGARD" from Asahi Glass,Plymouth, MI; "SCOTCHGARD" from 3M, Minneapolis, MN;"SOFTECH" from Dyetech, Dalton, GA; "TEX-TEL" fromAtochem, Philadelphia, PA; and "NK GUARD" from Nicca,Fountain, SC which are suitable for use herein. Suitablecommercially available silicone—based repellents include,but are not limited to, C2—O563 from Dow Corning,Midland, MI. Dow Corning C2—0563 is a silicone repellentmixture of polydialkylsiloxanes. Suitable commerciallyavailable wax emulsions include, but are not limited tothose sold under the trademark "NALAN"from DuPont, and"OCTOWAX" 312 from Tiarco Chemical Co, Dalton, GA.Suitable hydrophobic acrylate resins include water-repellent polymers and copolymers of acrylic acid estersand methacrylic acid esters such as the methyl, butpreferably ethyl and butyl,esters. Mixtures of thesepolymers and copolymers are also effective. One exampleof a commercially available resin is "Acrylic MatteMedium" from Golden Artist Colors, Hamilton, NY.Certain repellent finishes as used in thisinvention provide an underlay that is substantiallyimpervious to water—based spills. Other repellentfinishes provide an underlay that is substantiallySUBSTITUTE SHEET (RULE 26),.........u...a-u-—._m............»._.m....«-....u.,....n.. . ,.. ......Ml015202530W0 98/12375CA 02264947 1999-03-05PCTlUS96/1493510impervious to liquid spills, including both oil—based andwater—based spills. Thus the repellent finish isselected based on the desired type of imperviousness.Since the repellent finishes for water are typically lessexpensve than those for liquids, selecting a repellentfinish that provides an underlay substantially imperviousonly to water based spills can be preferred for certainenvironments.Preferred fluorochemical repellent finishesinclude the following aqueous dispersions: a polyfluoroorganic compound prepared by reacting a polyisocyanatewith a fluoroalcohol and water disclosed in EP A45364l(Repellent A of the Examples herein); a blend of afluoroalkyl citrate- urethane and polymethylmethacrylatedisclosed in U.S. Patent 3,923,715 (Repellent B of theExamples herein); a fluorocarbonylimino biuret obtainedby reacting polyisocyanate with a fluoroalcohol andmonochlorohydrin disclosed in U.S. Patent 4,958,039(Repellent C of the Examples herein); a blend of afluoroalkyl citrate urethane, a fluoroalkylmethacrylate/2—ethylhexyl methacrylate/2- hydroxyethylmeth—acrylate/N—methylolacrylamide copolymer, afluoroalkyl methacrylate/lauryl methacrylate/N-methylolacrylamide copolymer, a dimethylaminoethylmethacrylate/acrylic acid copolymer, and achloroprene/dichlorobutadiene copolymer disclosed in U.S.Patent 4,595,518 (Repellent D of the Examples herein);copolymers of an alkyl (meth)acrylate/fluoro—alkyl(meth)acrylate/vinylidene chloride disclosed in U.S.and FC~l355 and FC—1367Patent 5,344,903; (both anionicemulsions of fluoroaliphatic polymers, from 3M Company,Minneapolis, MN).SUBSTITUTE SHEET (RULE 26)1015202530CA 02264947 1999-03-05WO 98/12375 PCT/US96/14935llFluorochemical repellent finishes containingsolvents, exemplified by an aqueous dispersion of acopolymer disclosed in U.S. Patent 4,742,140 comprisingan alkyl acrylate or methacrylate, vinylidene chloride,and a mixture of fluoroalkyl alkyl methacrylates oracrylates (containing some acetone) are also effective inthis application, but less preferred due to concerns overflammability hazards and the disposal of organicsolvents. The preferred repellent finishes eithercontain no volatile organic solvents, or no more thanabout 1%.Preferred mixed fluorochemical and hydrocarbonrepellent finishes include a blend of wax, adiethylaminoethyl methacrylate/hexadecylmethacrylate/octadecyl methacrylate copolymer of the typedisclosed in U.S. Patent 4,595,518 and a fluoroalkylacrylate/hexadecyl methacrylate/octadecylmethacrylate/vinylidene chloride copolymer disclosed inU.S. Patent 4,742,140 (Repellent E of the Examplesherein); a blend of wax, a diethylaminoethylmethacrylate/hexadecyl methacrylate/octadecylmethacrylate copolymer and a fluoroalkylmethacrylate/dodecyl methacrylate copolymer of the typedisclosed in U.S. Patent 4,595,518 (Repellent F of theExamples herein).Preferred hydrocarbon water—repellent finishesinclude an aqueous dispersion of: a hydrocarbon wax and abehenic acid ester of melamine (Repellent G of theExamples herein); a hydrocarbon wax stearyl methacrylate/diethylaminoethyl methacrylate copolymer (Repellent H of“OCTOWAX" 321the Examples herein); and(an aqueousSUBSTITUTE SHEET (RULE 26)CA 02264947 1999-03-05W0 98/ 123751015202530PCT/U S96! 1493512paraffin wax emulsion, from Tiarco Chemical Co., Dalton,GA) .Results obtained using the preferred repellentfinishes are described in the Examples. Suitablecommercial repellent finishes after application, drying,and curing do not stain or transfer to the underlyingsubstrate (e.g. the carpet or the floor).Repellent finishes typically have an organicsegment of the molecule that binds to the fiber. Thosewhich show oil repellency may also have a fluorocarbonsegment. The repellent finishes are selected in partbased on the fiber composition. Typical mat fibers canrange from relatively hydrophilic fibers such as nylon,intermediate fibers such as polyester, to relativelyhydrophobic fibers such as polyolefins. The techniquesfor matching repellent finishes with fiber compositionare well known in the art. Typically the repellent finishis diluted with water or a suitable solvent such asalcohol for application to the mat, with water beingpreferred. The necessary dilution is determined by thewet pick—up and the required concentration of activeingredient in the dried and cured mat. The wet pick—upis the amount of repellent finish in the wet mat afterapplication but before drying or curing. The wet pick-up is expressed as a percentage based on the dry fiber.For instance, if a repellent finished mat is to contain1.5% of the active ingredient and the wet pick-up is200%, the repellent finish as applied should contain0.75% active ingredient (100 X 0.015/2).The amount of repellent finish, together withthe necessary diluent such as water or alcohol that isapplied to the underlay, is measured as wet pick—up priorSUB$HTUTESHEET(RULE26)CA 02264947 1999-03-05W0 98/123751015202530PCT/US96/ 1493513to drying and curing. The wet pick—up applied to the rugunderlay fabric will generally be in the range of 20 to300 % by weight, and preferably 50 to 200 % by weight,based on the untreated underlay fabric. Typically,commercially available repellent finishes contain about0.5 to about 40% by weight total active ingredient. Inthe case of silicones, the total active ingredient may begreater than 40% by weight. In this invention, the amountof active ingredient of repellent finish applied willgenerally be in the range of about 0.01 to 10% by weight,and preferably 0.05 to 3% by weight, of the activeingredient in the repellent finish based on the underlaymat.However, it is understood that the amount ofrepellent finish and active ingredient applied will beadjusted depending on the type and concentration of therepellent, the underlay mat construction and weight, thetype of fiber or fibers in the underlay mat, and the typeof adhesive application. In any application, it isimportant that a sufficient amount of repellent finish beuniformly applied to the underlay mat such that therepellent finished underlay is substantially imperviousto water or to liquids, according to Test Methods 1 and 2described below.The repellent finish is applied to the underlaymat by various means including foam, spray, dipping, orpadding processes, followed by a heat treatment to dry orcure the repellent finish, typically in an oven. Thedrying temperature, drying temperature profile, anddrying time are selected, based on the thermal stabilityof the fabric and the drying and curing properties of therepellent finish, to be sufficient to accomplish theSUBSTITUTE SHEET (RULE 26)CA 02264947 1999-03-05W0 98I123751015202530PCT/US96/1493514necessary drying and curing.Control of such dryingparameters are well known to those skilled in the art.It is necessary to ensure that the repellentfinish be completely and uniformly applied to theunderlay mat, and completely and uniformly dried andcured. Padding, in which the underlay mat is dipped in abath and the excess repellent finish squeezed off,typically gives excellent and uniform application and isthus the preferred application method. Foam and sprayapplications, on the other hand, can allow starved ormissed areas unless the foam or spray is Very carefullyapplied. Even very small undertreated areas will impairthe imperviousness desired. To ensure foam and sprayapplications are complete, it may be necessary to applythe repellent finish with greater wet pick—up than wouldbe necessary for padding. However, this can require thespray or foam repellent finish to be diluted with extrawater compared with the padding process, thus requiringextra drying. For foam and spray applications, a wettingagent may be added to the repellent finish to assist inthe complete and uniform application. Suitable wettingagents are exemplified by, but not limited to, "ALKANOL"6112 (poly(oxyethylene sorbitan monooleate in water/1-from E. I.decanol), du Pont de Nemours & Company,Wilmington, DE). Wetting agents were not necessary inthe preferred pad application.The undelay mat, now substantially imperviousto water or liquids, is then coated with adhesives. Forrug underlays the mat is coated on one, and preferablyboth, sides with a suitable adhesive, the adhesive iscured or dried, and one or both surfaces of the repellentfinished underlay is protected by an easily releasedSUBSTITUTE SHEET (RULE 26)CA 02264947 1999-03-05W0 98/123751015202530PCT/US96/1493515sheet of material, e.g., plastic, paper, or otherinexpensive material, to prevent adhesion of the underlayto itself or other surfaces during handling, storage,transportation, and appropriately packaged. Theadhesives suitable for underlays, the methods of adhesiveapplication to underlays, and the packaging of underlaysare well known to those skilled in the art. While theapplication of adhesive and packaging of the underlayhave been described with respect to certain embodiments,many modifications and changes can be made by thoseskilled in the art. It is intended that all suchmodifications are included in the meaning of the term"repellent finished underlay mat" as used herein.For carpet underlays, the mat is coated on oneside with an adhesive. The preferred adhesives forlaminating the water impermeable underlay to theunderside or backing of wall—to—wall carpeting will (1)cure at ambient temperatures, (2) adhere the carpetunderside to the impermeable backing immediately uponcontact, (3) remain adhered to carpet underside andimpermeable backing even when wet by liquids, and (4)provide a lamination strength of at least about 8.9 kg/m(0.5 lb/in), preferrably at least about 17.9 kg/m (1.0lb/in). Examples of effective adhesives are "3M Super 77Spray Adhesive", manufactured by 3M Industrial Tape andSpecialty Division, St. Paul, MN. Additional examples ofeffective adhesives include "Elmer's Spray Adhesive",Distributed by Borden Inc., Department HPPG Elmer's,Columbus, OH and "Liquid Nails Adhesive for Projects andConstruction", Macco Adhesives, The Glidden Company,Cleveland, OH. Many other adhesives with theseSUBSTITUTE SHEET (RULE 26)WO 98/123751015202530CA 02264947 1999-03-05PCTlUS96l1493516characteristics are well known in the art and aresuitable for use herein.The underlays of this invention preferablyutilize fabric with loft or height characteristicsdependent on the desired use. Fabric loft or height isimportant for a rug underlay between an area rug andwall—to—wall carpeting. The fabric height of betweenabout 2 mm and 5 mm allows complete contact with eachsurface and maximizes the non—slip aspects of the rugunderlay. A rug underlay fabric is also appropriate as awater impermeable backing on wall—to—wall carpeting.However, a fabric that does not contain about at least 2mm of loft can nevertheless be an effective waterimpermeable backing on wall—to—wall carpeting. Theadhesive insures that the water impermeable backing andthe wall—to—wall carpeting are in complete contact. Forease of installation, the water impermeable backing doesnot provide a non—slip feature in wall—to—wall carpeting.So, a fabric with less than about 2 mm in height or loftis an effective water impermeable backing for wall—to-wall carpeting. To achieve a lofted fabric with betweenabout 2 mm and 5 mm of height, a needlepunched nonwovenfabric is required. For water impermeable backingsattached to wall—to—wall carpeting, woven, nonwoven,knitted, stitch—bonded or other fabrics are suitable suchas fabrics made from polyethylene, polypropylene,polyolefin, acrylic fibers, polyester, polytrimethyleneterephthalate, nylon, wool, cotton, jute, thermoplasticpolymer films, mixtures of the same, or mixtures thereofwith cellulosics. Preferred for many applications arenonwovens such as “TYVEK" and “SONTARA”, each availablefrom E. I. du Pont de Nemours & Company,Wilmington, DE,SUBSTITUTE SHEET (RULE 26)WO 98/123751015202530CA 02264947 1999-03-05PCT/U S96/ 149351 7and “TYPAR” available from Norville Industrials, Dalton,GA. “TYVEK” is a flash spun nonwoven fabric ofpolyethylene, “TYPAR” is a spun bonded nonwoven fabric ofpolypropylene, and “SONTARA” is a spunlaced nonwovenfabric of polyester/cellulosic.In carpet applications, the underlays of thisinvention are laminated permanently to the carpeting.Suitable carpets include those wherein the pile yarns ofthe carpet are polyamide, polyester, polypropylene, wool,cotton, acrylic , polytrimethylene terepthalate, ormixtures thereof and other fibrous materials. For somewater impermeable fabrics, merely adhering the fabric tothe underside of the wall-to—wall carpeting results in acarpet with attached water impermeable backing. Somefabrics must be first treated with a water repellent andthen adhered to the underside of the wall-to—wallcarpeting. The methods for treating the fabric with anappropriate water repellent and curing the fabric aredescribed for rug underlays, above.The preferredmethods for adhering the fabric, whether inherently waterimpermeable or treated with water repellents to becomewater impermeable, to the wall-to—wall carpeting areeither (1) applying an adhesive to the fabric in anoperation separate from laminating the fabric to theunderside of the wall-to—wall carpeting or (2) applyingan adhesive to the fabric and/or the underside of thewall-to—wall carpeting concurrent with laminating thefabric to the underside of the wall-to-wall carpeting.Adhesives are applied to only one side of the fabric bykiss—roll,spray, or other methods known to those skilledin the art. The underlay is affixed to the primarybacking of the carpet having a fabric surface tufted withSUBSTITUTE SHEET (RULE 26)._ ... .—....,.r..._........«....... M _CA 02264947 1999-03-05W0 98/12375l015202530PCT/U S96/ 1493518pile yarns to which a latex has been applied on theunderside, or to a carpet having both a primary backingand a secondary backing. The secondary backing istypically a fabric of polyester, polypropylene, cotton,jute, felt, or a thermoplastic polymer film. Thepreferred locations for laminating the underlay to theunderside of the primary or secondary backing of thewall—to—wall carpeting are either (1) after the latexedand finished carpet has cooled but prior to roll—up or(2) during the cut—order operation when a large roll ofcarpet is being cut into smaller rolls to meet customerorders. The water impermeable fabric is laminated to theunderside of the wall—to—wall carpet backing eithermanually or automatically, without the water impermeablefabric being torn, punctured, or worn to compromise itswater impermeabilityIn another embodiment of this invention, therepellent finish is applied to the underlay mat after theadhesive has been applied and dried or cured. In thisembodiment, the repellent finish is chosen so as to notdiminish the adhesive properties of the repellentfinished underlay. In a third embodiment of thisinvention, the repellent finish is mixed with theadhesive and applied and dried or cured in a singleoperation. The repellent finish and adhesive are chosenso as to be mutually compatible and so that the repellenttreatment does not diminish the adhesive properties ofthe repellent finished underlay. In a fourth embodimentof this invention, the repellent finish and then theadhesive, or the adhesive and then the repellent finish,is applied, followed by a single heat treatment to dryand cure both applications.SUBSTITUTE SHEET (RULE 26)W0 98/1215751015202530CA 02264947 1999-03-05PCT/US96/1493519Although the repellent finishes used in thisinvention are similar to those used for making a carpetbacking substantially impervious to liquids there aresignificant differences in the application of thistechnology to underlays. Compared to carpet, an underlayis a thinner, nonwoven fabric, without the tufted fibersor the latex binder that secures the tufted fibers in thebacking. Consequently, the underlay has much lesscapacity to absorb liquid spills and to lower thehydrostatic pressure exerted by a liquid spill. Thesedifferences require that the repellent finish be veryuniformly applied. For this reason the pad method ofapplication, in which the underlay is immersed in a bathcontaining the repellent finish at the desiredconcentration and then squeezed to reduce the wet pick—upto the necessary level, is preferred over spray or foamapplications. Spray and foam application are suitable ifcarefully controlled, so as to not leave small areas inwhich the amount of repellent finish active ingredient isinadequate to provide the imperviousness desired.A second important difference between carpetsand underlays is that the repellent finish is applied tounderlays either before or after the application of theadhesive. In the case of carpets, the binding latex isapplied to the primary backing before the repellentfinish, else the imperviousness of the product isreduced. The binding latex must be worked into the backof the carpet, for instance by a roller, to secure thetuftsl A possible explanation of this difference is thatworking the latex into the carpet after it has beentreated with a repellent finish in this manner createsSUBSTITUTE SHEET (RULE 26).- ...i.‘. .._._.........._.........w CA 02264947 1999-03-05W0 98/ 123751015202530PCT/U S96/ 1493520channels for liquids to pass through, thus theimperviousness is impaired.Test Methods 1 and 2 determine the oil andwater imperviousness of the underlay mats, while TestMethod 3 and 4 determine oil and water repellency of theunderlay mat, both after the repellent finish has beenapplied, dried, and cured. The oil repellency rating fromTest Method 3 correlates strongly with the desiredproperty of being substantially impervious to liquids asdetermined by Test Method 1. the waterSimilarly,repellency rating from Test Method 4 correlates stronglywith the desired property of being substantiallyimpervious to water, determined by Test Method 2. Therepellency Test Methods 3 and 4 may be easier to use oncertain samples. Test Methods 1 and 2 are used for therepellent finished underlay.The present invention is further illustrated bythe Test Methods and Examples below.TEST METHODSTest Method 1. Oil ImperviousnessThe underlay sample is placed with an adhesiveside down on a white absorbent paper towel. 20 ml ofS.A.E. 10W3O Motor Oil, adjusted to room temperature of24°C +/— 3°C (75°F +/— 5°F) is poured onto the underlaysample through a cylinder of about 4 cm diameter and froma height of about 6 cm to create a circular puddle. Thecylinder is removed and the sample is not disturbed for30 minutes. The underlay is removed and the diameter ofany oil spot on the towel is measured. The sample istermed as substantially impervious to oil if none or avery slight amount of oil has passed through the underlaysample. The diameter on the paper towel of any oil spotSUBSTITUTE SHEET (RULE 26)1015202530CA 02264947 1999-03-05W0 93/12375 PCT/US96/1493521that has passed through the underlay is measured. An oilspot diameter of 2.54 cm (one inch) or less is requiredfor the underlay to be substantially impervious to oil.Test Method 2. Water ImperviousnessThe underlay sample is placed with an adhesiveside down on a white absorbent paper towel. 20 ml ofwater, adjusted to room temperature of 24°C +/— 3°C (75°F+/— 5°F) is poured onto the underlay sample through acylinder of about 4 cm diameter and from a height ofabout 6 cm to create a circular puddle. The cylinder isremoved and the sample is not disturbed for 30 minutes.The underlay is removed and the diameter of any waterspot on the towel is measured. The sample is termed assubstantially impervious to water if none or a veryslight amount of water has passed through the underlaysample. The diameter on the paper towel of any waterspot that has passed through the underlay is measured. Awet spot diameter of 2.54 cm (one inch) or less isrequired for the underlay to be substantially imperviousto water.Test Method 3. Oil RepellencyAATCC Test Method NO. ll8-1989After proper conditioning, the underlayspecimen is placed on a flat level surface with anadhesive side down. Three drops of the selected oil oroil mixture are placed on the fabric and left for 30seconds. If no penetration has occurred, the fabric isjudged to "pass" this level of repellency and the nexthigher numbered oil mixture is tested.The fabric ratingis the highest numbered oil mixture that does not wet orpenetrate the fabric.SUBSTITUTE SHEET (RULE 26)CA 02264947 1999-03-05W0 98/12375101520253035PCT /U S96! 1493522The test oil compositions are:AATCC Oil RepellencyRating Number Oil Composition1 Nujol2 65:35::Nujol:n—hexadecane3 n-hexadecane4 n—tetradecane5 n—dodecane6 n—decaneA rating of 0 indicates no oil repellency; arating of 3 or higher is desired.Test Method 4. Water RepellencyDuPont "TEFLON" Standard Test Method No. 311.56After proper conditioning, the underlayspecimen is placed on a flat level surface with anadhesive side down. Three drops of the selectedwater/isopropanol mixture are placed on the fabric andleft for 10 seconds. If no penetration has occurred, thefabric is judged to "pass" this level of repellency andthe next higher numbered test liquid is tested. Thefabric rating is the highest numbered test liquid thatdoes not wet the fabric.The water/isopropanol mixtures have thefollowing compositions:DuPont Water Composition (wt %)RepellencyRating Number Water Isopropanol1 98 22 95 53 90 104 80 205 70 306 60 40SUBSTITUTE SHEET (RULE 25)101520253035W0 98/ 12375CA 02264947 1999-03-05PCT/US96/1493523A rating of 0 indicates no water repellency, a rating of6 indicates maximum water repellency. A test rating of 3or higher is desired.Control — Underlays Without a Repellent finishA needle—punched, nonwoven polyester fabric(approximately 0.14 kg/m2, 4 oz./square yard) was sprayedwith Air Products Pressure Sensitive Adhesive #625 onboth the top and bottom face to a total wet pick—up of20% by weight of adhesive solution. The treated fabricwas dried at 132°C (270°F) for 3 min. resulting in arepellent finished underlay containing 10% by weight ofadhesive active ingredient. The following test resultswere obtained using the Test Methods described above onthe fabric before and after the application of theadhesive. The results for Test Metods 1 and 2 are listedin cm.T_a.h."L_e__.LTes n d s ith e e ent 1 is .Impervjgdsnessi Bepellency Eating()il 1%/ater ()il 11/aterUnderlay (by Test (by Test (by Test (by Test§2Q_r;1;o1 1 Method 1) Ethsflll Method 3) Methgd 4)BefineAdhesiveAppln. 15 or more 25 or more 0 0AfterAdhesiveAppln. 15 or more 25 or more 0 0The control underlays failed all tests and arenot substantially impervious to either water or oil.SUBSTITUTE SHEET (RULE 26)101520CA 02264947 1999-03-05W0 98/12375 PCT/US96I1493524Ex 1 1Preparation of an Underlay Sequentially TreatedWith a Repellent finish and Then an Adhesive, and Testsfor Oil and Water Permeability.A needle—punched, nonwoven polyester fabric(approximately 0.14 kg/m2, 4 oz./square yard) wassaturated with the repellent solution indicated in Table2 and the liquid was reduced by squeezing to 200% byweight of the fabric. The treated fabric was dried at82°C(180°F) for 10 min. and cured at 149°C (300°F) for 3min. resulting in a fabric with the content of repellentactive ingredient indicated in Table 2. The fabric wasthen sprayed with Air Products Pressure SensitiveAdhesive #625 (Air Products, Allentown, PA) on both thetop and bottom face to a total wet pick—up of 20% byweight of solution. The treated fabric was dried at 132°C(270°F) for 3 min. to give a fabric containing 10% byweight of adhesive active ingredient. The following testresults were obtained using the Test Methods describedabove. Results for Test Methods 1 and 2 are listed incm.SUBSTITUTE SHEET (RULE 26)101520253035CA 02264947 1999-03-05WO 98112375PCT/US96/149352 5‘$12.13.;11 U 1' a re in x le - 2Active Imperviousness Repgllency RatingIngredient (spot diameter, cm 1based oninitial Oil Water Oil Waterfabric (% (by Test (by Test (by Test (by TestEzsflmk Meflridll mtlmill Mgtlmlil .1\/LtflilFluorochemical Water-Repellent Finishes1 A 3.0% 0 0 6 62 B 1.4% 0 0 6 43 C 1.0% 0 0 6 44 D 0.30% 0 O 6 65 B 3.0% 0 0 6 56 FC-1355 1.5% 0 0 5 57 FC-1367 1.5% 0 0 6 5Mixed Fluorochemical and Hydrocarbon Water—Repel1ent Finishes8 E 2.4% 0 0 6 69 F 0.96% 0 0 6 6Hydrocarbon Water-Repellent Finish10 G 1.2% 15 O 0 51 1 H 1 .2% 1 5 0 0 412 Octowax 2.5% 18 0 53 2 1The tests showed the underlay treated withRepellents G and H as well as Octowax 321 weresubstantially impervious to water, all other treatedunderlays were substantially impervious to oil and water.*The repellent finishes used were as follows:A — polyfluoro organic compound prepared by reacting apolyisocyanate with a fluoroalcohol and water asdisclosed in EP A 453641.SUBSTITUTE SHEET (RULE 26)10152025CA 02264947 1999-03-05W0 98/12375 PCTlUS96/1493526B — blend of fluoroalkyl citrate - urethane andpolymethylmethacrylate disclosed in U.S. Patent3,923,715.C — fluorocarbonylimino fuiret prepared by reactingpolyisocyanate with fluoroalcohol andmonochlorohydrin disclosed in U.S. Patent 4,958,039.D — a blend of a fluoroalkyl citrate urethane, afluoroalkyl methacrylate/2—ethylhexyl methacrylate/2-hydroxyethyl meth-acrylate/N—methylolacrylamidecopolymer, a fluoroalkyl methacrylate/lauryl meth-acrylate/N—methylolacrylamide copolymer, adimethylaminoethyl methacrylate/acrylic acidcopolymer, and a chloroprene/dichlorobutadienecopolymer disclosed in U.S. Patent 4,595,518.F3-1355 — aniomic emulsion of fluoroaliphatic polymersavailable as FC—l355 from 3M, Minneapolis, MN.FC—1367 — anionic emulsion of fluoroaliphatic polymersavailable as FC—1367 from 3M, Minneapolis, MN.E — a fluoroalkyl acrylate/hexadecyl methacrylate/octadecyl methacrylate/vinylidene chloride copolymerdisclosed in U.S. Patent 4,742,140.a blend of wax, a diethylaminoethyl methacrylate/hexadecyl methacrylate/ocradecyl methacrylatecopolymer and a fluoroalkyl methacrylate copolymer ofthe type disclosed in U.S. Patent 4,595,518.aqueous dispersion of: a hydrocarbon wax and abehenic acid ester of melamine.a hydrocarbon wax stearyl methacrylate/diethylaminoethyl methacrylate copolymer.SUBSTITUTE SHEET (RULE 26)101520W0 98/ 12375CA 02264947 1999-03-05PCTIU S96/ 149352713-Preparation of an Underlay Sequentially TreatedWith an Adhesive and Then a Repellent finish, and Testsfor Oil and Water Permeability.A needle—punched, nonwoven polyester fabric(approximately 0.14 kg/m2, 4 oz./square yard) was sprayedwith Air Products Pressure Sensitive Adhesive #625 (AirProducts, Allentown, PA) on both the top and bottom faceto a total wet pick—up of 20% by weight of solution. Thetreated fabric was dried at 132°C (270°F) for 3 min. togive a fabric containing 10% by weight of adhesive activeingredient. The fabric was then saturated with a water-repellent solution and the liquid was reduced bysqueezing to 200% by weight of the fabric. The treatedfabric was dried at 82°C (l80°F) for 10 min. and cured at149°C (300°F) for 3 min. resulting in a fabric with thecontent of repellent active ingredient indicated in Table3. The following test results were obtained using theTest Methods described above. The results for TestMethods 1 and 2 are in cm. Repellent finishes A to Gwere as defined in Examples 1-12.SUBSTITUTE SHEET (RULE 26)101520253035W0 98/ 12375TExample RepellentCA 02264947 1999-03-052 8Ial2L¢_.'io 1 Pre ared in Exam 1 -1Active ImperviousnessIngredient (_smn_dia based oninitial Oil Waterfabric (% (by Test (by Testby wejghtl Method 1 ) Method 2)Fluorochemical Water-Repellent Finishes3.0% 0 O1.0% 0 00.30% 0 03.0% 0 0PCTIUS96/14935Repellency RatingOil(by TestMethocillO‘\C\O'\O\Mixed Fluorochemical and Hydrocarbon Water-Repellent Finishes13 A14 C15 D16 B17 E18 F19 G1.2% 0 00.96% 0 0Hydrocarbon Water-Repellent Finish1 .2% 15 066Water(by TestMethod 4)o\O\UlU‘IThe tests showed that the underlay treated with RepellentG was substantially impervious to water, all othertreated underlays were substantially impervious to oiland water.mm Preparation of Underlays sequentially TreatedWith a Repellent finish and Then an Adhesive, Followed bya Combined Drying and Curing Treatment, and Tests for Oiland Water Permeability.A needle-punched, nonwoven polyester fabric(approximately 0.14 kg/m2, 4 oz./square yard) wassaturated with the indicated repellent solution and theliquid was reduced by squeezing to 200% by weight of theSUBSTITUTE SHEET (RULE 26)1015202530CA 02264947 1999-03-05W0 98/ 1237529fabric. The fabric was then sprayed with Air ProductsPressure Sensitive Adhesive #625 (Air Products,PCT/US96/14935Allentown, PA) on both the top and bottom face to a totalwet pick-up of 200% by weight of solution.fabric was dried at 132°C (270°F) for 3 min. to give aThe treatedfabric containing about 25% by weight of adhesive activeingredient and with the content of repellent activeingredient indicated in Table 4. The following testresults were obtained using the Test Methods describedabove. The results for Test Methods 1 and 2 are in cm.Repellent finishes D, F and G were as defined in Examples1 - 12 .Ial2l§_4.T P E a -Active lmperviousnessIngredient ( Bepellencv Ratingbased on -initial Oil Water Oil Waterfabric (% (by Test (by Test (by Test (by TestExempt B..¢.l1§l1§J11 flwfiifihfl M§_£hQd_1.l M§.thQCL2.l Mflgdll Method 4)Fluorochemical Repellent Finish20 D 0.30% O 0 6 6Mixed Fluorochemical and Hydrocarbon Repellent Finishes21 F 0.95% 15 0 2 6Hydrocarbon Water-Repellent Finish22 G 2.5% 15 0 0 5The tests showed the underlays treated with Repellents F and G were substantiallyimpervious to water. The underlay treated with Repellent D was substantiallyimpervious to oil and water.SUBSTITUTE SHEET (RULE 26)I .....,_.......r.....~.«..........................,,.."., W0 98/123751015202530CA 02264947 1999-03-05PCT/U S96/ 149353 0E — 2Examples 23-62 demonstrated the application ofwater impervious underlay fabrics to carpet and werecompared with a control sample of the carpet without theimpermeable underlay. The water impervious underlaysused are listed on Table 5. Examples 24-26 were “TYPAR"available from Norville Industrials, Dalton, GA. Example“ TYVEK”27 was available from E. I.du Pont de Nemoursand Company, Wilmington, DE. Example 28 was acommercially available melt blown polypropylene nonwovenfabric. Examples 29-38 were “SONTARA” available from E.I. du Pont de Nemours & Co., Wilmington, DE. Examples39-46 were nonwoven fabrics RB 400 (130 g/m2) and RB 406(l5Og/m2) obtained from Synthetic Industries, Ringold,GA. Examples 47-62 were various commercially availablewoven and knit fabrics purchased in Walmart inChattanooga, TN. Some fabrics did not require oil orwater repellent treatments and others were treated with arepellent as listed in Table 5. Repellents D and E asdefined in Examples l—l2 were employed. Both areavailable from E. I. du Pont de Nemours & Company,Wilmington, DE.For treating the underlay, the chemicals werespray applied, and the underlay fabric was dried at 82°C(l80°F) and cured at 148°C (300°F) for 3 min. The waterimpervious underlays were adhered to the underside of thewall—to~wall carpeting using 3M Super 77 Spray Adhesiveavailable from 3M Company, St. Paul, MN and applying acoating to both the fabric and the underside of thecarpeting by spraying each surface for 15-20 secondsbefore laminating the two surfaces according to theSUBSTITUTE SHEET (RULE 26)101520253035W0 98/ 12375CA 02264947 1999-03-05PCT/US96/1493531directions on the adhesive package. For all Examples 23-62 the underlays were affixed to carpet from CoronetMills, Dalton GA, style name "Torrey Pines Plus", 1.02kg/m2 (30 oz/ydz) nylon carpet treated with DuPont's“STAINMASTER” stain and soil resists. For Examples 38,42, and 46 the underlay was sprayed with the adhesive,affixed to the underside of the carpet, and then treatedwith repellent, followed by drying and curing as notedabove. The water imperviousness,oil repellency, andwater repellency tests, Test Methods 2 through 4 aspreviously described, were conducted on the carpetsamples. The resulting data are summarized in Table 5.Results for test Method 2 are in cm.TABLE 5Ex. Attached mL ;P‘amn #2 #2; #423 none(carpet control) none 25+ 0 024 Polypropylene, none 0 O 4Spunbondednonwoven, 150 g/m225 PolypropyleneSpunbonded none 0 O 4nonwoven 120g/m226 PolypropyleneSpunbonded none 0 O 4nonwoven 110 g/m227 PolyethyleneFlash spun none 0 O 4nonwoven 40 g/m2SUBSTITUTE SHEET (RULE 26)101520253035CAW0 98/ 123752829303132333435363738PolypropyleneMelt blownnonwoven 70 g/m2Polyester/cellulosicspunlacednonwoven 78 g/m2Polyester/cellulosicspunlacednonwoven 78 g/m2Polyester/cellulosicspunlaced nonwoven78 g/m2Polyester, Spunlacednonwoven 110 g/m2Polyester Spunlacednon woven, 110 g/m2Polyester Spunlacednonwoven 130 g/m2Polyester Spunlacednonwoven 130 g/m2Polyester Spunlacednonwoven 130 g/m2Polyester Spunlacednonwoven 130 g/m2Polyester Spunlacednonwoven 130 g/m232nonenone65 g/m2130 g/m2none65 g/m2none65 g/m2none65 g/m2100 g/m202264947 1999-03-0525+25+25+25+SUBSTITUTE SHEET (RULE 26)PCT/U S96/ 14935O 4O OO 66 6O 14 6O O6 6O 14 66 610152025303540CA 02264947 1999-03-05W0 98/123753940414243444546474833Polypropylene needle nonepunched nonwoven,150g/m2Polypropylene needle Epunched nonwoven 65 g/m2150 g/m2Polypropylene needle Epunched nonwoven, 130 g/m2150 g/m2Polyester needle Dpunched nonwoven 100g/m2130 g/m2Polyester needle nonepunched nonwoven,130 g/m2Polyester needle Epunched nonwoven 65 g/m2130 g/m2Polyester needle Epunched nonwoven 130 g/m2130 g/m2Polyester needle Dpunched nonwoven 100 g/m2130 g/m2Woven none65% polyester/35% cotton100 g/m2Woven D65% polyester/35% 100 g/m2cotton100 g/m2SUBSTITUTE SHEET (RULE 26)25+25+25+PCT/US96/14935O 16 66 66 60 O6 66 66 6O O5 6101520253035W0 98/ 1237549 Knitted,180 g/m250 Knitted,180 g/m251 Knitted,110 g/m252 Knitted,110 g/m253 Knitted,100 g/m254 Knitted,100 g/m255 Knitted,CA 02264947 1999-03-05acrylicacrylicacetateacetatepolyesterpolyester85% nylon/15%Lycra—Spandex160 g/m256 Knitted,85% nylon/15%Lycra—SpandeX160 g/m257 Woven, cotton140 g/m258 Woven, cotton140 g/m259 Woven, wool260 g/m260 Woven, wool260 g/m2SUBSTITUTE SHEET (RULE 26)34I'lOI1€100 g/m2None100 g/m21'1OI1€100 g/m2none100 g/m2I1OI'1€100 g/m2noneD100 g/m225+25+25+25+25+25+ PCT/US96/14935CA 02264947 1999-03-05W0 98I12375 PCT/US96I149353 56 1 Woven , nylon none 2 5 + O 0100 g/m262 Woven, nylon D O 5 6100 g/m2 100 g/m2SUBSTITUTE SHEET (RULE 25)

Claims (9)

What is claimed is:

1. A tufted carpet comprising:

a) a primary backing having a surface tufted with pile yarns and an underside to which a water permeable latex has been applied;

b) an underlay having a surface and an underside, wherein the surface of said underlay is coated with a pressure sensitive adhesive which cures at ambient temperature and affixed to the underside of the primary backing, and said underlay comprises a nonlatex fabric, said fabric having in or on it a repellent finish and being substantially impervious to liquids, wherein the adhesive provides a lamination strength of at least 8.9 kg/m and said carpet is substantially impervious to liquids.

2. The carpet of claim 1 wherein the underlay is polyester, polyolefin, polytrimethylene terephthalate, nylon, wool, cotton, acrylic, jute, mixtures thereof, or mixtures with a cellullosic.

3. The carpet of claim 1 or 2 wherein the adhesive adheres the underlay to the primary or secondary backing immediately upon contact.

4. The carpet of any one of claims 1-3 wherein the adhesive remains adhered to the underlay and the primary or secondary backing when wet by liquid.

5. The carpet of any one of claims 1-4 wherein the pile yarns are polyamide, polyester, polypropylene, polytrimethylene terephthalate, wool, cotton, acrylic, or mixture thereof.

6. The carpet of any one of claims 1-5 wherein the underlay has in or on it a repellent finish comprising a fluorochemical, silicone, wax emulsion, naturally occurring oil, alkylacrylate resin, hydrophobic alkylmethacrylate resin, or a mixture thereof.

7. The carpet of claim 6 wherein the fluorochemical is selected from the group consisting of polyvinylidene fluoride; polytetrafluoroethylene;
perfluoroalkylethyl acrylates;
perfluoroalkylethyl methacrylates; mixtures thereof; and blends of the foregoing compounds and polymers with polyalkyl acrylates, polyalkylmethacrylates, wax emulsions, and copolymers of vinylidene chloride, vinylidene fluoride, tetrafluoroethylene, perfluoroalkylethyl acrylates, and perfluoroalkylethyl methacrylates.

8. The carpet of claim 6 wherein said fluorochemical is selected from the group consisting of fluoroalkyl citrate urethane, a fluoroalkyl methacrylate/2-ethylhexyl methacrylate/2-hydroxyethyl methacrylate/N-methylolacrylamide copolymer, a fluoroalkyl methacrylate/lauryl methacrylate/N-methylolacrylamide copolymer, a dimethylaminoethyl methacrylate/acrylic acid copolymer, a chloroprene/dichlorobutadiene copolymer, and a blend thereof.

9. A tufted carpet comprising:

a) a primary backing having a surface tufted with pile yarns and an underside to which a water permeable latex has been applied;

b) a water permeable secondary backing having a surface and an underside, wherein the surface of the secondary backing is adhered to the underside of the primary backing; and c) an underlay having a surface and an underside, wherein the surface of said underlay is coated with a pressure sensitive adhesive which cures at ambient temperature and affixed to the underside of the secondary backing, and said underlay comprises a nonlatex fabric, said fabric having in or on it a repellent finish and being substantially impervious to liquids, wherein the adhesive provides a lamination strength of at least 8.9 kg/m and said carpet is substantially impervious to liquids.