Classifications

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

Definitions

• the present invention relates to latex coating compositions comprising a vinyl ester/ethylene copolymer dispersion and a styrene/butadiene copolymer dispersion useful for forming carpet products as well as to processes for forming such carpet products.
• Most conventional carpets comprise a primary backing with yarn tufts in the form of cut or uncut loops extending upwardly from this backing to form a pile surface.
• the yarn is inserted into a primary backing (frequently a woven or nonwoven material) by tufting needles and a precoat (i.e., a binder) is applied thereto.
• a woven scrim typically made from polypropylene
• a secondary backing attached to the back of the carpet to provide dimensional stability.
• the scrim is attached to the precoated carpet back with another binder formulation typically referred to as a skipcoat or adhesive coating.
• the skipcoat is applied to the scrim, and the scrim is then applied to the precoated backing of the carpet before the assembled carpet elements are sent into a curing oven.
• the purpose of the skipcoat or adhesive coating is to provide a layer of material which will adhere the woven scrim to the back of the carpet.
• the physical properties of the binders are important to their successful utilization as carpet coatings.
• the coating must be capable of being applied to the carpet and dried using the processes and equipment conventionally employed in the carpet industry for latex coating.
• the binder composition must provide excellent adhesion to the pile fibers to secure them firmly in the backing.
• the coating will also typically have a high loading of fillers such as calcium carbonate, clay, aluminum trihydrate, barite, feldspar, cullet, fly ash and/or recycled carpet backing.
• the binders in coating compositions for carpet products are frequently emulsion polymers, i.e., latex dispersions, which can comprise copolymers of vinyl esters (such as vinyl acetate) and ethylene. Binders and carpet coating compositions based on vinyl ester/ethylene copolymers are disclosed, for example, in U.S. Patent Nos. 4,735,986; 5,026,765; 5,849,389 and 6,359,076 and in U.S. Publication No. 2005/0287336, the entireties of which are incorporated herein by reference. These copolymers are prepared by polymerizing appropriate co- monomers in an aqueous emulsion.
• latex coating compositions may be prepared having especially desirable physical properties, rendering them well-suited for use in adhesive compositions such as precoat and/or skipcoat binders in carpet manufacture.
• carpet products having particularly high tuft bind values may be formed using the processes and latex coating compositions of the present invention.
• the present invention is directed to a carpet product, e.g., a tufted or woven carpet product, comprising at least one substrate and at least one adhesive layer associated with said at least one substrate, e.g., directly or indirectly bound to the substrate, said adhesive layer being formed from an adhesive composition comprising a latex coating composition comprising: (a) a first copolymer of at least a vinyl ester of an alkanoic acid having from 1 to 13 carbon atoms and ethylene; and (b) a second copolymer of at least styrene and butadiene, wherein the first and second copolymers are colloidally dispersed in an aqueous medium comprising a surfactant.
• a latex coating composition comprising: (a) a first copolymer of at least a vinyl ester of an alkanoic acid having from 1 to 13 carbon atoms and ethylene; and (b) a second copolymer of at least styrene and butadiene, wherein
• the latex coating composition may be incorporated into an adhesive composition that functions as a precoat or as a skipcoat binder or as both.
• the substrate may comprise a primary backing or a secondary backing.
• the carpet products of the invention preferably are particularly durable exhibiting tuft bind values greater than 20 N, e.g., greater than 27 N.
• the latex coating composition functions as a precoat for binding carpet fibers, e.g., as tufts, to a primary backing.
• the invention is a process for forming a carpet product, the process comprising the steps of: (a) providing an adhesive composition comprising a latex coating composition comprising: (i) a first copolymer of at least a vinyl ester of an alkanoic acid having from 1 to 13 carbon atoms and ethylene; and (ii) a second copolymer of at least styrene and butadiene, wherein the first and second copolymers are colloidally dispersed in an aqueous medium comprising a surfactant; (b) contacting carpet fibers, e.g., tufted yarn, with a primary backing material, e.g., a primary tufting substrate or woven material; (c) applying the adhesive composition to the carpet fibers and the primary backing material; and (d) drying the adhesive
• the adhesive composition acts as a skipcoat binder in the manufacture of a carpet product.
• the invention is to a process for forming a carpet product, the process comprising the steps of: (a) providing an adhesive composition comprising a latex coating composition comprising: (i) a first copolymer of at least a vinyl ester of an alkanoic acid having from 1 to 13 carbon atoms and ethylene; and (ii) a second copolymer of at least styrene and butadiene, wherein the first and second copolymers are colloidally dispersed in an aqueous medium comprising a surfactant; (b) providing a primary carpet layer comprising yam tufted into a primary backing; (c) applying the adhesive composition to at least one of the primary carpet layer or a secondary backing; (d) contacting the primary carpet layer with the secondary backing; and (e) drying the adhesive composition under conditions effective to adhere the primary carpet
• the invention in one embodiment, is directed to latex coating compositions useful as coating and adhesive compositions incorporated into textile structures, e.g., carpet products.
• the latex coating compositions comprise a blend of a first copolymer, preferably in a first copolymer dispersion, and a second copolymer, preferably in a second copolymer dispersion.
• the first copolymer is a copolymer of at least a vinyl ester of an alkanoic acid having from 1 to 13 carbon atoms, preferably vinyl acetate, and ethylene
• the second copolymer is a copolymer of at least styrene and butadiene.
• the tuft bind strength may be characterized as a "tuft bind percentage" relative to a similar carpet formed using a coating composition containing the first dispersion (not blended with the second dispersion).
• the blended latex coating compositions of the invention may provide carpeting having a tuft bind percentage greater than 125%, greater than 150%, greater than 175% or greater than 200%.
• the first and second dispersions containing the first and second copolymers, respectively, can be prepared using conventional emulsion polymerization procedures. Such procedures are described in general, for example, in U.S. Patent No. 5,849,389, the entirety of which is incorporated herein by reference, as well as in Chorng-Shyan Chern, Principles and Applications of Emulsion Polymerization, John Wiley and Sons Inc. (2008), the entirety of which is incorporated herein by reference.
• the particle size of the first dispersion or the second dispersion, or the resulting blend of the first and second dispersions can be regulated by the quantity of non-ionic or anionic surfactants employed. To obtain smaller particles sizes, greater amounts of surfactants are used. As a general rule, the greater the amount of the surfactant employed, the smaller the average particle size.
• the raw materials used to form the second dispersion typically include the monomers (styrene and butadiene for SB or styrene, butadiene and acrylonitrile for SBA), water, an emulsifier, an initiator system, a modifier, a free radical scavenger (e.g., dimethyl dithiocarbamate or diethyl hydroxylamine) and a stabilizer system.
• the polymerization process may be performed batch wise or continuously. In a continuous process, the monomers are metered into the reactor chains and emulsified with the emulsifiers and catalyst.
• the invention is directed to an adhesive composition, preferably a carpet precoat or skipcoat binder, comprising an aqueous surfactant-stabilized, copolymer latex coating composition, and sufficient alkali to achieve a pH of 6 to 10, the latex coating composition having dispersed therein a first copolymer of an alkanoic acid having from 1 to 13 carbon atoms and ethylene, and a second copolymer of at least styrene and butadiene, wherein the latex coating composition is stabilized with anionic and/or non-ionic emulsifiers.
• Example 4B Due to its particularly high initial viscosity, 3.2 grams of water was added to Example 4B without any added thickener.
• the high initial viscosity of Example 4B when compared to the other examples indicates that surfactant stabilized VAE dispersions were surprisingly and unexpectedly more compatible with SB than PVOH stabilized VAE dispersions.
• the results presented in Table 2 show that polyvinyl alcohol stabilized VAE was not compatible with SB. Blends having higher viscosities, an indication of instability, were not further tested for precoat compound stability.
• Precoat binders were then formulated for blends having acceptable viscosities according to the formulation shown in Table 3.
• the precoat binders were formed to a solids level of 84 wt.% and a target viscosity of 9000-10,000 cPs. Once formed, the precoat binders were applied as a precoat on Beaulieu carpet (made from 300 denier polypropylene fibers with fiber face weight of 20 oz sq yd (678 g/m 2 )) at about 22-24 oz/sq yd (746-813 g/m 2 ) target coat weight. The resulting precoat binders were then dried and the carpet samples tested for tuft bind values and are reported in Table 4.

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

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• 2013
  • 2013-02-14 CN CN201380009136.2A patent/CN104105826A/zh active Pending
  • 2013-02-14 US US13/767,531 patent/US20130209726A1/en not_active Abandoned
  • 2013-02-14 EP EP13706869.8A patent/EP2815019A1/de not_active Withdrawn
  • 2013-02-14 WO PCT/US2013/026166 patent/WO2013123210A1/en active Application Filing

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