EP0970274A2 - Envers de revetement de surface, contenant des microspheres polymeres, et procedes de fabrication correspondant - Google Patents

Envers de revetement de surface, contenant des microspheres polymeres, et procedes de fabrication correspondant

Info

Publication number
EP0970274A2
EP0970274A2 EP99904068A EP99904068A EP0970274A2 EP 0970274 A2 EP0970274 A2 EP 0970274A2 EP 99904068 A EP99904068 A EP 99904068A EP 99904068 A EP99904068 A EP 99904068A EP 0970274 A2 EP0970274 A2 EP 0970274A2
Authority
EP
European Patent Office
Prior art keywords
backing
layer
secondary backing
surface covering
textile substrate
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP99904068A
Other languages
German (de)
English (en)
Inventor
Alonzo M. Burns, Jr.
Hao A. Chen
Nicholas Zerebecki
Charles Patterson
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Mannington Mills Inc
Original Assignee
Mannington Mills Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Mannington Mills Inc filed Critical Mannington Mills Inc
Publication of EP0970274A2 publication Critical patent/EP0970274A2/fr
Withdrawn legal-status Critical Current

Links

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
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0056—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the compounding ingredients of the macro-molecular coating
    • 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
    • D06N7/0076—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 a thermoplastic material applied by, e.g. extrusion coating, powder coating or laminating a thermoplastic film
    • 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
    • D06N2201/00—Chemical constitution of the fibres, threads or yarns
    • D06N2201/08—Inorganic fibres
    • D06N2201/082—Glass fibres
    • 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
    • D06N2203/048—Polyvinylchloride (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
    • D06N2203/061—Polyesters
    • 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
    • D06N2205/00—Condition, form or state of the materials
    • D06N2205/04—Foam
    • 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
    • D06N2205/00—Condition, form or state of the materials
    • D06N2205/08—Microballoons, microcapsules
    • 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
    • D06N2205/00—Condition, form or state of the materials
    • D06N2205/20—Cured materials, e.g. vulcanised, cross-linked

Definitions

  • the present invention relates to the backing on surface coverings, preferably carpet backings, and more particularly relates to the use of polymeric
  • microspheres in the backings of surface coverings such as carpets and resilient floor coverings.
  • surface coverings have a backing layer wherein a surface of the backing layer rests against the sub-surface or sub-floor on which it is applied, such as a concrete or wood floor.
  • the commercial carpet market in United States is approximately 80% 12
  • the modular tiles are gaining more and more of market share in the office
  • the 6 ft. vinyl backed roll goods are also increasing their market share in healthcare, institutional and other markets due to their higher performance over broadloom carpet, ability to provide wall to wall moisture barrier due to chemically weldable properties of vinyl at carpet seams, superior dimensional stability, easy to transport, install and remove carpet, as well as it's lower cost based on life cycle.
  • the carpet tiles and 6 ft. wide roll goods have been growing rapidly in the last 25 years. They are different in properties and end use applications compared to traditional 12 ft. wide SBR latex backed carpets.
  • the SBR latex chemistry is aqueous system (water based) where as the vinyl chemistry is non-aqueous.
  • SBR latex backed carpets are hard backed and as such, they are glued to the floor or installed over a cushioned padding.
  • SBR latex backed carpet as compared to vinyl
  • cushion backed products are increasing in demand because they offer better under foot comfort and hence better ergonomics as well as better
  • the 6 ft. wide, vinyl cushion backed roll goods and 18" x 18" vinyl cushion backed modular products are available in the market place today. These vinyl foam backed products predominantly use closed-cell chemical foam.
  • the closed-cell foams are achieved by the use of a blowing agent which blows the original thickness by 3 to 4 times when subjected to relatively high temperatures
  • Step-1 Apply pre-coat to the tufted carpet.
  • Step-2 Produce closed-cell PVC foam as a separate process.
  • Step-3 Laminate previously pre-coated carpet with pre- manufactured PVC foam closed-cell PVC foam sheet. Further, there are some disadvantages of this three step process. They are as follows: (1) Poor dimensional stability because process requires hot lamination at
  • the present invention removes many, if not all of the disadvantages of
  • the present invention preferably uses a one step process that is easy to control, and where elevated temperatures are not required.
  • fiberglass stabilizers are in use in the backing structure and thus imparts superior dimensional stability.
  • the PVC pre- coat layer provides a moisture barrier at the base of the tufts and wet-on-wet lamination of the adhesive coat and the foam coat imparts superior delamination strength.
  • the present invention relates to a secondary backing comprising a thermoplastic material and polymeric microspheres dispersed in the
  • thermoplastic material thermoplastic material
  • the present invention further relates to a textile substrate comprising a primary backing with textile fibers extending upwardly from the backing and forming a surface and a secondary backing fastened to the opposite of the primary
  • the present invention further relates to a secondary backing comprising a
  • foamed thermoplastic material having polymeric microspheres dispersed therein.
  • pre-expanded polymeric microspheres means that the polymeric microspheres are expanded beforehand (e.g., expanded before being dispersed in the secondary backing and substantially no-expansion or
  • the present invention also relates to a textile substrate comprising a primary backing with textile fibers extending upwardly from the backing and forming a surface, and a secondary backing fastened to the opposite side of the primary backing, wherein the .secondary backing comprises a foamed thermoplastic material having polymeric microspheres dispersed therein.
  • the present invention also relates to a method of making a textile substrate comprising forming a primary carpet fabric and affixing a secondary backing to the side of the primary carpet fabric, wherein the secondary backing comprises a thermoplastic material having polymeric microspheres dispersed therein.
  • An additional embodiment of the present invention is surface coverings which contain a secondary backing wherein the secondary backing contains at least one thermoplastic material and at least one activated blowing agent, wherein the secondary backing is affixed to a primary backing such that there is no delamination under ASTM-D-3936, and wherein the secondary backing is
  • Figures 1 and 2 are expanded side views of a carpet product showing the various layers of preferred embodiments of the present invention.
  • the present invention relates to a surface covering having a backing layer, wherein the backing layer is a
  • thermoplastic material having polymeric microspheres dispersed therein.
  • the surface covering can be any type of surface covering which uses a backing layer.
  • the polymeric microspheres can be pre- expanded (i.e., non-expandable type), and/or expandable polymeric microspheres.
  • pre-expanded polymeric microspheres i.e., pre-expanded polymeric microspheres
  • microspheres are expanded beforehand and not during the formation of the secondary backing, and substantially no expansion or no expansion at all
  • microspheres means the microspheres expand during formation of the secondary backing.
  • the surface covering is a floor covering, and more preferably, the surface covering is a textile substrate, for instance, a carpet.
  • the textile substrate is a broadloom carpet, modular tile, or a wide roll
  • the textile substrate is tile or 6 ft. roll goods.
  • the floor covering can be resilient floor covering, such as vinyl flooring and
  • the textile substrate comprises textile fibers defining a fibrous face, a primary backing to which the textile fibers are secured, and a secondary backing
  • the term "textile substrate” relates to, but is not limited to, a fiber, web, yarn, thread, sliver, woven fabric, knitted fabric, non-woven fabric, upholstery fabric, tufted carpet, and piled carpet formed, from natural and synthetic fibers.
  • the prefe ⁇ ed embodiment is a floor covering and more particularly a textile substrate
  • the details of the present invention will be directed to such a flooring material with the realization that the present invention can be applied to other types of surface coverings by modifications which would be known to those
  • a textile substrate contains a primary backing with textile fibers extending upwardly from the backing and forming a surface.
  • a secondary backing is fastened or affixed to the side of the primary backing which is opposite the
  • the secondary backing is
  • the secondary backing is preferably a thermoplastic material*.
  • the thermoplastic material can be an aliphatic thermoplastic resin such as one derived
  • the monomer can be a ethylenically unsaturated hydrocarbon such as an olefin or a nitrile (such as an acrylonitrile), vinyl or vinylidene chloride, vinyl acetate, or an acrylate, such as ethylacrylate or methylmethacrylate.
  • the thermoplastic material can be a polyethylene, ethylene/vinyl acetate, polyvinyl chloride, polyisobutylene, and the like.
  • the thermoplastic material is a vinyl-type material such as a vinyl resin and more particularly a polyvinyl
  • Suitable polymers for the backing layers of the present invention can be derived from at least one monomer selected from the group consisting of acrylic, vinyl, chlorinated vinyl, styrene, butadiene, ethylene. butene, and copolymers or blends thereof.
  • a preferred coating composition is polymer or copolymer of a vinyl compound, or halogenated polyolefin, e.g. , polyvinyl chloride,
  • polyvinylidine chloride polyethylene chloride, polyvinyl acetate, polyvinyl acetyl, chlorinated polyethylenes, and the like, and copolymers and mixtures thereof.
  • a specific example of a resin coating composition is a vinyl chloride, resin-based plastisol, wherein the plasticizer component of the plastisol is a phthalate-based
  • Particularly preferred vinyl chlorides include Vinycel 124 (Policyd SA DE CV, Mexico), Geon Registered TM 13 oz (Geon Company, Cleveland, Ohio), Pliovic M-70 (The Goodyear Tire and Rubber Company, Akron, Ohio), and Oxy 67SF (Occidental Chemical Corp. , Dallas, Tex.).
  • Particular alkyl include Vinycel 124 (Policyd SA DE CV, Mexico), Geon Registered TM 13 oz (Geon Company, Cleveland, Ohio), Pliovic M-70 (The Goodyear Tire and Rubber Company, Akron, Ohio), and Oxy 67SF (Occidental Chemical Corp. , Dallas, Tex.).
  • phthalate plasticizers include Santicizer Registered TM 160 (Monsanto Company,
  • the secondary backing can be a cushion-backed backing or a hard back backing.
  • the secondary backing can be a solid thermoplastic backing or a foamed thermoplastic backing.
  • the thermoplastic foamed backing is preferably a foamed vinyl backing and more preferably a polyvinyl chloride foamed backing, such as a closed -cell vinyl foamed backing.
  • the secondary backings will contain at least one plasticizer, in conventional amounts, like about 50 phr to about 80 phr and can include other ingredients, like wetting agents conventionally used in secondary backings.
  • Chemically expanded thermoplastic foamed backings can be used as the secondary backing and can be prepared by casting a thermoplastic resin plastisol containing at least one blowing agent onto the back of the primary backing and heating to expand and fuse the plastisol.
  • a pre-blown foamed secondary backing can be laminated, such as by heat, to the primary backing.
  • the solid thermoplastic secondary backing can be similarly prepared by casting or by
  • blowing agents can be used and include, but are not limited
  • the secondary backing preferably contains one or
  • polymeric microspheres which are preferably hollow particles and preferably contain a thermoplastic shell encapsulating a gas.
  • a blowing agent like isobutane or isopentane is inside the shell, wherein the shell is a copolymer of monomers, like vinylidene chlorde, acrylonitrile and methylmethacrylate, and the like.
  • polymicrospheres are DUALITE ® low density microspheres, such as DUALITE ® M6032AE or M7000, or Expancel * type polymeric microspheres.
  • the Expancel microspheres are available from Akzo Nobel, Duluth, Georgia.
  • the DUALITE ® polymeric microspheres are available from Pierce & Stevens Corporation, Buffalo, New York. Specific types of Expancel microspheres are set forth in the examples, and include 55 IDE, 461DE, 551-20,
  • the microspheres can be added in dry form or as a slurry for pu ⁇ oses of the present invention.
  • the particle diameter for the Expancel microspheres will be from about 15 microns to about 50 microns and having a true density of from about 0.030 to about 0.70 g/cc.
  • the polymeric microspheres are heat resistant to a temperature
  • the polymeric microspheres can withstand
  • polymeric microspheres can be present in any amount that is compatible with the thermoplastic material and to accomplish the pu ⁇ oses of the secondary backing layer.
  • the polymeric microspheres can be present in the secondary backing in an amount of from about 5 parts to about 100 parts or more per 100 parts by weight resin, and more preferably be present in a range of from about 5 parts per 100 parts by weight resin to about 50 parts per 100 parts by weight resin, and more preferably from about 10 parts per 100 parts by weight resin to about 30 parts per 100 parts by weight resin.
  • more polymeric microspheres are present than with a foamed secondary backing.
  • the hardback secondary backing can have from about 10% to about 60% by weight more polymeric microspheres than a foamed secondary backing of the present invention.
  • polymeric microspheres can be present in any one or more of the other layers of the surface covering, except the primary backing. Amounts in these layers will depend on the desired results to be achieved.
  • a blowing agent is also present with the polymeric
  • blowing agent any amount can be used. Preferably, amounts from about 0.5 phr to about 5.0 phr, and more preferably from about 2.0 phr to about 3.0 phr can be used. Examples of blowing agents include, but are not
  • blowing agent used in the present application, while any blow ratio can be used, preferably the blow ratio is from about 1.0 to about 2.5, and more
  • the surface coverings of the present invention can be made in a 1- step process as explained in more detail below.
  • a lower blow ratio is used compared to conventional blow ratios which are on the order of magnitude of above 2.5 and generally more on the order of 3 to 4, it is difficult to achieve a consistent thickness across the entire product due to such a high blow ratio which makes maintaining uniform thickness of the layer containing the blowing agent practically impossible due to such a large expansion of the layer.
  • Such conventional blow ratios are generally desired in conventional products, if not required due to the desired density of the layer as well as the final product. Unlike the conventional surface coverings, the present invention avoids the need for such a high blow ratio by using polymeric microspheres in combination with
  • blowing agents which achieves the desired density but without the need for such a high blow ratio.
  • conventional blow ratios on the order of magnitude of 3 or 4
  • high temperatures are required to achieve such
  • the present invention in at least one embodiment, overcomes this problem by a I -step process which permits the wet-on-wet formation of the
  • the foam containing layer e.g., such as
  • the foam containing layer can be formed directly on the primary backing without damage to the primary backing.
  • the ingredients comprising the secondary backing are preferably in liquid form
  • the ingredients comprising the secondary backing are in liquid form, the desired amount of polymeric microspheres are preferably added and dispersed amongst the liquid phase of the secondary backing. Then, the secondary backing is applied as a liquid layer onto the primary backing or any optional intermediate layer in a conventional manner known to those skilled in the art, such as with the use of a doctor blade.
  • thickness of the secondary backing layer can be any thickness desired by the user
  • the secondary backing has a thickness of from about 10 mils to about 50 mils and more preferably from about 30 mils to about 40 mils after curing.
  • the preferred thickness is from about 50 mils to about 150 mils in thickness and
  • the primary backing in the present application can be any conventional primary backing and the textile fibers extending upwardly from the primary backing and forming a surface can be any conventional textile fibers.
  • the primary backing or base fabric as it is also known, can be woven, for example, woven jute, woven polypropylene film, burlap, and the like, or may be
  • non-woven fabric e.g. , needle punched, non- woven polypropylene web, and the like.
  • the primary backing is a synthetic tufting substrate, and more
  • preferably is a non-woven polyester.
  • an adhesive or polymeric precoat layer beneath the primary backing is an adhesive or polymeric precoat layer.
  • This adhesive or polymeric precoat layer can be a precoat of latex or a hot melt
  • the adhesive or polymeric precoat layer is a polyvinyl chloride. This layer is primarily used to maintain permanently the textile fibers in the primary backing with the use of a heat-
  • This adhesive or polymeric precoat layer can optionally have polymeric microspheres dispersed therein in addition or as an alternative to the presence in
  • This optional layer can be made from the same material as the secondary backing, but its location is different within the textile substrate, as shown in Figures 1 and 2.
  • (1) is yarn - (nylon,
  • polypropylene, etc. (2) is a tufting substrate - (non-woven polyester) (primary backing); (3) is an adhesive precoat - (PVC) (e.g. , vinyl pre coat); (4) is an intermediate coat - (PVC) hardback (secondary backing hardback); (5) is a stabilizer - (non-woven fiberglass) cloth; and (6) is a secondary coat - (PVC
  • (1) is yarn - (nylon, polypropylene, etc.); (2) is a tufting substrate - (non- woven polyester); (3) is an adhesive precoat - (PVC);
  • intermediate backing is a hard back and is not a foamed layer. While the intermediate backing can contain polymeric microspheres, in the preferred
  • the intermediate coating is preferably a thermoplastic material, like the secondary backing, but with or without polymeric microspheres.
  • the intermediate backing is also a polymer or copolymer of a vinyl compound, and
  • the thickness of the intermediate backing can be the same as that of the non-foamed secondary backing.
  • the intermediate coating can be applied in a similar matter as other liquid coatings such as hot melt coating
  • thermoplastic material in contact with the top surface of a rotating roller partially submerged in a tank of the molten thermoplastic material.
  • the liquid thermoplastic material preferably, the liquid thermoplastic material
  • This layer is preferably a non-woven material, such as
  • Such a reinforcement material layer is generally placed on the bottom surface of the intermediate backing while the intermediate layer is still in a liquid or gel state.
  • the secondary backing layer can then be affixed to the intermediate backing layer with or without the reinforcement layer
  • the surface covering e.g., the carpet
  • the surface covering has a density of from
  • a preferred formula for the secondary backing is:
  • the Table below provides preferred coating amounts, thicknesses, and cure temperature and times for the preferred embodiment.
  • the need for a high blow ratio can be avoided when a blowing agent is used and a 1-step process can be achieved by pouring a liquid thermoplastic material with the polymeric microspheres onto the back of the primary backing or
  • the foam layer is not necessary, in part because the microspheres are present, thus resulting in a lower blow ratio to achieve the desired foam density.
  • the foaming can occur on the same manufacturing line as the rest of the ca ⁇ et or other surface covering.
  • distinct advantages can be achieved compared to conventional carpets, such as a moisture barrier created by the adhesive or polymeric precoat and also superior dimensional stability with the use of a reinforcement material such as a fiberglass material. Also, excellent physical
  • the secondary backing of the present invention can be inco ⁇ orated into such floor covering products.
  • a foam layer or pre-gel layer containing a polymeric material and a blowing or foaming agent along with the polymeric microspheres can be used.
  • a layer is located between a conventional substrate layer and a wear surface.
  • the wear surface and/or other top coat layers can be considered primary backings for pu ⁇ oses of the present invention.
  • the wear surface can comprise a base coat and a top coat.
  • the layer includes the polymeric microspheres disclosed herein.
  • the layer includes the polymeric microspheres disclosed herein.
  • the layer includes the polymeric microspheres disclosed herein.
  • the layer includes the polymeric microspheres disclosed herein.
  • the layer includes the polymeric microspheres disclosed herein.
  • the layer includes the polymeric microspheres disclosed herein.
  • the layer includes the polymeric microspheres disclosed herein.
  • the layer includes the polymeric microspheres disclosed herein.
  • the layer includes the polymeric microspheres disclosed herein.
  • the layer includes the polymeric microspheres disclosed herein.
  • the foam layer can be prepared using polymeric material and polymeric microspheres without the presence of a blowing or foaming agent just as described earlier as one of the possible embodiments above. Accordingly,
  • the use of polymeric microspheres are not necessary and a surface covering can be prepared wherein the secondary backing contains at least one thermoplastic material and at least one activated blowing agent wherein the secondary layer is preferably expanded from its original thickness by about 1 to about 2.5 times (blow ratio), and more
  • the secondary backing is coated onto the primary backing such that there is no delamination, for instance, as tested under ASTM-D-3936.
  • This secondary backing can be used for a variety of surface coverings and can be fixed to primary backings for textile substrates or vinyl-type floorings.
  • the method of preparing such a surface covering involves applying a secondary backing formulation comprising at least one liquid thermoplastic material, at least one blowing agent, and at least one activator onto the back of a substrate comprising a primary backing layer; gelling the formulation and activating the blowing agent; and curing the formulation to form the surface covering comprising the primary backing layer and the secondary backing layer.
  • a secondary backing was made in the following manner: Raw materials used were PVC Dispersion Resin, PVC Blending Resin, and
  • the batching equipment was a Nauta Planetary Mixer, model MBX-1225 with a 900 gallon working capacity.
  • Dualite ® polymeric microspheres were then charged manually into the Nauta mixer.- The Vanstay 5956 stabilizer and Printex G carbon black were then added, and the mixer turned on. Both PVC resins were added and allowed to mix until smooth. The remaining plasticizer was added and allowed to mix.
  • a 10 fluid ounce sample was taken and tested for viscosity using a Brookfield RVF viscometer at 20 ⁇ m with a #7 spindle. The sample was also
  • the tile line is a two level process, with a top section and a bottom section.
  • the ca ⁇ et to be coated was placed in the sew-on cradle at the end of the
  • the ca ⁇ et then went through a tension control station, through a guider and into the precoat coater station. Here, about 40 to 45 ounces per square yard of vinyl precoat was applied, using a knife over roll coater. The ca ⁇ et left the station and traveled around a gel
  • the ca ⁇ et passed through a knife over roll coater, where about 30 to 35 mils of hardback liquid vinyl was applied. Immediately after that a layer of nonwoven fiberglass was placed onto the liquid vinyl hardback, and the assembly was passed through a laminating nip roll, which squeezed the ca ⁇ et to the fiberglass.
  • nip was set at the same setting as the first coater setting. The ca ⁇ et then passed
  • the oven has steam-heated plates underneath the ca ⁇ et to maintain ca ⁇ et temperature, which are operated at between about 65 psi to about 100 psi.
  • the four zone oven passed heated air across the ca ⁇ et, raising
  • the ca ⁇ et exited the four zone oven, and passed through the embosser infrared oven, which raised the surface temperature of the vinyl layer to
  • the ca ⁇ et passed through a turn bar, which changed the orientation to face up.
  • the carpet entered an accumulator, which allowed the cutting press to stop without stopping the tile line.
  • the ca ⁇ et left the accumulator, and entered the cutting press.
  • There the carpet was cut face up into 18 inch by 18 inch squares, 8 tiles per cut.
  • the tiles were carried down an inspection line, where they are checked for defects, and any fizzy edges trimmed on rotating bevel cutters.
  • Second knife applicator set at 80 to 125 mils above the Fiberglass Laminating Nip.
  • Oven residence time was 5 to 7 minutes.
  • Total weight of the backing was 120 oz/sq yd.
  • Foam thickness was about .125 inches.
  • a secondary backing was made in the following manner: Raw materials used were PVC Dispersion Resin, PVC Blending Resin, and
  • the batching equipment used was a Hockmeyer disperser.
  • the Jayflex 77 and DINP plasticizers were added to the mixer and then the SI 60 plasticizer was added into the mixer. Afterwards, the blowing agent
  • the carbon black powder was added and then the dispersion resin was then added and the mixture mixed for 8 minutes. Afterwards, the blending resin was added while the mixer was set at low speed and mixed for 3 minutes ahd then the polymeric microspheres were added while the mixture was at low speed.
  • Example 2 The sample was tested for viscosity as in Example 1. Then, the formulation was used in the formation of a secondary backing
  • Zone 3 345 Zone 4 345
  • Total weight was slightly less than a standard hardback tile.
  • Foam thickness was .125 inches.
  • Foam density was 22-26 Lb. per cubic foot.
  • Example 2 was repeated expect the initial layer of vinyl hard back was replace with the same foam formula that was applied at the second coater station.
  • the particular process settings used in this process were as follows: 1. Line speed was 14 to 16 fpm;
  • Total weight was slightly less than a standard hardback tile, 112 ozs/sq yd.
  • Foam thickness was .125 inches.
  • the secondary backing had an enhanced
  • Example 4 In this example, the formulation as set forth in Example 2 was prepared
  • blowing agent was present in the formulation.
  • the formulation is set forth in
  • the secondary backing was prepared in the same manner as described in Example 1.
  • the particular process settings that were used are set forth below:
  • Total weight was from 76 oz/sq yd to 80 ozs/sq yd.
  • Foam thickness was .125 inches.
  • Foam density was 22-26 Lb. per cubic foot.
  • the product obtained in this example was a totally closed cell foam since the particular polymeric microspheres used in this example expanded upon the application of heat. Since no expansion gases evolved, there was no channeling
  • the secondary backing of the present invention has the following specifications.
  • Precoat Layer Closed Cell Vinyl, Non-Acquaous
  • Adhesive Layer Closed Cell Vinyl, Non-Acquaous
  • Cushion Volume Density 24 lbs/ft 3 avg.
  • Cushion Layer Weight 32 oz./s.y.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Laminated Bodies (AREA)
  • Synthetic Leather, Interior Materials Or Flexible Sheet Materials (AREA)

Abstract

Cette invention se rapporte à un envers secondaire pour revêtements de surface, qui comprend au moins une matière thermoplastique dans laquelle sont éventuellement dispersées des microsphères polymères. Cette invention présente également un substrat textile comprenant un envers primaire ayant des fibres textiles s'étendant vers le haut depuis l'envers et formant une surface, ainsi que l'envers secondaire décrit ci-dessus, fixé audit substrat. Des procédés de fabrication de ce substrat textile et de l'envers secondaire, qui peut être en mousse ou en dur, sont également décrits, ainsi qu'un revêtement de surface élastique, tel qu'un revêtement de sol vinylique, utilisant cet envers secondaire en une ou plusieurs couches.
EP99904068A 1998-01-12 1999-01-12 Envers de revetement de surface, contenant des microspheres polymeres, et procedes de fabrication correspondant Withdrawn EP0970274A2 (fr)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US7111098P 1998-01-12 1998-01-12
US71110P 1998-01-12
PCT/US1999/000605 WO1999035327A2 (fr) 1998-01-12 1999-01-12 Envers de revetement de surface, contenant des microspheres polymeres, et procedes de fabrication correspondant

Publications (1)

Publication Number Publication Date
EP0970274A2 true EP0970274A2 (fr) 2000-01-12

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EP99904068A Withdrawn EP0970274A2 (fr) 1998-01-12 1999-01-12 Envers de revetement de surface, contenant des microspheres polymeres, et procedes de fabrication correspondant

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EP (1) EP0970274A2 (fr)
AU (1) AU2454899A (fr)
CA (1) CA2282572C (fr)
WO (1) WO1999035327A2 (fr)

Families Citing this family (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE10326138A1 (de) * 2003-06-06 2004-12-23 Basf Ag Verfahren zur Herstellung von expandierbaren thermoplastischen Elastomeren
WO2009076920A1 (fr) * 2007-12-18 2009-06-25 Fleissner Gmbh Procédé et dispositif de solidification d'un matériau textile
DE102008045753A1 (de) 2008-09-04 2010-03-11 Fleissner Gmbh Verfahren und Vorrichtung zur Verfestigung von textilem Material
DE102008020716A1 (de) 2008-04-24 2009-10-29 Fleissner Gmbh Verfahren und Vorrichtung zur Verfestigung von textilem Material
DE102008010091A1 (de) 2007-12-18 2009-06-25 Fleissner Gmbh Verfahren und Vorrichtung zur Verfestigung von textilem Material
EP3245328B1 (fr) * 2015-01-16 2020-10-28 Beaulieu International Group NV Revêtement pour planchers, parois ou plafonds et procédé d'obtention d'un revêtement
GB2595665B (en) * 2020-06-01 2022-12-14 Altro Ltd Improvements in or relating to surface coverings

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Publication number Priority date Publication date Assignee Title
CA968239A (en) * 1971-11-17 1975-05-27 The Dow Chemical Company Carpet and preparation thereof
FR2496739A1 (fr) * 1980-12-24 1982-06-25 Boussac Saint Freres Bsf Revetement a forte isolation thermique et phonique pour l'interieur de locaux, et procede de fabrication
JPS6059183A (ja) * 1983-09-02 1985-04-05 Badische Yuka Co Ltd クツシヨン性を有する敷設材の製造方法
US4689256A (en) * 1986-08-29 1987-08-25 Compo Industries, Inc. Flame retardant tufted carpet tile and method of preparing same
US4836871A (en) * 1986-12-02 1989-06-06 Mitsubishi Yuka Badische Co., Ltd. Manufacturing method for an expanded laminated sheet
US5332457A (en) * 1992-03-12 1994-07-26 Mitsubishi Yuka Badische Co., Ltd. Process for producing carpet

Non-Patent Citations (1)

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Title
See references of WO9935327A3 *

Also Published As

Publication number Publication date
WO1999035327A8 (fr) 2000-09-14
AU2454899A (en) 1999-07-26
WO1999035327A3 (fr) 1999-11-04
CA2282572A1 (fr) 1999-07-15
WO1999035327A2 (fr) 1999-07-15
CA2282572C (fr) 2002-09-24

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