CN104105826A - Carpet products and processes for making same using latex coating compositions - Google Patents

Carpet products and processes for making same using latex coating compositions Download PDF

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Publication number
CN104105826A
CN104105826A CN201380009136.2A CN201380009136A CN104105826A CN 104105826 A CN104105826 A CN 104105826A CN 201380009136 A CN201380009136 A CN 201380009136A CN 104105826 A CN104105826 A CN 104105826A
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China
Prior art keywords
copolymer
carpet
carpet product
paint composition
aforementioned
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Pending
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CN201380009136.2A
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Chinese (zh)
Inventor
D·伦斯福德
E·米切尔
R·法瓦哈
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Celanese International Corp
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Celanese International Corp
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Publication of CN104105826A publication Critical patent/CN104105826A/en
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Classifications

    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
    • D06N7/0071—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing
    • D06N7/0073—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing the back coating or pre-coat being applied as an aqueous dispersion or latex
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L25/00—Compositions of, homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an aromatic carbocyclic ring; Compositions of derivatives of such polymers
    • C08L25/02—Homopolymers or copolymers of hydrocarbons
    • C08L25/04—Homopolymers or copolymers of styrene
    • C08L25/08—Copolymers of styrene
    • C08L25/10—Copolymers of styrene with conjugated dienes
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L31/00—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an acyloxy radical of a saturated carboxylic acid, of carbonic acid or of a haloformic acid; Compositions of derivatives of such polymers
    • C08L31/02—Homopolymers or copolymers of esters of monocarboxylic acids
    • C08L31/04—Homopolymers or copolymers of vinyl acetate
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J109/00—Adhesives based on homopolymers or copolymers of conjugated diene hydrocarbons
    • C09J109/06—Copolymers with styrene
    • C09J109/08—Latex
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J125/00—Adhesives based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an aromatic carbocyclic ring; Adhesives based on derivatives of such polymers
    • C09J125/02—Homopolymers or copolymers of hydrocarbons
    • C09J125/04—Homopolymers or copolymers of styrene
    • C09J125/08—Copolymers of styrene
    • C09J125/10—Copolymers of styrene with conjugated dienes
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J131/00—Adhesives based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an acyloxy radical of a saturated carboxylic acid, of carbonic acid, or of a haloformic acid; Adhesives based on derivatives of such polymers
    • C09J131/02—Homopolymers or copolymers of esters of monocarboxylic acids
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J131/00—Adhesives based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an acyloxy radical of a saturated carboxylic acid, of carbonic acid, or of a haloformic acid; Adhesives based on derivatives of such polymers
    • C09J131/02—Homopolymers or copolymers of esters of monocarboxylic acids
    • C09J131/04—Homopolymers or copolymers of vinyl acetate
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2203/00—Macromolecular materials of the coating layers
    • D06N2203/04—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D06N2203/042—Polyolefin (co)polymers
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2203/00—Macromolecular materials of the coating layers
    • D06N2203/04—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D06N2203/045—Vinyl (co)polymers
    • D06N2203/047—Arromatic vinyl (co)polymers, e.g. styrene
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/23907—Pile or nap type surface or component
    • Y10T428/23979—Particular backing structure or composition

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  • Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Dispersion Chemistry (AREA)
  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Adhesives Or Adhesive Processes (AREA)
  • Paints Or Removers (AREA)

Abstract

Disclosed are carpet products comprising at least one substrate and at least one adhesive layer associated with the at least one substrate, the adhesive layer being formed from a latex coating composition comprising (a) a first copolymer of at least a vinyl ester of an alkanoic acid having from 1 to 13 carbon atoms and ethylene; and (b) a second copolymer of at least styrene and butadiene, wherein the first and second copolymers are colloidally dispersed in an aqueous medium comprising a surfactant. The carpet products are particularly durable exhibiting high tuft bind values.

Description

Carpet product and use latex paint composition are manufactured its method
Priority request
The application requires the priority of the U.S. Provisional Application number 61/599,127 of submitting on February 15th, 2012, and its full content is incorporated herein by this reference.
Invention field
The present invention relates to comprise the method that can be used for forming vinyl esters/ethylene copolymer dispersion of carpet product and the latex paint composition of styrene/butadiene copolymers dispersion and form this type of carpet product.
Background of invention
The most conventional carpet comprises the first wadding, and described wadding has to cut or the form of uncut ring is upwards extended to form the yarn tufting of matte by this wadding.For tufted carpet, by tufting needle, yarn is inserted in the first wadding (being generally woven or nonwoven material) and to it and applies precoated shet (being adhesive).
Most of houses and commercial carpet are also manufactured so that DIMENSIONAL STABILITY to be provided with the woven scrim that is called the second wadding (conventionally being made by polypropylene) that pastes this carpet back side.This scrim pastes the carpet back side of pre-coating with the another kind of adhesive formulation that is commonly referred to race holiday material (skipcoat) or adhesive coating.This race holiday material is applied in scrim, before the carpet parts of assembling are sent into curing oven, this scrim is applied on the pre-coating wadding of this carpet subsequently.The object of this race holiday material or adhesive coating is to provide the material layer that woven scrim is glued to carpet back.
For precoated shet and race holiday material, it is important that the physical property of adhesive is successfully used as carpet coating to them.In this respect, the important requirement that exists many these type coatings to meet.This coating must be able to be used routine in carpet industry be applied on carpet and be dried for the method and apparatus of latex coating.It is bonding to they are securely fixed in wadding to the excellence of villus fiber (pile fiber) that adhesive composition must be able to provide.This coating also will have high filler load conventionally, as the carpet wadding of calcium carbonate, clay, aluminum trihydrate, barite, feldspar, cullet, flying dust and/or recirculation.
The adhesive that is used for the coating composition of carpet product is usually emulsion polymer, i.e. latex dispersion, and it can comprise the copolymer of vinyl esters (as vinyl acetate) and ethene.Adhesive based on vinyl esters/ethylene copolymer and carpet coating compositions are disclosed in for example U.S. Patent number 4,735,986; 5,026,765; 5,849,389 and 6,359,076 and US publication 2005/0287336 in, its full content is incorporated herein by this reference.These copolymers are prepared by the suitable comonomer of polymerization in water-based emulsion.This type of emulsion or dispersions obtained can be by adding conventional surfactants (anionic, nonionic or cationic) to stablize as emulsifying agent.This type of emulsion or dispersion can also be stablized by comprising protective colloid, described protective colloid for example based on polyvinyl alcohol (PVOH), ion modification starch, water soluble starch, starch ether, polyacrylic acid, carboxymethyl cellulose, natural gum, gelatin, synthetic polymer or water-soluble cellulose ether as those of hydroxyethylcellulose (HEC).
Although there are various carpet coating and adhesive compounds based on stabilisation vinyl acetate/ethene (VAE) latex adhesive, advantageously determine with option table and reveal and especially make them can be used for preparing fabric construction as this type of adhesive of the particular type of the desirable balance of the character of carpet product.
Therefore need improved VAE based coating composition and manufacture the method with this type of coating composition for the required adhesion strength characteristic of carpet Application in manufacture.
Summary of the invention
Have been found that now, by by specific vinyl esters/ethylene copolymer dispersion, preferably vinyl acetate/ethene (VAE) copolymer dispersion and the blend of phenylethylene/butadiene (SB) copolymer dispersion, can prepare latex paint composition, described latex paint composition has especially desirable physical property, make them well suited in adhesive compound, as the precoated shet in carpet manufacture and/or race leakage paint adhesive.Especially, can use method of the present invention and latex paint composition to form the carpet product with extra high tuft bind value.
In one embodiment, the present invention relates to carpet product, for example tufting or woven carpet product, comprise at least one substrate and at least one adhesive layer that is connected (being for example directly or indirectly bonded in this substrate) with described at least one substrate, described adhesive layer is formed by the adhesive compound that comprises latex paint composition, and described latex paint composition comprises: (a) at least one has the vinyl esters of alkanoic acid and first copolymer of ethene of 1 to 13 carbon atom; (b) the second copolymer of styrene and butadiene at least, wherein this first and second copolymers colloidal state is dispersed in the aqueous medium that comprises surfactant.This latex paint composition can be sneaked into and served as precoated shet and/or run in the adhesive compound that leaks paint adhesive.Therefore, this substrate can comprise the first wadding or the second wadding.The preferred durable of carpet product of the present invention, shows and is greater than 20N, for example, be greater than the tuft bind value of 27N.
In one embodiment, this latex paint composition serves as for carpet fiber is bonded to the precoated shet on the first wadding as pile.For example, in one embodiment, the present invention is a kind of method that is used to form carpet product, the method comprises the following steps: the adhesive compound that comprises latex paint composition (a) is provided, and described latex paint composition comprises: (i) at least one has the vinyl esters of alkanoic acid and first copolymer of ethene of 1 to 13 carbon atom; (ii) the second copolymer of styrene and butadiene at least, wherein this first and second copolymers colloidal state is dispersed in the aqueous medium that comprises surfactant; (b) make carpet fiber, for example tufted yarn and the first wadding material, for example the first tufting substrate or the contact of woven material; (c) apply this adhesive compound to this carpet fiber and the first wadding material; (d) dry this adhesive compound under the condition that effectively carpet fiber is glued to the first wadding material.
In another embodiment, be optionally combined with said method, this adhesive compound serves as race and leaks paint adhesive in carpet product manufacture.For example, in one embodiment, the present invention relates to a kind of method that is used to form carpet product, the method comprises the following steps: the adhesive compound that comprises latex paint composition (a) is provided, and described latex paint composition comprises: (i) at least one has the vinyl esters of alkanoic acid and first copolymer of ethene of 1 to 13 carbon atom; (ii) the second copolymer of styrene and butadiene at least, wherein this first and second copolymers colloidal state is dispersed in the aqueous medium that comprises surfactant; (b) provide and comprise first carpet layer of tufting to the yarn in the first wadding; (c) this adhesive compound is applied at least one of this first carpet layer or the second wadding; (d) this first carpet layer is contacted with the second wadding; (e) dry this adhesive compound under the condition that effectively the first carpet layer is glued to the second wadding.This first carpet layer optionally forms by the method that uses precoated shet coating composition, and this precoated shet coating composition optionally comprises and the same or similar latex paint composition using for the adhesive compound the first carpet layer being fixed on the second wadding.
Detailed Description Of The Invention
The present invention, in one embodiment, relates to and can be used as being incorporated to fabric construction, the latex paint composition of for example coating in carpet product and adhesive compound.The blend that this latex paint composition comprises the first copolymer (being preferably the first copolymer dispersion form) and the second copolymer (being preferably the second copolymer dispersion form).This first copolymer is at least one vinyl esters with the alkanoic acid of 1 to 13 carbon atom, preferably vinyl acetate, and with the copolymer of ethene, and the second copolymer is the copolymer of styrene and butadiene at least.In the time being used to form fabric, this latex paint composition is astonishing and desirable especially adhesive characteristic, particularly tuft bind value be against expectation provided.This latex paint composition is particularly useful for being used as precoated shet in the formation of carpet product or runs holiday material.Therefore the present invention also relates to the carpet product that uses latex paint composition of the present invention to form, and relates to the method that forms this type of carpet product.
In the latex paint composition of blend the relative quantity of the first copolymer and the second copolymer can be for example to be intended to for precoated shet, to run holiday material or the two changes according to the desirable characteristics of carpet product and this latex paint composition.In one embodiment, the latex paint composition of blend is with 30 to 99 % by weight of all copolymer gross weights in blendlatex coating composition, for example the amount of 40 to 75 % by weight comprises the first copolymer, and with 1 to 70 % by weight, for example the amount of 25 to 60 % by weight comprises the second copolymer.Preferably comprise the first copolymer of larger concentration for the latex paint composition of precoated shet, optionally with 50 to 99 % by weight, for example the amount of 70 to 90 % by weight comprises the first copolymer, and with 1 to 50 % by weight, for example the amount of 10 to 30 % by weight comprises the second copolymer.Preferably comprise the second copolymer of larger concentration for running the latex paint composition of holiday material, and can be for example with 25 to 75 % by weight of all copolymer gross weights in latex paint composition, for example the amount of 25 to 50 % by weight comprises the first copolymer, and with 25 to 75 % by weight, for example the amount of 50 to 75 % by weight comprises the second copolymer.
In some embodiments, latex paint composition of the present invention can comprise one or more outside crosslinking agents.Suitable outside crosslinking agent comprises that carbonate is as zirconium carbonate ammonium (AZC) and potassium zirconium carbonate (KZC).This outside crosslinking agent can optionally add in the first dispersion and/or the second dispersion before or after forming blendlatex coating composition in blend the first and second dispersions.If present, this outside crosslinking agent can be with 1 to 10 % by weight of blendlatex coating composition gross weight, and for example amount of 3 to 10 % by weight is present in this latex paint composition.
Because they preferably form and be blended together subsequently with independent dispersion, this second copolymer does not preferably mix with the first copolymer closely, although it is contemplated that this outside crosslinking agent (if present) can be cross-linked the carboxyl on carboxyl and the second copolymer on the first copolymer effectively.Using in the scope of internal crosslinking agent, preferably this type of crosslinking agent is used for making the first copolymer and himself and/or the second copolymer to be cross-linked with himself, is still not used in internal crosslinking the first copolymer and the second copolymer.In one embodiment, the first and second copolymers comprise respectively internal crosslinking agent, and it can be the crosslinking agent of identical or different type, but this type of crosslinking agent can internal crosslinking the first copolymer and the second copolymer.In another embodiment, this first and second copolymer dispersion and gained blendlatex coating composition of the present invention is not substantially containing inner and/or outside crosslinking agent.
As described, the first and second copolymers that are used to form described latex paint composition herein are preferably manufactured separately respectively in the first dispersion and the second dispersion, and it is blended together to form latex paint composition of the present invention.This first and second dispersion is preferably present in blendlatex coating composition with the amount that is enough to provide good especially carpet intensity.
Degree or toughness that yarn is fixed to carpet wadding material are called " tuft bind " intensity.The carpet with enough tuft bind intensity shows good ABRASION RESISTANCE and has longer service life.In order to have good Performance Characteristics, this viscosity wadding material should permeate the yarn (fibre bundle) being exposed on the first wadding material dorsal part substantially, and should significantly consolidate the single fiber in yarn.The good infiltration of yarn and the consolidation of fiber cause good ABRASION RESISTANCE.In addition,, except good tuft bind intensity and ABRASION RESISTANCE, this adhesive material preferably provides or allows good flexibility so that this carpet is installed to this carpet.In a preferred embodiment, blendlatex coating composition can be used for adhesive compound, and for example carpet precoated shet or run leaks paint adhesive and has to form being greater than 15N, for example, being greater than 20N or being greater than the carpet composition of the tuft bind value of 27N of measuring by ASTM D-1335.For velvet carpet, this tuft bind value preferably exceedes 2.3lbs f (10.2N).For loop-pile carpet, this tuft bind value preferably exceedes 3.5lbs f (15.6N), more preferably exceedes 6.25lbs f (27.8N) and most preferably exceedes 10lbs f (44.5N).
Because tuft bind value can change according to carpet type, the similar carpet that the coating composition that this tuft bind intensity can contain the first dispersion (not with the second dispersion blend) with respect to use forms is characterized by " tuft bind percentage ".In this respect, blendlatex coating composition of the present invention can provide to have and be greater than 125%, is greater than 150%, is greater than 175% or be greater than the carpet of 200% tuft bind percentage.
The first and second dispersions that contain respectively this first and second copolymer can be used conventional emulsion polymerisation program preparation.These class methods are generally described in for example U.S. Patent number 5,849, in 389, it is incorporated herein by this reference in full, and be described in Chorng-Shyan Chern, Principles and Applications of Emulsion Polymerization, in John Wiley and Sons Inc. (2008), it is incorporated herein by this reference in full.
In the time forming this first and second dispersion, monomer separately can be no more than polymerization in aqueous medium under the existence of catalyst and at least one emulsifying agent under 100 atmospheric pressure.For arbitrary dispersion, this water-based system can remain under 2 to 6 or 4 to 6 pH value by suitable buffer, and catalyst can incrementally or continuously add.For the first dispersion, vinyl esters, for example vinyl acetate, and another comonomer (if present) of 50% to 75% can be suspended in water and under operating pressure and under the existence of ethene, fully to stir the obtaining solution of ethene in this mixture until the essence limit of its solubility under the condition existing in conversion zone.This vinyl acetate and other optional comonomer can be heated to polymerization temperature subsequently gradually.In some embodiments, the first dispersion and/or the second dispersion or gained blendlatex coating composition of the present invention does not contain or substantially contains deflocculant, as polyvinyl alcohol, optionally comprise be less than 1.5pphm polyvinyl alcohol, be less than the polyvinyl alcohol of 1.0pphm or be less than the polyvinyl alcohol of 0.5pphm, it has now been found conventionally incompatible with SB dispersion.In other side, the polyvinyl alcohol that is less than 1.0 % by weight that the first dispersion and/or the second dispersion or gained blendlatex coating composition of the present invention comprises total monomer weight, or be less than the polyvinyl alcohol of 0.5 % by weight.But, can expect, some protective colloid, can be compatible with SB dispersion as hydroxyethylcellulose.
Conventionally connect with polymerization period at homogenizing after date, in polymerization period process, comprise major catalyst or initator and can comprise that the catalyst of activator increases progressively or adds continuously together with residue comonomer (if present).Monomer used can add with pure monomer form or with premixed emulsion form.
After polymerization, the solid content of gained the first and/or second dispersion can be by adding water or being adjusted to desired level by dephlegmate.Conventionally, for this first and second dispersion, 40 to 70 % by weight, 40 to 60 % by weight or 45 to 55 % by weight that the desired level of polymer solids content is each total dispersion weight.
The first dispersion or the second dispersion, or the granularity of the blend of gained the first and second dispersions can regulate by the amount of the nonionic surface active agent of use or anionic surfactant.In order to obtain less granularity, use more substantial surfactant.As general rule, the amount of the surfactant of use is larger, and particle mean size is less.
Described dispersion and coating composition be not optionally substantially containing alkylphenol ethoxylate (APE) herein.For the purposes of this invention, if this type of dispersion and coating composition contain the APE that is less than 500wppm, they are considered to substantially not containing APE's.In other embodiments, this dispersion, for example the first dispersion, the second dispersion or gained blendlatex dispersion of the present invention can comprise a small amount of APE.
The first dispersion
The first dispersion preferably by least one have 1 to 13 carbon atom alkanoic acid vinyl esters and ethene and choose any one kind of them or the emulsion polymerisation of multiple additional comonomer forms.The non-limiting list of the example of this type of alkanoic acid comprises vinyl formate, vinyl acetate, propionate, vinyl butyrate, isobutyric acid vinyl acetate, valeric acid vinyl acetate, 2 ethyl hexanoic acid vinyl acetate, isooctyl acid vinyl acetate, n-nonanoic acid vinyl acetate, capric acid vinyl acetate, new vinyl acetate acid (vinyl pivalate), tertiary ethylene carbonate (vinyl versatate) and composition thereof.Wherein, vinyl acetate is preferred monomers, because of its be easy to obtain and cost low.The preferred monomers combination of the first copolymer comprises vinyl acetate/ethene, vinyl acetate/propionate/ethene, vinyl acetate/vinyl neodecanoate/ethene, vinyl acetate/ethene/vinyl chloride.
Most preferably, vinyl esters (for example vinyl acetate) content that is used for the first copolymer of this embodiment will be for about 70 to 90pphm, for example 72pphm to 88pphm, 75pphm to 95pphm, 75pphm to 85pphm or about 78pphm to 82pphm (based on the umber of every hundred parts of whole monomers in copolymer).
Conventionally the ethylene contents that, should select the first copolymer provides aspect the adhesive compound of desirable high bonding strength especially effectively latex paint composition to provide in preparation.In some embodiments, this ethene will account for the 10pphm to 30pphm of the first copolymer, and for example 10 to 25pphm, 12pphm to 20pphm or 18 to 22pphm.More preferably, ethene will account for the 5pphm to 25pphm of the first copolymer conventionally, and for example 5 to 20pphm or 8 to 18pphm.More preferably, ethene will be present in this first copolymer with the amount of 8pphm to 16pphm.
If this first copolymer further comprises the 3rd comonomer, this first copolymer can be for example with 0.1 to 10pphm, for example 0.1 to 5pphm amount comprises the 3rd monomer.The comonomer of examples of such optional for example can be selected from vinyl halide as vinyl chloride, ethylenic unsaturated acid or its salt, there is the ethylenically unsaturated monomer of at least one acid amides, epoxy, hydroxyl, N-methylol, trialkoxy silane or carbonyl, and be selected from the combination of two or more monomers of described the 3rd monomer type arbitrarily.Optional comonomer can also be selected from the not vinyl esters of vinyl acetate, and nonvinylic alpha-olefin, vinyl aromatic compounds, the ester of olefinic unsaturated monocarboxylic and the diester of ethylenically unsaturated dicarboxylic.
Preferably, this first copolymer is in the stable emulsion polymerization process of surfactant instead of form in protective colloid-stabilised polymerization process.As a result, the particle mean size of the first copolymer tends to be less than the copolymer forming under protective colloid exists.In exemplary, this first copolymer have use by 90 Plus Particle Size Analyzer (Brookhaven Instruments) that the 35mW solid-state laser of 658 nano wave lengths at room temperature measures 50 to 500nm, for example 100 to 400nm, 150 to 350nm or 200 to 320nm particle mean size.
Optionally, this first copolymer further comprises the comonomer that serves as internal crosslinking agent.For example, this first copolymer optionally further comprises polyenoid and belongs to undersaturated comonomer, and it is selected from triallyl cyanurate, triallyl isocyanurate, diallyl maleate, diallyl fumarate, divinylbenzene, diallyl phthalate, silane and glycidyl methacrylate (GMA).Being incorporated to of one or more of these comonomers can improve branching or crosslinked valuably, improves molecular weight and improves performance.
In some embodiments, this first copolymer comprises and is selected from α, the unsaturated C of β-olefinic 3-C 10monocarboxylic acid, α, the unsaturated C of β-olefinic 4-C 10dicarboxylic acids with and acid anhydrides, and this α, the unsaturated C of β-olefinic 4-C 10the C of dicarboxylic acids 1-C 18the cross-linking comonomer of alkyl half ester.Such Exemplary comonomers comprises the C of acrylic acid and methacrylic acid, maleic acid, maleic anhydride, fumaric acid, itaconic acid and maleic acid 4-C 8alkyl half ester.
In another embodiment, this first copolymer comprises the cross-linking comonomer that is selected from olefinic unsaturated silane compound.Exemplary olefinic unsaturated silane comonomer is disclosed in the open WO 2011/139267 of for example PCT, and it is incorporated herein by this reference in full.This comonomer is conventionally corresponding to the substituted silane of structural formula I:
Wherein R is illustrated in the undersaturated organic group of olefinic of ω-position, and R 1, R 2and R 3, it can be identical or different, represents halogen, preferably chlorine, or group-OZ, and Z represents the acyl group of hydrogen or primary alkyl or secondary alkyl or optional alkoxy replacement.
The suitable unsaturated silane compound of formula I is preferably selected from radicals R in this formula wherein and represents ω-unsaturated chain thiazolinyl of 2 to 10 carbon atoms, particularly 2 to 4 carbon atoms, or those of the ω-esters of unsaturated carboxylic acids forming by the unsaturated carboxylic acid of maximum 4 carbon atoms with the alcohol of the Si group of maximum 6 carbon atoms.Suitable radicals R 1, R 2, R 3preferably group-OZ, Z represents maximum 10 carbon atoms, preferably primary alkyl and/or the secondary alkyl of maximum 4 carbon atoms, or the alkyl that preferably alkoxy of maximum 3 carbon atoms replaces, or maximum 6 carbon atoms, the preferably acyl group of maximum 3 carbon atoms, or hydrogen.Most preferred unsaturated silane comonomer is vinyl trialkyl oxysilane.
The example of the preferred silane compound of formula I comprises vinyl trichlorosilane, vinyl dimethyl dichlorosilane (DMCS), γ-methacryloxypropyl three (2-methoxy ethoxy) silane, vinyl methoxy silane, vinyltrimethoxy silane, vinyltriethoxysilane, vinyl diethoxy silane alcohol, vinyl Ethoxysilane glycol, allyltriethoxysilane, vinyl tripropoxy silane, vinyl silane triisopropoxide, vinyl three butoxy silanes, vinyltriacetoxy silane, trimethyl glycol vinyl silanes, γ-methacryloxypropyl trimethyl glycol silane, γ-acryloxy propyl-triethoxysilicane and γ-methacryloxypropyl trimethoxy silane.
Another group cross-linking comonomer is made up of the ethylenically unsaturated monomer that contains epoxide group, for example, and allyl glycidyl ether, methacryl glycidyl ether, butadiene monoepoxide, 1,2-epoxy-5-hexene, 1,2-epoxy-7-octene, 1,2-epoxy-9-decene, 8-hydroxyl-6,7-epoxy-1-octene, 8-acetoxyl group-6,7-epoxy-1-octene, N-(2,3-glycidyl) acrylamide, N-(2,3-glycidyl) Methacrylamide, 4-acrylamido phenyl glycidyl ether, 3-acrylamido phenyl glycidyl ether, 4-methacrylamido phenyl glycidyl ether, 3-methacrylamido phenyl glycidyl ether, N-glycidoxypropyl Methacrylamide, N-glycidoxypropyl Methacrylamide, N-glycidoxypropyl ethyl acrylamide, N-glycidoxypropyl ethyl-methyl acrylamide, N-glycidoxypropyl acrylamide, N-glycidoxypropyl Methacrylamide, N-glycidoxypropyl butyl acrylamide, N-glycidoxypropyl butyl methyl acrylamide, 4-acrylamide ylmethyl-2,5-3,5-dimethylphenyl glycidol ether, 4-methacrylamido methyl-2,5-3,5-dimethylphenyl glycidol ether, acrylamido propyl-dimethyl (2,3-glycidyl) ammonium chloride, methacrylamido propyl-dimethyl (2,3-glycidyl) ammonium chloride and glycidyl methacrylate.
Aforementioned cross-linking comonomer (if any) will be conventionally with 0.05pphm to 5pphm, and for example 0.05 is present in this first copolymer to the amount of 1pphm or 0.05pphm to 0.5pphm.More preferably, this type of polyenoid belongs to unsaturated comonomer/crosslinking agent (if any) amount with 0.2pphm to 0.8pphm is used for to this first copolymer.
Prepare and can have for the first copolymer of this latex paint composition the ethene segment of amorphous and crystallization herein.The content of amorphous ethene segment in this copolymer is measured by the glass transition temperature (Tg) of this copolymer.
According to an embodiment, can be for the preparation of the first copolymer of the dispersion making herein of carpet manufacture for example, to there are approximately-10 DEG C to about 20 DEG C, the Tg of about-10 DEG C to about 15 DEG C.In some aspects, this Tg can be-5 DEG C to 5 DEG C.In other side, can prepare the first dispersion having approximately+5 DEG C to the approximately+Tg of 15 DEG C, preferably approximately+8 DEG C to+10 DEG C.The Tg of this first copolymer can be by regulating ethylene contents to control, and common, with respect to other comonomer, the ethene existing in polymer is more, and this Tg is just lower.
The dispersion that comprises the first copolymer mentioned above can be used the preparation of conventional emulsion polymerization method, and the method can be prepared the dispersion of water-based latex form.These class methods are for example described in U.S. Patent number 5,849, and in 389, its disclosure is incorporated to herein through this incorporated.
In typical polymerization process, this vinyl esters, preferably vinyl acetate, can be no more than polymerization in aqueous medium under the existence of catalyst and at least one emulsifying agent under 100 atmospheric pressure with ethene and optional one or more the 3rd additional comonomers.This water-based volume can remain under 2 to 6 pH value by suitable buffer, and catalyst can incrementally or continuously add.More specifically, vinyl acetate and another comonomer (if present) of 50% to 75% can be suspended in and in water and under operating pressure, under the existence of ethene, fully stir to obtain the solution of ethene in this mixture until the essence limit of its solubility under the condition existing in conversion zone.This vinyl esters, for example vinyl acetate and other comonomer (if any) can be heated to polymerization temperature subsequently gradually.
As mentioned above, conventionally connect with polymerization period at homogenizing after date, in polymerization period process, the catalyst that comprises major catalyst or initator and can comprise activator increase progressively or continuously with residue comonomer (if present), for example one or more the 3rd comonomers add together.If you are using, one or more the 3rd comonomers can add with pure monomer form or with premixed emulsion form.
The suitable polymerization catalyst that is used to form the first dispersion comprises mentioned above and is generally used for the water-soluble free radical forming agent of emulsion polymerisation, as hydrogen peroxide, sodium peroxydisulfate, potassium peroxydisulfate and ammonium persulfate, and tert-butyl hydroperoxide, optionally with 0.01 % by weight to 3 % by weight of emulsion total amount, the preferred amount of 0.01 % by weight to 1 % by weight.This catalyst can with reductant as together with sodium sulfoxylate formaldehyde, ferrous salt, sodium dithionite, sodium hydrogensulfite, sodium sulfite, sodium thiosulfate, ascorbic acid, arabo-ascorbic acid or its salt with 0.01 % by weight to 3 % by weight of emulsion total amount, preferably the amount of 0.01 % by weight to 1 % by weight is as oxidation reduction catalyst.This free radical forming agent can be loaded in aqueous emulsifier solution or in polymerization process according to dosage adds.In a preferred embodiment, in this polymerization, use reductant Bruggolite FF6 tM.FF6 comprises three kinds of sulfenyl reductants: (i) 2-hydroxyl-S-sulfinic acid guanidine-acetic acid disodium salt (50-60%); (ii) sodium sulfite (30-35%); (iii) 2-hydroxyl-2-sulfonic group acetic acid disodium salt (10-15%).
The mode that merges polymerization composition can be to be undertaken by various known monomer feed methods, as continuous monomer adds, cumulative monomer adds or all monomers of amount of disposable interpolation.All the aqueous medium that contains polymeric additive of amount can be present in this aggregation container before introducing monomer, or this aqueous medium, or its part, can in the process of polymerisation, add continuous or cumulatively.
Emulsion polymerization for the preparation of the first copolymer of water-based latex form preferably carries out under the existence of stabilization systems, and described stabilization systems comprises one or more anionics and/or nonionic surface active agent as emulsifying agent.
The suitable nonionic surface active agent that is used as emulsifying agent in the emulsion-stabilizing system of coating composition that can be in this article comprises polyoxyethylene condensation product.Preferably do not comprise the ethoxylated non-ionic surface active agent based on alkyl phenol for this type of ethoxylated non-ionic type surfactant of stablizing adhesive dispersion of the present invention.Operable exemplary polyoxyethylene condensation product comprises polyoxyethylene aliphatic ether, as polyoxyethylene laurel ether and polyoxyl 10 oleyl ether; Polyoxyethylene alkyl aryl ether, as polyoxyethylene nonylphenyl ether and polyoxyethylene octyl phenol ether; The polyoxyethylene ester of higher fatty acids, as polyoxyethylene laurate and polyoxyethylene oleate, and the condensation product of oxirane and resin acid and tall oil acid; Polyoxyethylate amide and amine condensation product, as N-polyoxyethylene lauramide, and N-lauryl-N-polyoxyethylene amine etc.; And polyoxyethylene thioether, as polyoxyethylene dodecyl thioether.
Operable nonionic surface active agent also comprises can be with trade name Pluronic tMwith Tetronic tMavailable from a series of surfactants of BASF.Pluronic surfactant is oxirane (EO)/expoxy propane (PO)/epoxyethane block copolymer, by preparing on controlled PO two hydroxyls that add to propylene glycol.Add EO subsequently to hydrophobic chain segment is clipped between two hydrophilic radicals, by length control to form 10% to 80% (w/w) of final molecule.Pluronic surfactant is by EO being added to the PO/EO/PO block copolymer of ethylene glycol to provide the hydrophilic segment of design molecular weight to prepare.Add PO subsequently to obtain hydrophobicity block on the outside of this molecule.Tetronic surfactant is the four functional blocks copolymers that add EO and PO derived from order in ethylene diamine.Tetronic surfactant adds EO by order in ethylene diamine and PO manufactures.In addition, by Air Products with trade name Surfynol tMthe ethylene oxide adduct of a series of acetylenic glycol of selling is also suitable for as nonionic surface active agent.
The suitable anion surfactant that can be used as the emulsifying agent in the adhesive latex component of described carpet coating compositions herein comprises alkylaryl sulfonates, alkali metal alkyl sulfate, sulfonated Arrcostab and fatty acid soaps.Instantiation comprises neopelex, sodium butylnaphthalenesulfonate, NaLS, dodecyl diphenyl ether disulfonic acid disodium, N-octadecyl sulfosuccinate and dioctyl sodium sulphosuccinate.This surfactant is effectively to realize the suitable emulsification of polymer in water and to provide desired particle size and the amount of size distribution is used.In this area, known other composition that can be used for various special-purposes in emulsion polymerisation, as acid, salt, chain-transferring agent and chelating agent, also can be used for the preparation of this polymer.For example, belong to undersaturated carboxylic acid monomer if polymerizable composition comprises monoene, the polymerization under acid condition (pH2 to 7, preferably 2 to 5) is preferred.In such cases, aqueous medium can comprise those known weak acid and salt thereof of being generally used for providing the buffer system under required pH scope.
Routinely, as the substituting or supplementing of surfactant emulsifiers, various protective colloids are for the stable vinyl acetate/vac emulsion of described type above.For the dispersion that will use, can use the protective colloid of about 2 % by weight at most, as cellulose ether or other GPF (General Protection False gelatification material in fabric construction.In the time that one or more surfactants are combined, it can be for example acceptable or required using hydroxyethylcellulose.Dispersion for this object can also be substantially containing protective colloid.In some embodiments, the first dispersion, the second dispersion and/or blendlatex coating composition of the present invention not containing or substantially containing polyvinyl alcohol, optionally comprise be less than 1.5pphm polyvinyl alcohol, be less than the polyvinyl alcohol of 1pphm or be less than the polyvinyl alcohol of 0.5pphm.It in other embodiments, can use a small amount of polyvinyl alcohol, as long as can not make the first dispersion incompatible with the second dispersion.For example, in some embodiments, be used to form fabric construction as the latex paint composition of tufted carpet in, this first dispersion can comprise the polyvinyl alcohol of about 1 to 2 % by weight.
As mentioned above, the first copolymer in the dispersion of preparation can have conventionally as at room temperature measure by the 35mW solid-state laser of 90 Plus Particle Size Analyzer (Brookhaven Instruments) use 658 nano wave lengths 50 to 500nm herein, for example 100 to 400nm, 150 to 350nm, 150 to 200nm or 200 to 320nm average grain diameter dw.Can there is 200 to 600nm average grain diameter dw for the preparation of the copolymer in the dispersion of tufted carpet.The viscosity of this dispersion can differ widely, and is 50 to 400mPas in some respects, or can be larger, may be 400 to 1,600mPas, as recorded at 25 DEG C with Brookfield viscosimeter.
The second dispersion
The second dispersion is preferably by least styrene and butadiene (SB) and choose any one kind of them or multiple additional comonomer forms as the emulsion polymerisation of acrylonitrile (SBA) or acrylic comonomers.
As above, to as described in the first copolymer, this second copolymer optionally further comprises the comonomer that serves as internal crosslinking agent.For example, this second copolymer optionally further comprises polyenoid and belongs to undersaturated comonomer, and it is selected from triallyl cyanurate, triallyl isocyanurate, diallyl maleate, diallyl fumarate, divinylbenzene and diallyl phthalate.Such preferred comonomers comprises diallyl maleate, diallyl fumarate and diallyl phthalate.Such polyenoid belongs to unsaturated comonomer (if any) and is conventionally present in this second copolymer with the amount of 0.05pphm to 0.5pphm.More preferably, this type of polyenoid belongs to unsaturated comonomer/crosslinking agent (if any) amount with 0.1pphm to 0.3pphm is used for to this second copolymer.
The method of manufacturing the second dispersion before blend can be that SB or SBA change according to this second polymer.Conventionally, this type of second dispersion can form by known emulsion polymerization technology, and illustrative methods is for this reason disclosed in for example U.S. Patent number 5,288,787; 5,326,853; 5,362,798; With 6,365, in 647, it is incorporated herein by this reference in full.The catalyst that is used to form the second dispersion can be selected to form the first dispersion relevant above-mentioned those.
The raw material that are used to form the second dispersion for example generally include monomer (be styrene and butadiene for SB, or be styrene, butadiene and acrylonitrile for SBA), water, emulsifying agent, initiator system, modifier, free radical scavenger (for example aminodithioformic acid dimethyl ester or diethyl hydroxylamine) and stabiliser system.This polymerization process can in batches or be carried out continuously.In continuous process, monomer is metered in reactor chain and with emulsifying agent emulsification together with catalyst.Initiator system can be the redox reaction for example using between chelated iron and the organic peroxide of for example formaldehyde sulfoxide sodium (SFS) of reductant.Or potassium persulphate can be used as this initator.The method can be used as cold polymerization process or heat polymerization process is carried out.Amine-thiol chain transfer agents can be used for providing free radical and controls molecular weight distribution.In the process of polymerization, can control reaction condition for example temperature, flow and stirring so that required level of conversion to be provided.
The relative quantity of the monomer of the second dispersion also can extensively change.This second polymer is in the embodiment of SB therein, and styrene can exist with 20 to 80pphm amount, and butadiene can exist with 20 to 80pphm amount.In other embodiments, styrene can exist with 5 to 50pphm, 10 to 40pphm or 20 to 30pphm amount, and butadiene can exist with 50 to 95pphm, 60 to 90pphm or 70 to 80pphm amount, based on the whole monomers in the second dispersion.Larger styrene is also possible to the ratio of butadiene.This styrene for example can exist with the amount of 40 to 75pphm, 55 to 70pphm or 60 to 65pphm of whole monomers in the second dispersion, and butadiene can exist with 25 to 60pphm, 30 to 45pphm or 35 to 40pphm amount.
In the time that the second polymer is SBA, styrene can for example exist with 30 to 70pphm, 40 to 60pphm or 45 to 55pphm amount, butadiene can exist with 1 to 40pphm, 5 to 30pphm or 10 to 25pphm amount, acrylonitrile can exist with 5 to 45pphm, 15 to 35pphm or 20 to 30pphm amount, all the whole monomers based in the second dispersion.For SBA and manufacture SBA method further describe the C.A. referring to Harper, Handbook of Plastic and Elastomers, McGraw-Hill, New York (1975), it is incorporated herein by this reference in full.
Adhesive compound
Fabric construction herein has the latex paint composition of the present invention of sneaking into wherein as a part for adhesive compound conventionally.This type of adhesive compound is except above containing multiple conventional additives to change its character described latex paint composition.Wherein, these additives can comprise filler, thickener, catalyst, blowing agent, dispersant, colouring agent, bactericide, defoamer etc.The fabric construction that contains the adhesive compound of being prepared by described latex paint composition herein can have about 1000 to 4000 grams/m, for example per unit area weight of 1000 to 3000 grams/m.
The viscosity of this adhesive compound can extensively change, and depends primarily on the required purposes of said composition.Aspect general, this adhesive compound can have 2,000 to 60,000cP viscosity.Lower viscosity, for example 4000 to 15000cP, can be preferred to the adhesive compound of applying for precoated shet.For running leakage application of paints, 10,000 to 18,000cP viscosity may be to use the coating machine of roller or dish method needed, and may need 25,000 to 45,000cP viscosity to Tilitson type coating machine.Described latex paint composition or adhesive compound can also contain enough alkali to keep 6 to 10, more preferably 7 to 9 pH value herein.
Thus, in another embodiment, the present invention relates to a kind of adhesive compound, preferably paint adhesive is leaked in carpet precoated shet or race, comprise the stable copolymer emulsion coating composition of aqueous tenside, and be enough to the alkali of the pH value that realizes 6 to 10, this latex paint composition has and is scattered in the first copolymer of the alkanoic acid with 1 to 13 carbon atom wherein and ethene and the second copolymer of styrene and butadiene at least, and wherein this latex paint composition is stable with anionic and/or nonionic emulsifier.Preferably, this latex paint composition is with the first dispersion that comprises vae copolymer thing as above with comprise at least blend formation of the second dispersion of styrene and butadiene.Said composition is not preferably substantially containing APE.
Latex paint composition of the present invention and the performance of this type of latex paint composition in carpet composition are described by following non-limiting examples.
Embodiment 1-4
By in varing proportions various VAE dispersions as shown in table 1 and the blend of SB dispersion being prepared to several blendlatex coating compositions to test its compatibility each other.The SB dispersion using in embodiment 1-4 is Rovene 4487 (Mallard Creek Polymers), this SB dispersion have the solid content of 54.5 to 55.5 % by weight, approximately the styrene of 62:38 to butadiene weight ratio, 200 to 1500cps Brookfield viscosity and approximately+Tg of 11 DEG C.
In table 1, formula and ratio are provided to embodiment 1-4.As shown in table 1, each embodiment with different VAE and/or SB and with several different VAE:SB than and different filler carrying capacity carry out.Embodiment 1-4 also comprises for the VAE based adhesive of not blend relatively and the SB based adhesive of blend not.The dry umber that all amounts shown in table are by weight.
To as shown in table 2, each embodiment is carried out to different viscosity measurements to measure VAE/SB compatibility.Initial viscosity has reflected adding blended adhesive viscosity before filler.Final viscosity comprises the filler of the amount showing in table 1.After adding filler, the adhesive that makes blend without leaving standstill 24 hours under stirring state, and is measured 24 hours and is not stirred viscosity under environmental condition, then stirs about 5 minutes and measures 24 hours and stir viscosity.Table 2 has also shown the amount of the thickener (Sodium Polyacrylate thickener, CT1015) adding in different adhesive formulas.
Because of its extra high initial viscosity, in embodiment 4B, add 3.2 grams of water and do not add any thickener.When with other embodiment comparison the high initial viscosity of embodiment 4B show surfactant-stabilized VAE dispersion astonishing with against expectation more can be compatible with SB compared with PVOH stabilisation VAE dispersion.The result presenting in table 2 shows, polyvinyl alcohol stabilized VAE can not be identical with SB.Having the more blend of high viscosity (instable index) fails precoated shet compound stability further to test.
According to the formula showing in table 3, the blend with acceptable viscosity is prepared to pre-coat adhesive subsequently.
Pre-coat adhesive is shaped to solid level and the 9000-10 of 84 % by weight, the target viscosities of 000cPs.Once be shaped, be applied on Beaulieu carpet (be made up of 300 Denier polypropylene fibers, fibrous face weight is 20oz/sq yd (678 grams/m)) with the target coating weight of about 22-24oz/sq yd (746-813 gram/m) this pre-coat adhesive as precoated shet.Subsequently gained pre-coat adhesive is dried, and tests the tuft bind value of carpet sample, result is reported in table 4.
As shown in table 4, those of the pre-coat adhesive of several blend, particularly embodiment 1B and 3B, show astonishing especially and unforeseeable high tuft bind value.
Embodiment 5
In embodiment 5A, several VAE/SB dispersions are prepared with different ratios by two kinds of different VAE SB different with two kinds.VAE (VAE1) in embodiment 5A is polyvinyl alcohol stabilized with the surfactant of 2.5 weight portions and 2.5 weight portions, and surfactant-stabilized with the polyvinyl alcohol of 4.5 weight portions and 0.5 weight portion of VAE (VAE2) in embodiment 5B.Subsequently along with the past of time obtains viscosity measurement to determine the relative stability of dispersion blend.Relative composition and viscosity results are provided at table 5 in 6 respectively for embodiment 5A and 5B.Do not wish to be bound by theory, in embodiment 5B, the high density polyethylene alcohol of VAE has seemed to improve the viscosity of dispersions obtained blend, has reflected that improve and incompatibility SB.
Although specifically described exemplary of the present disclosure, it being understood that various other changes it will be apparent to those skilled in the art that and can easily carry out in the situation that not leaving spirit of the present disclosure and scope.Therefore, the scope of claims does not want to be limited to the embodiment and the description that provide herein, claims should be considered as having comprised all features with patent novelty that are present in the disclosure, comprise all features of disclosure those skilled in the art as its equivalent processing.

Claims (53)

1. carpet product, comprises at least one substrate and at least one adhesive layer being connected with described at least one substrate, and described adhesive layer is formed by latex paint composition, and described latex paint composition comprises:
(a) at least one has the vinyl esters of alkanoic acid and first copolymer of ethene of 1 to 13 carbon atom; With
(b) the second copolymer of styrene and butadiene at least, wherein this first and second copolymers colloidal state is dispersed in the aqueous medium that comprises surfactant.
2. carpet product according to claim 1, at least one adhesive layer being wherein connected with at least one substrate is that carpet fiber is bonded to this suprabasil precoated shet.
3. carpet product according to claim 1, at least one adhesive layer being wherein connected with at least one substrate is that the first backing layer is bonded to the race holiday bed of material on the second backing layer.
4. according to the carpet product described in aforementioned claim any one, there is the tuft bind value that is greater than 20N.
5. according to the carpet product described in aforementioned claim any one, there is the tuft bind value that is greater than 27N.
6. according to the carpet product described in aforementioned claim any one, there is the tuft bind percentage as defined herein that is greater than 150%.
7. according to the carpet product described in aforementioned claim any one, wherein this first copolymer exists with the amount of 30 to 99 % by weight, and this second copolymer exists with the amount of 1 to 70 % by weight.
8. according to the carpet product described in aforementioned claim any one, wherein this first copolymer exists with the amount of 40 to 75 % by weight, and this second copolymer exists with the amount of 25 to 60 % by weight.
9. according to the carpet product described in aforementioned claim any one, wherein this first copolymer is to have vinyl esters, ethene and the acrylic monomers of alkanoic acid of 1 to 13 carbon atom or the copolymer of its ester.
10. according to the carpet product described in claim 1-8 any one, the copolymer that wherein this first copolymer comprises vinyl acetate, vinyl neodecanoate and ethene.
11. according to the carpet product described in claim 1-8 any one, and wherein this first copolymer comprises 75 to 95pphm vinyl acetate and 5 to 25pphm ethene.
12. according to the carpet product described in aforementioned claim any one, and wherein this first copolymer has 100 to 400nm the particle mean size that uses by 90 Plus Particle Size Analyzer that the 35mW solid-state laser of 658 nano wave lengths at room temperature measures.
13. according to the carpet product described in aforementioned claim any one, and wherein this second copolymer comprises 20 to 80pphm styrene and 20 to 80pphm butadiene.
14. according to the carpet product described in claim 1-12 any one, the copolymer that wherein this second copolymer is styrene, butadiene and acrylonitrile.
15. according to the carpet product described in aforementioned claim any one, wherein this first copolymer or this second copolymer further comprise polyenoid and belong to unsaturated comonomer, and this monomer is selected from triallyl cyanurate, triallyl isocyanurate, diallyl maleate, diallyl fumarate, divinylbenzene, diallyl phthalate, silane and GMA.
16. according to the carpet product described in aforementioned claim any one, wherein this adhesive layer further comprises filler, and described filler is selected from the combination of kaolin, calcium carbonate, aluminum trihydrate ATH, recirculation filler, cullet, silica, flying dust and described filler.
17. according to the carpet product described in aforementioned claim any one, and wherein this latex paint composition is stable with at least one anionic or nonionic surface active agent.
18. according to the carpet product described in aforementioned claim any one, and wherein this latex paint composition has the solid content of 40 to 70 % by weight.
19. according to the carpet product described in aforementioned claim any one, the blend that wherein this latex paint composition comprises the first dispersion that contains the first copolymer and the second dispersion that contains the second copolymer.
20. according to the carpet product described in aforementioned claim any one, and wherein this first dispersion comprises the polyvinyl alcohol that is less than 1.0pphm.
21. according to the carpet product described in aforementioned claim any one, and wherein this first dispersion comprises the polyvinyl alcohol that is less than 0.5pphm.
22. according to the carpet product described in claim 1-19 any one, the polyvinyl alcohol that is less than 1.0 % by weight that wherein this first dispersion comprises all total monomer weights.
23. according to the carpet product described in aforementioned claim any one, and wherein this first and second copolymer does not mix closely.
24. according to the carpet product described in aforementioned claim any one, and wherein this adhesive compound has 2,000 to 60,000cP viscosity.
25. according to the carpet product described in aforementioned claim any one, and wherein this latex paint composition has after 48 hours and to improve the final viscosity as defined herein that is no more than 50%.
26. according to the carpet product described in aforementioned claim any one, and wherein this latex paint composition further comprises hydroxyethylcellulose.
27. form the method for carpet product, and the method comprises the following steps:
(a) provide the adhesive compound that comprises latex paint composition, described latex paint composition comprises:
(i) at least one has the vinyl esters of alkanoic acid and first copolymer of ethene of 1 to 13 carbon atom; With
(ii) the second copolymer of styrene and butadiene at least, wherein this first and second copolymers colloidal state is dispersed in the aqueous medium that comprises surfactant;
(b) make carpet fiber contact with the first wadding material;
(c) apply this adhesive compound to this carpet fiber and the first wadding material; With
(d) dry this adhesive compound under the condition that effectively carpet fiber is glued to the first wadding material.
28. methods according to claim 27, wherein this carpet product has the tuft bind value that is greater than 20N.
29. methods according to claim 27, wherein this carpet product has the tuft bind value that is greater than 27N.
30. according to the method described in claim 27-29 any one, and wherein this carpet product has the tuft bind percentage as defined herein that is greater than 150%.
31. according to the method described in claim 27-30 any one, and wherein this first copolymer exists with the amount of 30 to 99 % by weight, and this second copolymer exists with the amount of 1 to 70 % by weight.
32. according to the method described in claim 27-31 any one, and wherein this first copolymer exists with the amount of 40 to 75 % by weight, and this second copolymer exists with the amount of 25 to 60 % by weight.
33. according to the method described in claim 27-32 any one, the copolymer that wherein this first copolymer comprises vinyl acetate, vinyl neodecanoate and ethene.
34. according to the method described in claim 27-32 any one, and wherein this first copolymer is to have vinyl esters, ethene and the acrylic monomers of alkanoic acid of 1 to 13 carbon atom or the copolymer of its ester.
35. according to the method described in claim 27-32 any one, and wherein this first copolymer comprises 75 to 95pphm vinyl acetate and 5 to 25pphm ethene.
36. according to the method described in claim 27-35 any one, and wherein this first copolymer has 100 to 400nm the particle mean size that uses by 90 Plus Particle Size Analyzer that the 35mW solid-state laser of 658 nano wave lengths at room temperature measures.
37. according to the method described in claim 27-36 any one, the copolymer that wherein this second copolymer is styrene, butadiene and acrylonitrile.
38. according to the method described in claim 27-36 any one, and wherein this second copolymer comprises 20 to 80pphm styrene and 20 to 80pphm butadiene.
39. according to the method described in claim 27-38 any one, wherein this first copolymer or this second copolymer further comprise polyenoid and belong to unsaturated comonomer, and this monomer is selected from triallyl cyanurate, triallyl isocyanurate, diallyl maleate, diallyl fumarate, divinylbenzene, diallyl phthalate, silane and GMA.
40. according to the method described in claim 27-39 any one, wherein this adhesive compound further comprises filler, and described filler is selected from the combination of kaolin, calcium carbonate, aluminum trihydrate ATH, recirculation filler, cullet, silica, flying dust and described filler.
41. according to the method described in claim 27-40 any one, and wherein this latex paint composition is stable with at least one anionic or nonionic surface active agent.
42. according to the method described in claim 27-41 any one, and wherein this latex paint composition has the solid content of 40 to 70 % by weight.
43. according to the method described in claim 27-42 any one, the blend that wherein this latex paint composition comprises the first dispersion that contains the first copolymer and the second dispersion that contains the second copolymer.
44. according to the method described in claim 27-43 any one, and wherein this first dispersion comprises the polyvinyl alcohol that is less than 1.0pphm.
45. according to the method described in claim 27-43 any one, and wherein this first dispersion comprises the polyvinyl alcohol that is less than 0.5pphm.
46. according to the method described in claim 27-43 any one, the polyvinyl alcohol that is less than 1.0 % by weight that wherein this first dispersion comprises all total monomer weights.
47. according to the method described in claim 27-46 any one, and wherein this first and second copolymer does not mix closely.
48. according to the method described in claim 27-47 any one, and wherein this adhesive compound has 2,000 to 60,000cP viscosity.
49. according to the method described in claim 27-48 any one, and wherein this latex paint composition has after 48 hours and to improve the final viscosity as defined herein that is no more than 50%.
50. according to the method described in claim 27-49 any one, and wherein this latex paint composition further comprises hydroxyethylcellulose.
51. form the method for carpet product, and the method comprises the following steps:
(a) provide the adhesive compound that comprises latex paint composition, described latex paint composition comprises:
(i) at least one has the vinyl esters of alkanoic acid and first copolymer of ethene of 1 to 13 carbon atom; With
(ii) the second copolymer of styrene and butadiene at least, wherein this first and second copolymers colloidal state is dispersed in the aqueous medium that comprises surfactant;
(b) provide and comprise first carpet layer of tufting to the yarn in the first wadding material;
(c) this adhesive compound is applied at least one of this first carpet layer or the second wadding;
(d) this first carpet layer is contacted with the second wadding; With
(e) dry this adhesive compound under the condition that effectively the first carpet layer is glued to the second wadding.
52. according to the method for claim 51, and wherein precoated shet bonds to yarn on this first wadding material.
53. according to the method for claim 51, and wherein this precoated shet comprises identical latex paint composition as this adhesive compound.
CN201380009136.2A 2012-02-15 2013-02-14 Carpet products and processes for making same using latex coating compositions Pending CN104105826A (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US201261599127P 2012-02-15 2012-02-15
US61/599,127 2012-02-15
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CN107002352A (en) * 2014-12-12 2017-08-01 瓦克化学股份公司 Water redispersible polymer powder for carpet coating composition
CN107002352B (en) * 2014-12-12 2019-07-12 瓦克化学股份公司 Water redispersible polymer powder for carpet coating composition
CN108367549A (en) * 2015-12-15 2018-08-03 肖氏工业集团公司 Carpet coating, the carpet with improved wet delamination strength and its manufacturing method
CN109898337A (en) * 2019-01-28 2019-06-18 山东优尼科斯科技股份有限公司 Embryo blanket applies glue formula and embryo blanket pre-coat process
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CN113896844B (en) * 2021-11-19 2023-08-04 湖北分聚新材料有限公司 Carboxyl styrene-butadiene latex for carpet and preparation method thereof

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