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
• • 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

Definitions

• the present invention relates to polyurethane backed carpets.
• the present invention particularly relates to polyurethane backed carpets and to a process used in making same from polyurethane latex compositions.
• a secondary adhesive backing is required to anchor the carpet tufts to the primary backing of the carpet.
• Carpets having an attached polyurethane backing can provide superior performance in the areas of tuft bind, hand, delamination, resistance to property loss in the presence of water, and wear resistance.
• Carpets and other substrates having attached polyurethane foam layers as backing are described in U.S.
• Carpets having polyurethane backings tend to be more expensive than carpets that incorporate other types of backings due to the raw material costs in producing a polyurethane backing. For this reason, polyurethanes are typically used in higher grade carpets, and are typically not used in low and intermediate grade carpets.
• polyurethane carpet backings be prepared from an isocyanate formulation (A- side formulation) and a polyol formulation (B-side formulation) at the carpet manufacturing site. This is sometimes referred to as "A+B chemistry".
• A+B chemistry Preparing a polyurethane by A+B chemistry can result in unpredictable loss of production and inefficiency due to problems that can occur in carrying out the reaction at the manufacturing site.
• Styrene-butadiene (SB) latexes are well known. SB latex for use in carpet is described, for example, in P. L. Fitzgerald, “Integral Latex Foam Carpet Cushioning", J. Coat. Fab. 1977, Vol. 7 (pp.107 - 120); and in R. P.
• SB latexes are used extensively as anchor coatings in carpets. SB latexes can provide good tuft bind, with a relatively high degree of stiffness, at a relatively low investment cost. SB latexes can provide relatively low stiffness with reduced tuftbind properties at a relatively low investment cost, as well. SB latexes also can provide flexibility in production costs owing to the ability to include low to high concentrations of filler component in a low viscosity latex. However, SB latexes with filler may not meet the rigorous standards set for intermediate grade carpets.
• SB latexes having solids content of greater than 55 percent are not typical of commercially available SB latexes because such latexes generally are not storage stable.
• Elimination of the use of volatile organic solvents from the process can be desirable from both a cost saving standpoint and an environmental perspective.
• polyurethane backed carpets it would be desirable to prepare polyurethane backed carpets according to a process wherein a high performance polyurethane backing can be applied to any grade of carpet in a cost-effective process. It would also be desirable to eliminate the need to prepare a polyurethane carpet backing using A+B chemistry at a carpet manufacturing site. Further, it would be desirable to prepare a polyurethane backed carpet by a continuous process wherein a polyurethane latex can be applied to a carpet without the additional step of removing a volatile organic solvent.
• the present invention is a backed carpet having as a backing at least one coat of polymer that is obtained from a dispersion of a polyurethane or polyurethane-forming material in water.
• the present invention is a process for preparing a backed carpet comprising the steps: (1) dispersing a polyurethane prepolymer in water to obtain an aqueous dispersion of prepolymer; (2) applying the aqueous dispersion to the back of a carpet substrate; (3) removing the water from the aqueous dispersion to obtain a backed carpet.
• the carpet of the present invention comprises a polyurethane carpet backing that is obtained by application of a polyurethane latex composition to the back of a carpet substrate.
• polyurethane can refer to a polyurethane compound, a polyurea compound, or a mixture thereof.
• Polyurethanes can be obtained by the reaction of a polyol with an polyisocyanate.
• Polyureas can be obtained by the reaction of amines with polyisocyanates.
• a polyurethane or polyurea can contain both urea and urethane functionality, depending on what is included in the A-side or B-side formulations, or in any combination thereof. For the purposes of the present application, no further distinction will be made herein between the polymeric materials.
• a PU latex is an aqueous dispersion of: a polyurethane; polyurethane forming materials; or a combination thereof.
• Polyurethane-forming materials as used in the present invention are materials which are capable of forming polyurethane polymers.
• Polyurethane-forming materials include, for example, polyurethane prepolymers.
• Prepolymers useful in the practice of the present invention are prepared by the reaction of active hydrogen compounds with any amount of isocyanate in excess material relative to active hydrogen material. The isocyanate functionality can be present in an amount of from 0.2 weight percent to 40 weight percent.
• a suitable prepolymer can have a molecular weight in the range of from 100 to 10,000.
• Prepolymers useful in the practice of the present invention should be substantially liquid under the conditions of dispersal.
• the present invention optionally includes a chain extender.
• a chain extender is used herein to build the molecular weight of the polyurethane prepolymer by reaction of the chain extender with the isocyanate functionality in the polyurethane prepolymer, that is, chain extend the polyurethane prepolymer.
• a suitable chain extender is typically a low equivalent weight active hydrogen containing compound having 2 or more active hydrogen groups per molecule.
• the active hydrogen groups can be hydroxyl, mercaptyl, or amino groups.
• An amine chain extender can be blocked, encapsulated, or otherwise rendered less reactive. Other materials, particularly water, can function to extend chain length and so are chain extenders for purposes of the present invention. Polyamines are preferred chain extenders.
• the chain extender be selected from the group consisting of amine terminated polyethers such as, for example, Jeffamine D-400 from Huntsman Chemical Company, amino ethyl piperazine, 2-methyl piperazine, 1 ,5-diamino-3-methyl-pentane, isophorone diamine, ethylene diamine, diethylene triamine, triethylene tetramine, triethylene pentamine, ethanol amine, lysine in any of its stereoisomeric forms and salts thereof, hexane diamine, hydrazine and piperazine.
• the chain extender is often used as solution of chain extender in water.
• chain extender In preparing a polyurethane backing of the present invention, small amounts of chain extender can be advantageously used.
• the chain extender is employed at a level sufficient to react with from zero (0) to 100 percent of the isocyanate functionality present in the prepolymer, based on one equivalent of isocyanate reacting with one equivalent of chain extender. It can be desirable, under certain conditions, to allow water to act as a chain extender and react with some or all of the isocyanate functionality present.
• a catalyst may optionally be used to promote the reaction between a chain extender and an isocyanate.
• an organometallic catalyst such a cure can be obtained using from 0.01 to 0.5 parts per 100 parts of the polyurethane-forming composition, by weight.
• a tertiary amine catalyst is employed, the catalyst preferably provides a suitable cure using from 0.01 to 3 parts of tertiary amine catalyst per 100 parts of the polyurethane-forming composition, by weight. Both an amine type catalyst and an organometallic catalyst can be employed in combination.
• the present invention optionally includes a filler material.
• the filler material can include conventional fillers such as milled glass, calcium carbonate, ATH, talc, bentonite, antimony trioxide, kaolin, fly ash, or other known fillers.
• a suitable filler loading in a PU latex can be from 100 to 1000 parts of filler per 100 parts of polyurethane.
• filler can be loaded in an amount of at least 200 pphp, more preferably at least 300 pphp, most preferably at least 400 pphp.
• the present invention also optionally includes a filler wetting agent.
• a filler wetting agent generally performs the function of compatiblizing the filler and the polyurethane-forming composition.
• Useful wetting agents include phosphate salts such as sodium hexametaphosphate.
• a filler wetting agent can be included in a polyurethane-forming composition of the present invention at a concentration of at least 0.5 parts per 100 parts of filler, by weight.
• Thickeners can be used in any amount necessary to obtain a dispersion of desired viscosity.
• a polyurethane-forming composition of the present invention can include surfactants, blowing agents or frothing agents, fire retardant, pigments, antistatic agents, reinforcing fibers, antioxidants, preservatives, acid scavengers.
• suitable blowing agents include gases such as air carbon dioxide, nitrogen, argon, helium,; liquids such as water, volatile halogenated alkanes such as the various chlorfluoromethanes and chlorfluoroethanes; azo-blowing agents such as azobis(formamide).
• gases such as air carbon dioxide, nitrogen, argon, helium,
• liquids such as water, volatile halogenated alkanes such as the various chlorfluoromethanes and chlorfluoroethanes
• azo-blowing agents such as azobis(formamide).
• a frothing agent can differ from a blowing agent in that frothing agents are typically introduced by mechanical introduction of a gas into a liquid to form a froth.
• Surfactants can be desirable in the present invention.
• Surfactants useful herein can be cationic surfactants, anionic surfactants, or a non-ionic surfactants.
• anionic surfactants include sulfonates, carboxylates, and phosphates.
• cationic surfactants include quaternary amines.
• non-ionic surfactants include block copolymers containing ethylene oxide and silicone surfactants.
• Surfactants useful in the practice of the present invention can be either external surfactants or internal surfactants. External surfactants are surfactants which do not become chemically reacted into the polymer during latex preparation. Internal surfactants are surfactants which do become chemically reacted into the polymer during latex preparation.
• a surfactant can be included in a formulation of the present invention in an amount ranging from 0.01 to 20 parts per 100 parts by weight of polyurethane component.
• any method known to one skilled in the art of preparing polyurethane latexes can be used in the practice of the present invention to prepare a PU latex material suitable for preparing a carpet of the present invention.
• a suitable storage-stable PU latex as defined herein is any PU latex having a mean particle size of less than 5 microns.
• a PU latex that is not storage-stable can have a mean particle size of greater than 5 microns.
• a suitable dispersion can be prepared by mixing a polyurethane prepolymer with water and dispersing the prepolymer in the water using a commercial blender.
• a suitable dispersion can be prepared by feeding a prepolymer into a static mixing device along with water, and dispersing the water and prepolymer in the static mixer.
• Continuous methods for preparing aqueous dispersions of polyurethane are known and can be used in the practice of the present invention.
• U.S. Pat. Nos.: 4,857,565; 4,742,095; 4,879,322; 3,437,624; 5,037,864; 5,221 ,710; 4,237,264; and 4,092,286 all describe continuous processes useful for obtaining polyurethane latexes.
• a polyurethane latex having a high internal phase ratio can be prepared by a continuous process as described in U.S. Pat. No. 5,539,021 , incorporated herein by reference.
• any of the steps used in preparing a polyurethane carpet backing can be carried out in a continuous manner.
• the prepolymer in a first step can be prepared from a suitable active hydrogen containing compound in a continuous manner; the prepolymer can be fed, as it is obtained in the first step, into a mixing device with water to obtain an aqueous dispersion; the aqueous dispersion can be applied to a carpet substrate in a continuous manner to obtain a polyurethane backed carpet.
• a polyurethane dispersion of the present invention can be stored for later application to the back of a carpet. Storage for this purpose requires that the dispersion be storage-stable.
• the polyurethane latex can be applied in a continuous manner to the back of a carpet substrate. That is, the dispersion can be applied to the back of a carpet as the dispersion is obtained according to the practice of the present invention.
• Polyurethane latexes applied to carpet in a continuous manner are not required to be storage-stable, and can have higher solids content and larger mean particle size or, alternatively, larger mean particle size than typical storage-stable polyurethane latex formulations.
• the polyurethane-forming composition can be applied to one surface of a carpet substrate before it cures to a tack-free state.
• a PU latex containing no unreacted isocyanate functionality can be applied, thereby removing the need to cure the polymer.
• the polyurethane-forming composition is applied to the surface attached to a primary backing.
• the composition may be applied to the carpet substrate using equipment such as a doctor knife, air knife, or extruder to apply and gauge the layer.
• the composition may be formed into a layer on a moving belt or other suitable apparatus and dehydrated, or partially cured, or both dehydrated and partially cured, then married to the carpet substrate using equipment such as a double belt (also known as double band) laminator or a moving belt with an applied foam cushion.
• equipment such as a double belt (also known as double band) laminator or a moving belt with an applied foam cushion.
• the amount of polyurethane-forming composition used can vary widely, from 16.95 mg per cm 2 1695 mg per cm 2 (5 to 500 ounces per square yard), depending on the characteristics of the textile.
• water is removed from the dispersion and the layer can be cured using heat from any suitable heat source such as an infrared oven, a convection oven, or heating plates.
• the prepolymer stream and the water/surfactant stream were merged at the first T, passed through a static mixer, and fed to the input port of a IKA-SD 41 SUPER-DISPAXTM dispersing instrument (a Trademark of IKA- WORKS, Inc.), a rotor/stator device operated at 1200 rpm.
• Chain extension was accomplished in a LIGHTNINTM model .025 LB inline blender (a Trademark of GREEY/LIGHTNIN).
• the HIPR emulsion from the dispersing instrument was fed into a first arm attached to a third T and merged with an aqueous stream fed through a second arm of the third T at the rate of 5.1 grams/minute.
• the output of the combined streams was fed into one arm of a fourth T, which was attached to the input of the in-line blender.
• a 10 percent aqueous piperazine solution was pumped at a constant rate of 18.0 grams/minute (0.75 equivalents, based on the isocyanate groups of the prepolymer) through the other arm of the fourth T.
• the two streams were mixed in the in-line blender operating at 1500 rpm.
• the product was collected and allowed to stand overnight to allow water to react with the remaining isocyanate groups.
• the resulting stable poly(urethane/urea) latex had a solids content of 56.0 percent by weight, a volume average particle size of 0.256 micron, and a polydispersity of 3.5, as measured by a Coulter LS 230 particle size analyzer.
• the latex was compounded by mixing 178.6 parts latex (100 parts latexes solids) with 200 parts calcium carbonate filler. Stirring was begun with latex alone, then the filler was added as quickly as it was dispersed in the liquid. Paragum TM 241 thickener (a Trademark of Para-Chem Southern, Inc.) was added until the a viscosity of 9300 cPs was reached.
• the carpet for testing was a nylon level loop style with a greige weight of 77.98 mg per cm 2 (23 ounces per square yard).
• Compound was applied to the back of this carpet at a coating weight of 118.7 mg per cm 2 (35 ounces per square yard), followed by a polypropylene scrim, 11.19 mg per cm 2 (3.3 ounces per square yard), as a secondary backing.
• the carpet was dried at 132° C for 12 minutes, then allowed to equilibrate overnight before testing.
• the procedure used to prepare the latex from Example 1 was repeated, with the following exceptions.
• the surfactant was DeSULFTM TLS-40 surfactant (a 40 percent aqueous solution of triethanolamine lauryl sulfate, a Trademark of DeForest Enterprises, Inc.) and the flow rates were: prepolymer, 32.0 grams/minute; surfactant, 2.4 grams/minute; and water, 3.5 grams/minute.
• the ratios of the components that were fed into the disperser were prepolymer, 84.4 percent; surfactant solution, 6.3 percent; and water, 9.2 percent.
• the HIPR emulsion had a volume average particle size of 0.182 micron and a polydispersity of 1.6, as measured by a Coulter LS130 particle size analyzer.
• the aqueous stream used to dilute the HIPR emulsion was flowed at a rate of 4.6 grams/minute, and the piperazine solution was pumped at a rate of 17.9 grams/minute.
• the final poly(urethane/urea) latex had a solids content of 53.9 percent by weight, and a volume average particle size of 0.365 micron.
• the latex was compounded as in Example 1. Paragum 241 thickener
• Example 1 (supplied by Para-Chem Southern, Inc.) was added until a viscosity of between 8,000 and 10,000 cPs was reached.
• Compound was applied to the back of the same carpet as in Example 1 at a coating weight of 121.0 mg per cm 2 (35.7 ounces per square yard), followed by a polypropylene scrim, 11.19 mg per cm 2 (3.3 ounces per square yard), as a secondary backing.
• the carpet was dried at 132°C for 12 minutes, then allowed to equilibrate overnight before testing.
• This carpet had a tuftbind of 2.92 kg-meters (21.1 ft-pounds), a hand punch of 2.36 kg-meters (17.1 ft-pounds), a dry delamination of 1.7679 kg per cm (9.9 pounds/inch) and a re-wet delamination of 1.3036 kg per cm (7.3 pounds/inch).
• Example 2 a standard, carpet grade styrene-butadiene latex (53.3 percent solids content) was compounded with calcium carbonate and thickener and applied as a carpet backing as in Example 1.
• the resulting carpet had a coating weight of 115.6 mg per cm 2 (34.1 ounces per square yard), a tuftbind of 2.24 kg-meters (16.2 ft-pounds), a delamination of 1.7501 kg per cm (9.8 pounds/inch), a hand punch of 3.37 kg-meters (27.0 ft-pounds) and a re-wet delamination of 1.1786 kg per cm (6.6 pounds/inch).

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• Engineering & Computer Science (AREA)
• Textile Engineering (AREA)
• Chemical & Material Sciences (AREA)
• Dispersion Chemistry (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
• Polyurethanes Or Polyureas (AREA)
• Adhesives Or Adhesive Processes (AREA)
• Carpets (AREA)
• Compositions Of Macromolecular Compounds (AREA)
• Synthetic Leather, Interior Materials Or Flexible Sheet Materials (AREA)
• Laminated Bodies (AREA)

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• 1998
  • 1998-03-16 BR BR9808342-2A patent/BR9808342A/pt not_active IP Right Cessation
  • 1998-03-16 JP JP54066098A patent/JP2001518148A/ja active Pending
  • 1998-03-16 CO CO98014588A patent/CO5021193A1/es unknown
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  • 1998-03-16 KR KR1019997008397A patent/KR20000076296A/ko not_active Application Discontinuation
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• 1999
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