CN1250497A - Process for preparing carpets having polyurethane backings obtained from polyurethane latex formulations - Google Patents

Process for preparing carpets having polyurethane backings obtained from polyurethane latex formulations Download PDF

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Publication number
CN1250497A
CN1250497A CN98803452A CN98803452A CN1250497A CN 1250497 A CN1250497 A CN 1250497A CN 98803452 A CN98803452 A CN 98803452A CN 98803452 A CN98803452 A CN 98803452A CN 1250497 A CN1250497 A CN 1250497A
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China
Prior art keywords
carpet
polyurethane
dispersion
latex
prepolymer
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CN98803452A
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Chinese (zh)
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CN1136356C (en
Inventor
A·K·施洛克
F·E·帕克斯
W·R·威尔克姆
D·R·莫尔
R·L·塔伯尔
J·M·科恩斯多克
J·J·亚库伯夫斯基
J·E·培特
M·A·诺顿
R·A·约翰逊
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Dow Global Technologies LLC
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Dow Chemical Co
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    • 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
    • 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
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/12—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins
    • D06N3/14—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins with polyurethanes
    • 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
    • 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
    • D06N7/0086—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 characterised by the cushion backing, e.g. foamed polyurethane
    • 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
    • D06N2203/06—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D06N2203/065—Polyamides
    • 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
    • D06N2203/06—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D06N2203/068—Polyurethanes

Abstract

The present invention relates to a polyurethane backed carpet having a backing prepared by application of an aqueous dispersion of a polyurethane or a polyurethane-forming material to the back of a carpet substrate. The present invention can eliminate the need to prepare a polyurethane backing from its monomeric components at the carpet manufacturing site. The polyurethane backed carpet of the present invention can be efficiently prepared by a continuous process.

Description

Preparation has the method for the carpet of the polyurethane backing that is made by the polyurethane adhesive emulsion formulation
The present invention relates to the carpet of polyurethane backing.The present invention be more particularly directed to the carpet of polyurethane backing and relate to by the used method of this carpet of polyurethane rubber latex composition production.
In the production of tufted carpet, require the gluing backing of the second layer that the tufting of carpet is anchored on the main backing of this carpet.Have the carpet that adheres to the polyurethane backing in tuft bind, feel, delamination, prevent that aspects such as loses in performance in the presence of water and ABRASION RESISTANCE from can provide good performance.Have and adhere to polyurethane foam and be described in following patent as the carpet of backing and other ground: for example United States Patent (USP) 3,755, and 212,3,772,224,3,821,130,3,862,879,4,022,941,4,171,395,4,278,482,4,286,003,4,296,159,4,405,393,4,483,894,4,512,831,4,515,646,4,595,436,4,611,044,4,657,790,4,696,849,4,853,054,4,853,280 and 5,104,693.Because expense of raw materials in producing the polyurethane backing, the carpet with polyurethane backing is often than the carpet costliness that comprises the other types backing.Therefore, polyurethane is generally used for higher carpet and is not used in rudimentary and intermediate carpet.
Existing operation in the carpet manufacturing industry requires to prepare polyurethane carpet backing at the carpet manufacture scene with isocyanates prescription (A-surface compositions) and polyalcohol prescription (B-surface compositions).This is referred to as " A+B chemistry " sometimes.Adopt A+B chemical preparation polyurethane can cause unpredictalbe production loss and owing to carry out this reaction in the production scene and some problems can take place make the efficient reduction.
Styrene-butadiene (SB) latex is well-known.For example, narrated the SB latex that is used for carpet among " the latex paint system of carpet backing (the Latex Coating Systems for CarpetBacking) " that rolls up (82-91 page or leaf) R.P.Brentin in " coated fabric magazine (J.Coat.Fab.) " 1977 the 7th volume (107-120 page or leaf) P.L.Fitzgerald " integrated foamed latex carpet lining (Integral latex Foam Carpet Cushioning) " and " coated fabric magazine " nineteen eighty-two the 12nd.SB latex is widely used as the anchoring coating in the carpet.SB latex can provide the solid tuft bind with higher stiffness under lower investment cost.SB latex also can provide lower stiffness with lower investment cost under the situation that reduces the tuft bind performance.Owing in low viscous latex, can comprise low filler component, thereby SB latex also has flexibility on producing cost to high-load.Yet the SB latex that contains filler may not meet the strict standard of intermediate carpet defined.In addition, may to require latex material be stable storage in year nearly to existing technology.Therefore, have solids content and be not industrial available SB latex greater than 55% SB latex, unsettled because this latex is normally stored.
Polyurethane/urea (PU) latex is well-known and is used as for example coating, adhesive and automobile finish and the priming paint of wood finishing, glass fibre applying glue, fabric.The adhesive of automobile finish, food Package and fabric mainly uses aliphatic isocyanate.Wood finishing and finish paint mainly use aromatic isocyanate.PU latex can be by at reactant, for example is used for preparing the isocyanates of polyurethane and the organic solvent of polyalcohol carries out polymerization, and then the solution with gained is dispersed in the water, optionally then removes organic solvent and makes.PU latex can adopt and comprise that the prepared in various methods narrated in the following patent for example: United States Patent (USP) 4,857,565, United States Patent (USP) 4,742,095, United States Patent (USP) 4,879,322, United States Patent (USP) 3,437, and 624, United States Patent (USP) 5,037,864, United States Patent (USP) 5,221,710, United States Patent (USP) 4,237, and 264 and United States Patent (USP) 4,092,286.Consider that from the viewpoint of cost saving and environmental protection cancellation uses the volatile organic solvent in this method to meet the requirements.
The carpet for preparing the polyurethane backing according to a kind of like this method is desirable, wherein adopts cost-effective method high performance polyurethane backing can be coated on any other carpet of level.Wish that also cancellation must prepare polyurethane carpet backing in the method for carpet manufacture field by using A+B chemistry.In addition, wish to adopt continuity method to prepare the carpet of polyurethane backing, wherein polyurethane rubber latex can be coated on the carpet and needn't add the step of removing volatile organic solvent.
In one aspect, the present invention is a kind of carpet that backing is arranged, this carpet have at least a by the coating that is dispersed in the polyurethane in the water or generates the polymer that the material of polyurethane obtains as backing.
In one aspect of the method, the present invention is a kind of method of making the backing carpet, and this method may further comprise the steps: (1) is dispersed in the water polyurethane prepolymer to obtain the aqueous dispersion of prepolymer; (2) this aqueous dispersion is coated in the back side of carpet ground; (3) water is removed from aqueous dispersion to obtain the carpet of backing.
Carpet of the present invention comprises polyurethane carpet backing, and this backing is by obtaining on the back side that the polyurethane adhesive dairy compositions is coated in the carpet ground.In the present invention, the polyurethane of indication can be urethanes, polyurea compound or its mixture.Polyurethane can make by polyalcohol and polyisocyanate reaction.Polyureas can make by amine and polyisocyanate reaction.Polyurethane or polyureas can contain urea and urethanes degree of functionality, and this depends in A-face or B-surface compositions or in its any composition what contains.For the application, between these polymeric materials, do not do further difference herein.Term " polyurethane " one of is commonly used to illustrate in polyether polyols with reduced unsaturation and the polyurea polymer or both.When being used for the application, term " latex " and " aqueous dispersion " are used for illustrating same material interchangeably.Being used to implement PU latex composition of the present invention comprises water and polyurethane, can generate one of the mixture of polyurethane or both mixtures.Described herein PU latex can be chosen wantonly and comprise: cahin extension agent, surfactant, filler, dispersant, foam stabiliser, thickener, fire retardant or other can be used for the combination of the optional material of polyurethane formulation.
According to practice of the present invention, PU latex is a kind of polyurethane, the material that generates polyurethane or the aqueous dispersion of its composition.The material that is used for generation polyurethane of the present invention is the material that can generate polyether polyols with reduced unsaturation.The material that generates polyurethane comprises for example polyurethane prepolymer.Being used to implement prepolymer of the present invention can be by active dydrogen compounds and prepared in reaction with respect to the isocyanates of arbitrary excessive materials amount of reactive hydrogen material.The amount of this isocyanate functionality can be 0.2% to 40% (weight).The molecular weight that suitable prepolymer can have is 100-10,000.Be used to implement prepolymer of the present invention and under the condition of disperseing, should be liquid basically.
Active dydrogen compounds can be described as having and comprise at least one Direct Bonding at the electronegative atom compound of the functional group of the hydrogen atom on nitrogen, oxygen or the sulphur for example.Suitable active dydrogen compounds can be a molecular weight less than 6000 polyalcohol.
Other latex can be combined together use to prepare carpet backing of the present invention with polyurethane rubber latex of the present invention.The suitable latex that can be used for mixing with polyurethane rubber latex of the present invention comprises: styrene-butadiene latex, styrene-butadiene-vinylidene chloride latex, styrene-propene acid alkyl ester latex or acrylic latex, similar compounds and composition thereof.
The optional cahin extension agent that comprises of the present invention.The cahin extension agent that the present invention adopts is in order to enlarge the molecular weight of polyurethane prepolymer by the reaction of the isocyanate functionality in this cahin extension agent and the polyurethane prepolymer, that is, to make the chain growth of polyurethane prepolymer.Suitable cahin extension agent normally comprises the low equivalent reactive hydrogen that per molecule has the compound of 2 or a plurality of reactive hydrogen bases.The reactive hydrogen base can be hydroxyl, sulfydryl or amino.The amine cahin extension agent can be block, end-blocking or become less activity.Other material particularly water can work to prolong chain length, also is cahin extension agent for the purpose of the present invention therefore.Polyamines is preferred cahin extension agent.Particularly preferred cahin extension agent is to be selected from amine terminated polyether for example Jeffamine D-400, aminoethyl piperazine, the 2-methyl piperazine, 1 of Huntsman Chemical company, 5-diaminourea-3-methyl-pentane, isophorone diamine, ethylenediamine, diethylenetriamines, trien, triethylene five amine, monoethanolamine, the lysine that is its any heterogeneous type and salt, hexamethylene diamine, hydrazine and piperazine.In practice of the present invention, cahin extension agent usually uses with the cahin extension agent solution in the water.
It is favourable using a small amount of cahin extension agent in the preparation of polyurethane backing of the present invention.Usually, be benchmark with the isocyanates of 1 equivalent and the cahin extension agent reaction of 1 equivalent, the consumption of cahin extension agent should be enough to and the 0-100% isocyanate functionality reaction that is present in this prepolymer.Under certain conditions, water can be meeted the requirements as cahin extension agent and with the some or all of isocyanate functionality reaction that exists.Can choose wantonly and use catalyst to promote the reaction between cahin extension agent and the isocyanates.
Be applicable to that catalyst of the present invention comprises tertiary amine and organo-metallic compound, similar compounds and composition thereof.For example Shi Yi catalyst comprise two (TGA isooctyl acrylate) dibutyl tins, two laurate stannous methides, dibutyl tin laurate, butyl disulfide tin, stannous octoate, lead octoate, ferric acetyl acetonade, bismuth carboxylate, triethylenediamine, N-methylmorpholine, similar compounds, and composition thereof.Catalyst consumption is advantageously for obtaining more promptly to be cured to the state that is not clamminess.If generating the composition of polyurethane, use organo-metallic catalyst, per 100 parts (weight) use 0.01-0.5 part (weight) organo-metallic catalyst can obtain such curing.If the use tertiary amine catalyst, the composition that per 100 parts (weight) generate polyurethane uses 0.01-3 part (weight) tertiary amine catalyst, and this catalyst can preferably provide suitable curing.Amines catalyst and organo-metallic catalyst can be used.
The optional filler that comprises of the present invention.This filler can comprise glass, calcium carbonate, ATH, talcum, bentonite, antimonous oxide, kaolin, flying dust or other the known fillers that conventional filler for example grinds.In practice of the present invention, the suitable amount of filler that is filled in the PU latex can be per 100 parts of polyurethane 100-1000 part fillers.The charge weight of preferred filler can be 200pphp at least, more preferably 300pphp, 400pphp at least most preferably at least.
The also optional filler wetting agent that comprises of the present invention.The filler wetting agent can play a part to make filler compatible with the composition that generates polyurethane usually.The wetting agent that is suitable for comprises phosphate, for example calgon.Can be included in the content that the present invention generates the filler wetting agent in the composition of polyurethane and be at least per 0.5 part of 100 parts of filler (weight).
The optional thickener that comprises of the present invention.Being used for thickener of the present invention is in order to increase the viscosity of low viscosity PU latex.Be applicable to that implementing thickener of the present invention is any thickener of knowing in the field of preparation polyurethane rubber latex.For example, Shi Yi thickener comprises Alcogum TMVEP-II (trade mark is Alco Chemical Corporation) and Paragum TM231 (trade mark is Para-Chem Southern, Inc.).The consumption of thickener can by can obtain the required any amount of the dispersion of requirement viscosity use.
The present invention can comprise the component that other are optional.For example, the composition of generation polyurethane of the present invention can comprise surfactant, blowing agent or frothing agent, fire retardant, pigment, antistatic additive, fortifying fibre, antioxidant, preservative agent, plumper.The example of suitable blowing agent comprises some gases for example air, carbon dioxide, nitrogen, argon, helium, and some liquid are water, for example various chlorofluoromethanes of volatility halogenated alkane and chlorine fluoroethane for example, and azoic foaming agent is azo two (formamide) for example.Preferred in the embodiment of this invention using gases is as blowing agent or frothing agent.Especially preferably use air as blowing agent or frothing agent.Frothing agent is different from the blowing agent part and is, frothing agent is introduced liquid by machinery with gas usually and formed foam.
Wish to have surfactant in the present invention.Being used for surfactant of the present invention can be cationic surface active agent, anionic surfactant or nonionic surface active agent.The example of anionic surfactant comprises sulfonate radical, carboxylate radical and phosphate radical.The example of cationic surface active agent comprises quaternary amine.The example of nonionic surface active agent comprises the block copolymer that contains oxirane and silicone surfactant.Being used to implement surfactant of the present invention can be external surfactants or internal surfactants.External surfactants is can not become to participate in chemical reaction and enter surfactant in the polymer in the preparation process of latex.Internal surfactants is can become to participate in chemical reaction and enter surfactant in the polymer in the preparation process of latex.The amount that can be included in the surfactant in the present invention's prescription is that per 100 parts of (weight) polyurethane components contain 0.01-20 part.
Usually, known any method of technical staff in the preparation polyurethane rubber latex field all can be used to implement the PU latex material of the present invention with preparation suitable for making carpet of the present invention.The suitable PU latex of stable storage defined herein is that any has particle mean size less than 5 microns PU latex.Store particle mean size that unsettled PU latex has greater than 5 microns.For example, can adopt industrial batch mixer that polyurethane prepolymer is mixed with water then is dispersed in this prepolymer in the water to prepare suitable dispersion.Perhaps, can be by prepolymer be infeeded static mixing device with water, then in this static mixer disperse water and prepolymer to prepare suitable dispersion.The continuity method of preparation polyurethane aqueous dispersion body is well-known and can be used for implementing the present invention.For example United States Patent (USP) 4,857, and 565,4,742,095,4,879,322,3,437,624,5,037,864,5,221,710,4,237,264 and 4,092,286 have all narrated the continuity method that is used to obtain polyurethane rubber latex.In addition, the polyurethane rubber latex with high internal phase ratio can adopt United States Patent (USP) 5,539, and the continuity method preparation described in 021 is incorporated herein by reference this patent now.
In enforcement of the present invention, the arbitrary step that is used to prepare polyurethane carpet backing all can adopt continuous method to carry out.For example, in a first step, can adopt continuous method to prepare prepolymer with the suitable compound bearing active hydrogen that contains; Prepolymer and the water that obtains in a first step can be infeeded mixing arrangement together to make aqueous dispersion; Can adopt continuous method that this aqueous dispersion is coated on the carpet ground to make the carpet of polyurethane backing.
Dispersions of polyurethanes of the present invention can be stored, and is coated to the usefulness on the carpet backing after being made for.To require this dispersion be stable storage in the storage of being done for this purpose.On the other hand, can adopt continuous method that polyurethane rubber latex is coated on the back side of carpet ground.That is, after obtaining this dispersion, just it can be coated on the back side of carpet according to enforcement the present invention.The polyurethane rubber latex that adopts continuous method to be coated on the carpet does not require it is stable storage, and can have higher solids content and bigger particle mean size, and perhaps the particle mean size than the polyurethane adhesive emulsion formulation of typical stable storage is bigger.
When the carpet of polymer-backed produced according to the present invention, the composition that generates polyurethane is applied one deck with preferred uniform thickness on the one side of carpet ground.PU latex of the present invention can be used as precoated shet, laminated coating and applies or apply as foam coating.The coating of polyurethane precoated shet, laminated coating and foam coating can adopt method preparation as known in the art.Be described in " the latex paint system of carpet backing " of for example rolling up (82-91 page or leaf) R.P.Brentin in " coated fabric magazine " 1977 the 7th volumes (107-120 page or leaf) P.L.Fitzgerald " integrated foamed latex carpet lining " and " coated fabric magazine " nineteen eighty-two the 12nd by the method for latex preparation precoated shet, laminated coating and foam coating coating., preferably all components are mixed together when (foaming) at preparation foamed polyurethane backing, adopt the device of Oakes for example or Firestone foam maker that gas is sneaked in this mixture then.
Before the composition that generates polyurethane is cured to the state that is not clamminess, it can be coated on the one side of carpet ground.On the other hand, can apply the PU latex that does not contain unreacted isocyanate functionality, thereby need not to solidify this polymer.Usually, the composition that generates polyurethane is coated on the surface attached to main backing.Can adopt for example scalpel, air knife or extruder etc., said composition is coated on the carpet ground, so that apply and the calibration coating.On the other hand, can said composition be formed coating by moving belt or other suitable devices, then with its dehydration, or partly solidify, or dehydration and partly curing, then, for example double belt (being also referred to as biobelt), laminator or have the moving belt that applies foam carpet it is combined on the carpet ground of employing equipment.The consumption of the composition of generation polyurethane can change in the wide range of every square centimeter 16.95 milligrams to every square centimeter 1695 milligrams (every square yard of 5-500 ounces) according to the characteristic of fabric.Applied with calibrated this coating after, water is removed from this dispersion, be used to then that for example infrared heating heating furnace, convection furnace or heating plate are heating and curing this coating from any suitable thermal source.
Provide following examples that the present invention is elaborated.These embodiment and not meaning that limit the scope of the present invention, nor should so understand.Material regulation used among these embodiment is as follows:
Voranol 4702=1650 equivalent, the triol of 16%EO end-blocking
Voranol 4701=1650 equivalent, the triol of 18%EO end-blocking
Voranol 2120=1000 equivalent, the PO glycol
2 of Isonate 50=50/50 w/w, 4'-MDI and 4,4'-MDI mixture EXAMPLE Example 1
Following process is carried out under room temperature (19 ℃).With prepolymer A under the speed of 32.1 gram/minute by being assemblied in first support arm (arm) charging continuously on the T.With DeSULF TMDBS-60T surfactant (the aqueous solution of 60% triethanolamine dodecyl benzene sulfonate, trade mark is DeForest Enterprises, Inc.) first support arm by the 2nd T infeeds under the speed of 1.61 gram/minute, converges with the second support arm flowing water flow by the 2nd T under the speed of 5.5 gram/minute then.This pre-polymerization logistics and water/surfactant stream converges at a T place, flows through static mixer, and deliver to IKA-SD 41 SUPER-DISPAX TMDispersal device (trade mark is IKA-WORKS, Inc.), and the input port of the rotor-stator apparatus of under 1200rpm, operating.
The ratio that enters the charging of dispersal device is 81.9% prepolymer, 4.1% surfactant solution and 14.0% water.The HIPR latex that forms in dispersal device, measuring the volume average particle sizes have by Coulter LS 130 Particle Size Analyzers is that 0.265 micron and polydispersity are 3.1.
At LIGHTNIN TMFinish chain elongation in the online batch mixer of the .025LB of type (trade mark is GREEY/LIGHTNIN).The HIPR latex is delivered to first support arm that is assemblied on the 3rd T and is converged with the water liquid stream of carrying second support arm by the 3rd T under the speed of 5.1 gram/minute from dispersal device.This output that converges liquid stream is sent into the support arm of the 4th T that is connected to online batch mixer porch.Simultaneously, the piperazine aqueous solution of the pumping 10% under the constant rate of speed of 18.0 gram/minute (0.75 equivalent is a benchmark with the isocyanate groups of prepolymer) of other support arms by the 4th T.Mix in the online batch mixer that this two kinds of liquid stream is operated under 1500rpm.Collect this product and allow its standing over night make water and the reaction of remaining isocyanate groups.The solids content that stable poly-(urethanes/urea) latex of gained has is 56.0% (weight), presses Coulter LS230 Particle Size Analyzer and measures, and volume average particle sizes is 0.256 micron, and polydispersity is 3.5.
By being mixed with 200 parts of pearl fillers, 178.6 parts of latex (100 parts of latex solids) formed this latex.Stir latex during beginning separately, then, add filler as early as possible, it is dispersed in the liquid.Add Paragum TM(trade mark is Para-Chem Southern to 241 thickeners, Inc.) till viscosity reaches 9300 centipoises.The carpet that is used to test is a nylon level looped pile style, and grey cloth weight is 77.98mg/cm 2(23 ounces every square yard).By coating content is 118.7mg/cm 2(35 ounces every square yard) are coated in the back side of this carpet with compound, then paste the sparse cloth 11.19mg/cm of polypropylene 2(3.3 ounces every square yard) are as second backing.With this carpet 132 ℃ dry 12 minutes down, then, before test, allow its equilibrate overnight.
It is 2.97 kilogram-metres (21.5 foot-pounds) that the carpet of embodiment 1 has tuft bind.The tuft bind value obtains according to ASTM D1335.It is 1,803 kg/cm (10.1 pounds/inch) that the carpet of embodiment 1 has dried delamination, and wetting again delamination is 892.9 kg/cm (5.0 pounds/inch).Delamination is to remove the required intensity of the sparse cloth of second layer polypropylene from the carpet that is made into.It is to measure like this: cut a small area of ground blanket of 22.86 centimetres of 7.62 cm x (3 inches * 9 inches), the sparse cloth of the second layer is peeled off from the major part of carpet, measure required power simultaneously.Except this carpet sample was soaked in water 1 minute, and outside blotting before the test, adopting uses the same method measures wetting again delamination.It is 2.04 kilogram-metres (17.4 foot-pounds) that the carpet of embodiment 1 has hand flush shear force (handpunch).The hand flush shear force is measured like this: adopting the external diameter be connected on the force cell is that the solid cylinder of 5.715 centimetres (2.25 inches) pushes the carpet of a slices 1.27 centimetres (0.5 inches) of 22.86 centimetres of 22.86 cm x (9 inches * 9 inches) under the speed of 30.48 cm per minute (12.0 inch per minute clock) in the cylinder of 13.97 (5.5 inches) internal diameter and records required power.Embodiment 2
Except following difference, repeat embodiment 1 and prepare the used method of latex.Surfactant is DeSULF TM(the 40% triethanolamine sulfuric acid moon was hung the aqueous solution of ester to the TLS-40 surfactant, and trade mark is DeForest Enterprises, and Inc.), and flow rate is: prepolymer 32.0 gram/minute, surfactant 2.4 gram/minute, water 3.5 gram/minute.The ratio of sending into the component of disperser is: prepolymer 84.4%, surfactant solution 6.3%, water 9.2%.By adopting Coulter LS 130 Particle Size Analyzers to measure, the volume average particle sizes that the HIPR latex has is 0.182 micron, and polydispersity is 1.6.
Be used for diluting the speed current downflow of the water liquid stream of HIPR latex, pumping piperazine solution under the speed of 17.9 gram/minute in 4.6 gram/minute.The solids content that final poly-(urethanes/urea) latex has is 53.9% (weight), and volume average particle sizes is 0.365 micron.
Formed this latex by the method for embodiment 1.Add Paragum 241 thickeners (Para-Chem Southern, Inc. supply) and reach 8 up to viscosity, 000-10 is till 000 centipoise.By coating content is 121.0 milligrams/centimetre 2(35.7 ounces every square yard) are coated in the back side of the carpet identical with embodiment 1 with compound, then paste 11.19 milligrams/centimetre of the sparse cloth of polypropylene 2(3.3 ounces every square yard) are as second backing.With this carpet 132 ℃ dry 12 minutes down, then, before test, allow its equilibrate overnight.It is 2.92 kilogram-metres (21.1 foot-pounds) that this carpet has tuft bind, the hand flush shear force is 2.36 kilogram-metres (17.1 foot-pounds), dried delamination is 1.7679 kg/cm (9.9 pounds/inch), and wetting again delamination is 1.3036 kg/cm (7.3 pounds/inch).Comparative Examples 3:
As a comparison, the carpet level styrene-butadiene latex (53.3% solids content) of standard is mixed with calcium carbonate and thickener, then, the method for pressing embodiment 1 applies the backing as carpet.The coating content that resulting carpet has is 115.6 milligrams/centimetre 2(34.1 ounces every square yard), tuft bind is 2.24 kilogram-metres (16.2 foot-pounds), delamination is 1.7501 kg/cm (9.8 pounds/inch), and the hand flush shear force is 3.37 kilogram-metres (27.0 foot-pounds), and wetting again delamination is 1.1786 kg/cm (6.6 pounds/inch).

Claims (33)

1. carpet that backing is arranged, this carpet have at least a by the coating that is dispersed in the polyurethane in the water or generates the polymer that the material of polyurethane obtains as backing.
2. the carpet of claim 1, wherein this dispersion comprises: polyurethane prepolymer, water and surfactant.
3. the carpet of claim 2, wherein this dispersion also comprises cahin extension agent.
4. the carpet of claim 1, wherein this this polymer-backed is a precoated shet.
5. the carpet of claim 4, wherein this carpet also comprises laminated coating.
6. the carpet of claim 5, wherein this laminated coating is made by the aqueous dispersion of the material that generates polyurethane.
7. the carpet of claim 6, wherein this this dispersion also comprises at least a filler.
8. the carpet of claim 7, wherein this filler is a calcium carbonate.
9. the carpet of claim 7, wherein this filler is a flying dust.
10. the carpet of claim 7, wherein this dispersion comprises thickener.
11. the carpet of claim 10, wherein this dispersion comprises dispersant or wetting agent.
12. the carpet of claim 7 has wherein applied second layer backing.
13. the carpet of claim 12, wherein this second layer backing is polypropylene net goods or fiber web.
14. the carpet of claim 4, wherein this carpet also comprises foam coating.
15. the carpet of claim 14, wherein this foam coating is made by the aqueous dispersion of the material that generates polyurethane.
16. the carpet of claim 14, wherein this foam coating is made by the reactant mixture that generates polyurethane.
17. the carpet of claim 16, wherein this foam coating foams by the reactant mixture that will generate polyurethane and makes.
18. the carpet of claim 1, wherein this dispersion comprises at least a other latex material.
19. the carpet of claim 18, wherein this other latex material be selected from styrene-butadiene latex, styrene-butadiene-vinylidene chloride latex, styrene-propene acid alkyl ester latex, acrylic latex, similar compounds, and composition thereof.
20. a method of making the backing carpet, this method may further comprise the steps: (1) is dispersed in the water polyurethane prepolymer to obtain the aqueous dispersion of prepolymer; (2) this aqueous dispersion is coated in the back side of carpet ground; (3) water is removed from aqueous dispersion to obtain the carpet of backing.
21. the method for claim 20, wherein this dispersion comprises surfactant.
22. the method for claim 21, wherein this dispersion comprises cahin extension agent.
23. the method for claim 22, wherein this prepolymer is chain growth.
24. the method for claim 23, wherein this dispersion adopts the continuity method preparation.
25. the method for claim 24 wherein adopts continuity method that this dispersion is coated on the carpet ground.
26. the method for claim 20 wherein is dispersed in polyalcohol, polyisocyanate and optional catalyst in the water and mixes earlier before, adopts continuity method to prepare this prepolymer.
27. the method for claim 23, wherein this cahin extension agent is a polyamines.
28. the method for claim 20 wherein is dispersed in this prepolymer in the mixture of water and filler.
29. the method for claim 20, wherein when prepolymer being coated on the carpet ground, at least a portion isocyanate functionality is unreacted in this prepolymer.
30. the method for claim 20 wherein in the step before the back side that dispersion is coated to the carpet ground, is mixed the aqueous dispersion of prepolymer and filler and optional additive.
31. a method of making carpet, this method may further comprise the steps: (1) will generate polyurethane in the presence of water and filler material mixes; (2) this mixture is coated to the back side of carpet ground; (3) remove with this urethane cures and in heating steps and anhydrate to obtain the carpet of backing, wherein this carpet comprises the filler of 200pph at least.
32. the method for claim 31, wherein this carpet comprises the filler of 300pph at least.
33. the method for claim 32, wherein this carpet comprises the filler of 400pph at least.
CNB988034522A 1997-03-17 1998-03-16 Process for preparing carpets having polyurethane backings obtained from polyurethane latex formulations Expired - Fee Related CN1136356C (en)

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CN1298276C (en) * 2004-07-14 2007-02-07 上海巨东静音环保方块地毯有限公司 Method for producing environmental protection soft bottom carpet
CN1298275C (en) * 2004-07-14 2007-02-07 上海巨东静音环保方块地毯有限公司 Method for producing environmental protection soft bottom carpet
CN1308540C (en) * 2000-06-05 2007-04-04 美利肯公司 Low Weight cushioned carpet carpet tile and method
CN102084054B (en) * 2008-05-06 2013-03-27 陶氏环球技术公司 Frothable aqueous composition
CN101631911B (en) * 2006-11-13 2013-08-21 肖氏工业集团公司 Methods and systems for recycling carpet and carpets manufactured from recycled material
CN104822876A (en) * 2012-10-16 2015-08-05 陶氏环球技术有限责任公司 Polyurethane dispersion based synthetic leathers comprising acrylic latex
CN105683236A (en) * 2013-10-28 2016-06-15 巴斯夫欧洲公司 Low density polyurethane microcellular elastomer
CN107690495A (en) * 2014-09-24 2018-02-13 戴索有限公司 For producing the floor covering of the recovery inclusion with proactive definition（Including carpet and carpet tile）Method
WO2018133610A1 (en) * 2017-01-18 2018-07-26 新辉（中国）新材料有限公司 Latex-containing polyurethane-modified carboxyl butadiene-styrene copolymer and preparation method thereof

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US6518348B1 (en) 1999-12-14 2003-02-11 Dow Global Technologies Inc. Carpet backing compounds thickened by hydrophobically-modified ethylene-oxide-based urethane block copolymers
JP2018161448A (en) * 2017-03-27 2018-10-18 日本絨氈株式会社 Tile carpet

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CN1308540C (en) * 2000-06-05 2007-04-04 美利肯公司 Low Weight cushioned carpet carpet tile and method
CN1298276C (en) * 2004-07-14 2007-02-07 上海巨东静音环保方块地毯有限公司 Method for producing environmental protection soft bottom carpet
CN1298275C (en) * 2004-07-14 2007-02-07 上海巨东静音环保方块地毯有限公司 Method for producing environmental protection soft bottom carpet
CN101631911B (en) * 2006-11-13 2013-08-21 肖氏工业集团公司 Methods and systems for recycling carpet and carpets manufactured from recycled material
CN102084054B (en) * 2008-05-06 2013-03-27 陶氏环球技术公司 Frothable aqueous composition
CN104822876A (en) * 2012-10-16 2015-08-05 陶氏环球技术有限责任公司 Polyurethane dispersion based synthetic leathers comprising acrylic latex
CN104822876B (en) * 2012-10-16 2017-03-08 陶氏环球技术有限责任公司 The synthetic leather based on polyurethane dispersion liquid comprising acrylic latex
CN105683236A (en) * 2013-10-28 2016-06-15 巴斯夫欧洲公司 Low density polyurethane microcellular elastomer
CN105683236B (en) * 2013-10-28 2018-11-23 巴斯夫欧洲公司 Low density polyurethane micropore elastomer
CN107690495A (en) * 2014-09-24 2018-02-13 戴索有限公司 For producing the floor covering of the recovery inclusion with proactive definition（Including carpet and carpet tile）Method
WO2018133610A1 (en) * 2017-01-18 2018-07-26 新辉（中国）新材料有限公司 Latex-containing polyurethane-modified carboxyl butadiene-styrene copolymer and preparation method thereof

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DE69807673D1 (en) 2002-10-10
CO5021193A1 (en) 2001-03-27
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CA2283909A1 (en) 1998-09-24
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HUP0001810A3 (en) 2001-09-28
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DE69807673T2 (en) 2003-01-02
CN1136356C (en) 2004-01-28
EP0970273B1 (en) 2002-09-04
TR199902224T2 (en) 2000-05-22
KR20000076296A (en) 2000-12-26
AU6466498A (en) 1998-10-12
AU727413B2 (en) 2000-12-14

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