JP2001501105A - Rug and carpet underlays substantially impermeable to liquids - Google Patents

Abstract

  (57) [Summary] A carpet underlay and carpet are disclosed. The underlay comprises a fibrous non-woven substrate of natural or synthetic fibers having a repellent finish therein or thereon that renders the substrate substantially impermeable to liquids. The carpet has an underlay that is substantially impervious to liquids, and the underlay is affixed to the back of the carpet to render the carpet substantially impervious to liquids.

Description

DETAILED DESCRIPTION OF THE INVENTION Rug underlays and carpet underlays substantially impermeable to liquids Related application This application is a continuation-in-part of Ser. No. 08 / 424,754, filed Apr. 18, 1995. Technical field to which the invention belongs The present invention relates to novel rug and carpet underlays that are substantially impermeable to liquids. Background of the Invention Partial rugs, such as, for example, oriental rugs, are conventionally laid on lined or other carpets or on decorative wood flooring to achieve the desired aesthetic effect. When such a rug is laid on a carpet, the rugs tend to slide or move in one direction due to the alternating compression and release of fibers in the underlying carpet caused by normal traffic. . Thus, the lug and the furniture placed thereon move from the desired location. In addition, the lugs may wrinkle instead of being flat. Such lugs may slip on the polished surface of a decorative wooden floor. Such movements detract from the aesthetics of the room and can cause slip and trip hazards. Rug underlays have been proposed as a solution to such problems. For example, underlays for such lugs are disclosed by Mussallem in U.S. Patent Nos. 4,504,538 and 4,985,279. The underlay typically consists of a lightweight non-woven mat, which is composed of filamentary fibers and needle punched into a coarse, thin mat. Needle punches are conventionally used to compress fibrous mats into felt-like materials. Mussallem discloses that although any natural or synthetic fiber can be used for the underlay, synthetic fibers such as polyolefins, nylons, polyesters, acrylic polymers, etc. are preferred. Needle punching is also used to fill the woven mesh in such non-woven mats, making the mats strong and stiff. The needle-punched mat is then treated on at least one side and preferably on both sides with an emulsion adhesive such as synthetic rubber latex. The adhesive is then cured. The adhesive properties of the underlay effectively secure it to the underlying rug or surface and prevent movement. The adhesive coating of the underlay is selected and can be easily and restored from the surface on which the lugs are laid for cleaning or other purposes, with the required adhesive strength to prevent slippage or movement So as to provide both sufficiently low peel strength. If water-based or oil-based liquids are spilled on rugs or carpets placed on carpets or decorative wooden floors, the things underneath can smear and degrade . Water-based spills may also transfer dye from the rug to the one below. Other water-based spills, such as colored beverages or coffee, may contain colored ingredients or may contain other undesirable components that penetrate below. Oil-based liquids, such as mineral oil, baby oil, kerosene, or alcohol, may penetrate into the ones below with potential undesirable effects. Detergent applied to the rug also passes through the rug and can adversely affect what is below. Oil-in-water emulsions, such as milk or lotions, and water-in-oil emulsions, such as dairy spreads, require a substantially and simultaneously impermeable barrier to both water-based and oil-based spills. It is a specific example of a spill. Broad woven carpets typically used for built-in or laid carpets can also be laid on a substrate such that the appearance of the substrate is preserved. Broad woven carpets are typically made with a primary backing to which the carpet tufts are attached by means of a latex adhesive. Such carpets with latex adhesive and a single backing are referred to as "unitary" carpets. Most wide woven carpets also have a secondary backing of open fabric (weave spacing of about 0.6-0.9 cm (0.25-0.375 inch)), which is impregnated with latex Being dimensionally stable, and providing a finished look to the back of its carpet. While the open weave of the secondary backing fabric itself cannot be impervious to liquids, US Pat. No. 5,348,785 describes a secondary backing impregnated with carpet latex, Disclosed is a method of rendering substantially liquid impervious by treating with a fluorochemical, silicone-based composition, oil, wax, and / or a repellent composition such as a hydrophobic acrylic resin. are doing. Partial and oriental rugs are typically not treated by such a process and are therefore permeable to liquids. Similarly, carpets used for built-in or laid carpets can be laid on a substrate such that the appearance of the substrate is preserved. Such carpets are not prone to the risk of rug movement or slippage, but substrate stains result from spills. Such spots act particularly unknowingly, since the spotting and blocking of spots following a spill is typically impractical in large or built-in carpets. Spills on wide woven carpets often create puddles in the padding or subfloor that cannot be removed by washing. This spill then promotes the growth of mold, mildew, and odors. By making it possible to more thoroughly clean the dirt, the waterproof lining reduces the growth of mold and mildew, which causes malodor. The prior art also describes waterproof carpets constructed with impermeable backings, such as poly (vinyl chloride) and polyurethane based backings. However, such linings are expensive and difficult to manufacture. It is desired that the underlay be treated to create a substantially impervious barrier to liquids between the rug or carpet and the underlying one. Such treatments must not interfere with the adhesive surface of the underlay and, ideally, would be easily incorporated into the underlay manufacturing process. It is also desirable to have a carpet backing that is substantially impermeable to liquids. The present invention provides such underlays and carpets having such a lining. Summary of the Invention The present invention relates to rugs or carpet underlays that are substantially impermeable to liquids such as oil and water, and to a method of making them. The underlay is also oil and water repellent. The present invention comprises: a) a primary lining having a tufted surface with pile yarns and a back surface coated with a water permeable latex; and b) an optional water permeable secondary lining having a front surface and a back surface, comprising: C) an underlay having a front side and a back side, the surface of the underlay having an adhesive on the back side of either the secondary backing or the primary backing; Tufted pile carpet, wherein the underlay comprises a non-latex fabric, the fabric comprises a material substantially impermeable to liquids, and the carpet is substantially impervious to liquids. including. Detailed description of the invention The present invention provides an underlay comprising one or more adhesive surfaces having a repellent finish, whereby the underlay and the carpet backing are substantially impervious to oil-based and / or water-based liquids. And provide carpet lining. The method of the present invention for rendering an underlay or lining liquid impervious is readily incorporated into the underlay manufacturing process. As used herein, the term "repellent finish" is dispersed, dissolved, or suspended in a solvent, such as water or alcohol, and forms a film-like barrier on or in an underlay. A composition containing an oil-repellent and / or water-repellent chemical that renders the underlay substantially impermeable to liquids. The repellent finish optionally contains surfactants, foaming agents, and other additives. Further, the repellent finish can contain a mixture of different repellents. Suitable repellents for use in the repellent finish are selected from the group consisting of fluorochemicals, silicone compositions, wax emulsions, natural oils, hydrophobic alkyl acrylate resins, and hydrophobic alkyl methacrylate resins. The term "liquid" means an oil-based liquid and / or a water-based liquid. The phrase "substantially impervious to oil-based liquids" is described below in addition to being substantially impervious to water, non-aqueous liquids (eg, mineral oil or alcohol). Means substantially no penetration through the underlay according to Test Method 1. The phrase "substantially impervious to water" means that water or an aqueous solution or suspension (e.g., coffee, wine, soda, fruit juice, or urine) can be applied to an underlay in accordance with Test Method 2 described below. Means substantially non-penetrating through. The phrase "substantially impervious to liquids" means that 20 ml of liquid poured into the underlay from a height of 6 cm does not create a wet spot after 30 minutes or that the underlay into which the liquid is poured It means making a wet spot with a diameter of 2.54 cm or less on a paper towel placed directly underneath the place. The term "water permeable" means that when the above test is performed, a wet spot having a diameter greater than 2.54 cm is obtained. Mats for the underlay of the present invention are generally prepared by conventional techniques. The underlay typically consists of a lightweight nonwoven mat, which is composed of filamentary fibers and needle punched into a coarse, thin mat. Any natural or synthetic fiber can be used to make this underlay, but fibers such as polyolefin, nylon, polyester, wool, cotton, jute, acrylic polymers, etc. are suitable. The fibers can be woven, non-woven, knitted, or stitched. Optionally, a woven mesh is incorporated into the mat. Such methods and materials are well-known to those skilled in the art. Although the underlay mat is described with respect to certain embodiments, many modifications and changes may be made by those skilled in the art. Similarly, many methods for continuous production of underlays and coating of underlays are well known to those skilled in the art. All such modifications and methods of manufacture are intended to be included in the meaning of the term "underlay mat" as used herein. The underlay of the present invention is sufficiently strong and is about 40 to 50 g / m ^Two The underlayment is typically repellent to oil and water, but may not be impermeable. The underlay of the present invention, when affixed to a carpet, may be described as a "tertiary" lining and applies to unitary carpets and carpets with a secondary lining. The underlay of the present invention applies to carpets and rugs that do not already have a water-impermeable backing, such as the poly (vinyl chloride) and polyurethane backings described above. The underlay of the invention is typically applied to carpets having a primary backing coated with a latex such as a styrene-butadiene rubber-based latex (SBR) or an ethylene vinyl acetate-based latex (EVA), and the unit The resulting carpet or secondary backing has not been treated with an oil or water repellent finish. The underlay of the present invention is useful as a separate underlay affixed to a partial rug or to a carpet backing and provides liquid impermeability and several advantages over the prior art. Fluorocarbon treatment is more complete with the underlying material than with the primary or secondary lining treated with latex where incompatibility occurs between the fluorocarbon treating agent and the latex, so the underlay is more complete Provides excellent, durable, and permanent repellency and impermeability to water. Thus, the uniformity of the application excludes untreated places where spills can pass. The underlay of the present invention is applied separately from carpet making, rather than throughout the manufacturing process, eliminating the need to stop production for special drying steps, and allowing the underlay to be applied to the desired location on the carpet To Carpet drying is typically a production limiting process. The underlay of the present invention can be applied independently of carpet production, for example, at an installation site. In addition, the applied underlay improves the cushioning of the carpet, contributing to reduced wear, improved feel and improved aesthetics. Suitable fluorochemicals for use herein include, but are not limited to, polymers or other compounds having a molecular weight greater than 500 and having pendant or terminal groups of the perfluoroalkyl component. Specific examples of some suitable fluorochemicals are: polymers and copolymers of vinylidene fluoride, tetrafluoroethylene, perfluoroalkylethyl acrylate, perfluoroalkylethyl methacrylate, mixtures thereof; said polymers and copolymers and alkyl acrylates and alkyls Includes polymers and copolymers of methacrylates, copolymers of vinylidene chloride, vinylidene fluoride, tetrafluoroethylene, perfluoroalkylethyl acrylate and perfluoroalkylethyl methacrylate, and blends with wax emulsions. Many commercially available fluorochemicals are used both as repellent finishes and as effective oil and water repellents. These are, for example, E. of Wilmington, Delaware. I. "TEFLON" and "Z ONYL" from du Pont de Nemours and Company; "MILEASE" from ICI, Wilmington, Delaware; "ASAHIGARD" from Asahi Glass, Plymouth, MI; "SCOTCHGARD" from 3M, Minneapolis, Minnesota; Dalton, Georgia. And "TX-TEL" from Atochem, Philadelphia, Pennsylvania; and "NK GUARD," a commercial proprietary product sold by Nicca of Fountain, South Carolina, and Suitable for use here. Suitable commercially available silicone-based repellents include, but are not limited to, C2-0563 from Dow Corning, Midland, Michigan. Dow Corning C2-0563 is a silicone repellent mixture of polydialkylsiloxane. Suitable commercially available wax emulsions are available from DuPont under the trademark "NALAN" and Tiarco Chemical Co. of Dalton, Georgia. Including, but not limited to, those sold under the trade name "OCTOWAX" 312. Suitable hydrophobic acrylate resins include water-repellent polymers and copolymers of acrylates and methacrylates, such as methyl, preferably ethyl and butyl esters. Mixtures of these polymers and copolymers are also effective. One example of a commercially available resin is "Acrylic Matte Medium" from Golden Artist Colors of Hamilton, NY. Certain repellent finishes used in the present invention provide an underlay that is substantially impermeable to water-based spills. Other repellent finishes provide an underlay that is substantially impermeable to liquid spills, including both oil-based spills and water-based spills. Thus, the repellent finish is selected based on the desired type of impermeability. Since water-repellent finishes are typically less expensive than for liquids, choosing a water-repellent finish that provides a substantially impervious underlay only against water-based spills can be a challenge in some environments. This is preferred. Preferred fluorochemical repellent finishes include the following aqueous dispersions: Polyfluoroorganic compounds prepared by the reaction of a polyisocyanate with a fluoroalcohol and water as disclosed in EP-A-4536441A (the practice herein). Examples of repellents A); blends of fluoroalkyl citrate-urethane and polymethyl methacrylate disclosed in U.S. Pat. No. 3,923,715 (repellents B of the examples herein); U.S. Pat. U.S. Pat. No. 4,595,518, obtained from the reaction of polyisocyanates with fluoroalcohols and monochlorohydrin as disclosed in U.S. Pat. Fluoroalkyl methacrylate, fluoroalkyl methacrylate, Formulation of acrylate / 2-ethylhexyl methacrylate / 2-hydroxyethyl methacrylate / N-methylol acrylamide copolymer, fluoroalkyl methacrylate / lauryl methacrylate / N-methylol acrylamide copolymer, dimethylaminoethyl methacrylate / acrylic acid copolymer, and chloroprene / dichlorobutadiene copolymer (Repellent D of the example herein); an alkyl (meth) acrylate / fluoro-alkyl (meth) acrylate / vinylidene chloride copolymer disclosed in U.S. Pat. No. 5,344,903; and FC-1355 and FC-1367 (both from 3M, Minneapolis, MN) anionic emulsions of fluoroaliphatic polymers. Illustrated by an aqueous dispersion of a copolymer disclosed in US Pat. No. 4,742,140 containing a mixture of an alkyl acrylate or alkyl methacrylate, vinylidene chloride, and a fluoroalkylalkyl methacrylate or acrylate (containing some acetone). Solvents containing fluorochemical repellent finishes are also effective in this application, but are less preferred due to the flammability hazards of organic solvents and concerns about disposal. Preferred repellent finishes either contain no volatile organic solvents or contain up to about 1%. Preferred mixed fluorochemical and hydrocarbon repellent finishes are waxes, diethylaminoethyl methacrylate / hexadecyl methacrylate / octadecyl methacrylate copolymers of the type disclosed in US Pat. No. 4,595,518, and US Pat. Formulation of a fluoroalkyl acrylate / hexadecyl methacrylate / octadecyl methacrylate / vinylidene chloride copolymer disclosed in U.S. Pat. No. 4,742,140 (repellent E in the Examples herein); wax, diethylaminoethyl methacrylate / hexadecyl methacrylate / Octadecyl methacrylate copolymers and fluoroalkyl methacrylate / dodecyl methacrylate copolymers of the type disclosed in U.S. Patent No. 4,595,518. Including compound (the repellent agent F in examples herein). Preferred hydrocarbon water repellent finishes are aqueous dispersions of hydrocarbon waxes and behenic acid esters of melamine (here repellent G); aqueous dispersions of hydrocarbon waxes and stearyl methacrylate / diethylaminoethyl methacrylate copolymer Dispersion (repellent H of the examples herein); and "OCTOWAX" 321 (Tiarco Chemical Co., Dalton, Georgia). Aqueous paraffin wax emulsion). The results obtained with the preferred repellent finish are described in the examples. After application, drying and curing, suitable commercial repellent finishes do not stain or transfer to the underlying substrate (eg, carpet or floor). Repellent finishes typically have a pre-determined organic segment that binds to the fiber. Those exhibiting oil repellency may also have fluorocarbon segments. The repellent finish is selected based in part on the fiber composition. Typical matte fibers can range from relatively hydrophilic fibers, such as nylon, to intermediate fibers, such as polyester, to relatively hydrophobic fibers, such as polyolefin. Techniques for matching a repellent finish with a fiber composition are well known in the art. The repellent finish is typically diluted with water or a suitable solvent such as alcohol for application to the mat, but water is preferred. The required dilution is determined by the impregnation amount and the required concentration of active ingredient in the dried and cured mat. Impregnation is the amount of repellent finish in a wet mat after application but before drying or curing. Impregnation is expressed as a percentage based on dry fiber. For example, mats with a repellent finish include: With a 5% active ingredient content and a 200% pick-up, the applied repellent finish is 0.1%. 75% (100 × 0. 015/2). The amount of repellent finish along with the required diluent, such as water or alcohol, applied to the underlay is measured as a wet up prior to drying and curing. The impregnation applied to the rug underlay fabric generally ranges from 20 to 300% by weight, preferably 50 to 200% by weight, based on the untreated underlay fabric. Commercially available repellent finishes are typically about 0. Contains from 5 to about 40% by weight of total active ingredients. In the case of silicones, the total active ingredient may exceed 40% by weight. In the present invention, the amount of active ingredient of the repellent finish applied is generally between 0. 0.01 to 10% by weight, preferably 0.1 to 10% 05 to 3% by weight and refers to the amount of active ingredient in the repellent finish based on the underlying mat. However, the amount of repellent finish and active ingredient applied will be adjusted depending on the type and concentration of repellent, the structure and weight of the underlying mat, the type or fiber of the underlying mat, and the type of adhesive application. It is understood that. In any application, a sufficient amount of the repellent finish is evenly applied to the underlay mat, and the repellent-finished underlay is exposed to water or liquid according to Test Methods 1 and 2 described below. It is important that the material be substantially impermeable. The repellent finish is applied to the underlay mat by various methods including a foaming process, a spraying process, a dip process, or a padding process, followed by drying or curing of the repellent finish, typically in an oven. Is subjected to heat treatment. The drying temperature, drying temperature curve (profile), and drying time that are sufficient to achieve the required drying and curing are selected based on the thermal stability of the fabric and the drying and curing characteristics of the repellent finish. You. Control of such drying parameters is well known to those skilled in the art. It is necessary to apply the repellent finish to the underlay mat completely and uniformly, and to ensure complete and uniform drying and curing. Padding where the underlay mat is immersed in the bath and squeezes out the excess repellent finish typically gives excellent and uniform application and is therefore the preferred method of application. On the other hand, foaming and spraying can leave extremely poor or dislodged parts unless foaming or spraying is applied very carefully. Even very small and poorly treated parts will weaken the desired impermeability. It may be necessary to apply a repellent finish that exceeds the impregnation required for the padding to ensure that the foam and spray applications are completed. However, this requires diluting the spray or foam repellent finish with additional water, and therefore additional drying, as compared to the padding process. For foaming and spray application, wetting agents can also be added to the repellent finish to help complete and uniform application. Suitable humectants are available from Wilmington, Del. I. Exemplified by, but not limited to, "ALKANOL" 6112 (poly (oxyethylene sorbitan monooleate) in water / 1-decanol) from du Pont de Nemours & Company. Wetting agents were not required in a suitable pad application. The underlying mat, which is substantially impervious to water or liquid, is then coated with an adhesive. For a rug underlay, the mat is coated on one side, preferably on both sides, with a suitable adhesive, the adhesive is cured or dried, and a sheet of material that is easily peeled off one or both sides of the underlay with a repellent finish For example, protected by plastic, paper, or other inexpensive materials, while handling, storing, transporting, and properly packing, bonding the underlay to the underlay itself or to other surfaces Hinder. Suitable adhesives for the underlay, methods of applying the adhesive to the underlay, and packaging of the underlay are well known to those skilled in the art. Although the application of the adhesive and the packaging of the underlay are described with respect to certain embodiments, many modifications and variations can be made by those skilled in the art. All such modifications are intended to be included in the meaning of the term "repellent finished underlay" as used herein. For carpet bedding, the mat is coated on one side with an adhesive. Preferred adhesives for laminating a waterproof underlay to the back or lining of a lined carpet include (1) curing at ambient temperature, (2) upon contact, the back of the carpet immediately adheres to the impervious lining, 7.) remains in close contact with the back of the carpet and the impervious backing when wet with liquid; and (4) at least about 8. 9 kg / m (0. 5 lb / in), preferably at least about 17. 9 kg / m (1. 0 lb / in). Specific examples of effective adhesives are described in St. Minnesota. "3M Super 77 Spray Adhesive" manufactured by Paul's 3M Industrial Tape and Specialty Division. Another specific example of an effective adhesive is Borden Inc. of Columbus, Ohio. Includes "Elmer's Spray Adhesive", sold by HPPG Elmer's, and The Glidden Company, Cleveland, Ohio, Macco Adhesives "Liquid Nails Adhesive for Projects and Construction". Many other adhesives with these properties are well known in the art and are suitable for use herein. The underlay of the present invention preferably utilizes a fabric with bulk or height characteristics depending on the desired application. The bulk or height of the fabric is important for the rug underlay between the partial rug and the paved carpet. A fabric height of between about 2 mm and 5 mm allows full contact with each surface and maximizes the non-slip properties of the lug underlay. Rug underlay fabric is also suitable as a water-impermeable lining in lined carpets. However, fabrics that do not have a bulkiness of at least about 2 mm may nonetheless be an effective water impervious lining for lined carpets. The adhesive ensures that the water impervious lining and the bedding carpet are in perfect contact. Due to the loose installation, the water impervious lining does not provide the non-slip properties of the bedding carpet. Thus, fabrics that are less than about 2 mm in height or bulk are an effective water impervious backing for bedding carpets. Needle-punched nonwovens are required to obtain bulked fabrics with a height between about 2 mm and 5 mm. Polyethylene, polypropylene, polyolefin, acrylic fiber, polyester, polytrimethylene terephthalate, nylon, wool, cotton, jute, thermoplastic polymer films, and mixtures thereof, against water-impermeable linings attached to lined carpets Woven, non-woven, knitted, stitch-bonded or other fabrics are suitable, such as fabrics made from a mixture of cellulose derivatives with them. Preferred for many applications is E. of Wilmington, Delaware. I. Nonwoven fabrics such as "TYVEK" and "SONTARA" available from du Pont de Nemours & Company, respectively, and "TYPAR" available from Norville Industrials, Dalton, Georgia. "TYVEK" is a flash spun nonwoven fabric of polyethylene, "TYPAR" is a spunbonded nonwoven fabric of polypropylene, and "SONTALA" is a spunlaced nonwoven fabric of a polyester / cellulose derivative. In carpet applications, the backing of the present invention is permanently laminated to the carpet. Suitable carpets include those where the pile yarns of the carpet are polyamide, polyester, polypropylene, wool, cotton, acrylic, polytrimethylene terephthalate, or mixtures thereof, and other fibrous materials. For some water-impermeable fabrics, the fact that the fabric simply adheres to the underside of the paved carpet results in a carpet with an attached water-impermeable lining Become. Some fabrics must first be treated with a repellent and then glued to the back of the carpet. Methods of treating the fabric with a suitable water repellent and curing the fabric are described above for rug underlays. The preferred method of bonding the fabric to the bedding carpet is whether it is inherently water impervious or treated with a water repellent to make it impermeable to water. Applying glue to the fabric in a separate step from laminating to the back of the fabric, or (2) laminating the fabric to the back of the carpet and simultaneously bonding to the back of the fabric and / or carpet Agent is applied. The adhesive is applied to only one side of the fabric by spraying, kissing, or other methods known to those skilled in the art. The underlay is affixed to the primary backing of a carpet having a fabric surface tufted with pile yarns coated on the backside, or to a carpet having both a primary and a secondary backing. You. The secondary backing is typically a polyester, polypropylene, cotton, jute, felt, or thermoplastic polymer film fabric. Preferred locations for laminating the underlay to the back of the primary or secondary backing of the carpet are as follows: (1) After the latex has been applied and the carpet to which the finish has been applied has been cooled, Either prior to or during the cut order process when (2) the large roll carpet is cut into smaller rolls to meet customer orders. Water impervious fabrics can be laid down on carpet linings either manually or automatically, without tearing, stinging, or abrading and compromising the water impermeability. Laminated on the back. In another embodiment of the present invention, the repellent finish is applied to the underlying mat after the adhesive has been applied and dried or cured. In this embodiment, the repellent finish is selected so as not to reduce the adhesive properties of the repellent finished underlay. In a third embodiment of the invention, the repellent finish is mixed with the adhesive and applied and dried or cured in a single step. The repellent finish and the adhesive are selected to be mutually compatible, so that the repellent treatment does not reduce the adhesive properties of the repellent finished underlay. In a fourth embodiment of the invention, the repellent finish and then the adhesive, or the adhesive and then the repellent finish, are applied, followed by a single heat treatment to dry and apply both coatings. To cure. The repellent finish used in the present invention is similar to that used to make carpet backings substantially impermeable to liquids, but there are significant differences in the application of this technology to underlays . Compared to carpet, the underlay is a thinner non-woven fabric without tufted fibers or a latex binder that secures the tufted fibers to the backing. Thus, the underlay has little capacity to absorb liquid spills and to reduce the hydrostatic pressure exerted by the liquid spills. These differences require that the repellent finish be applied very uniformly. For this reason, the padding method of application, in which the underlay is immersed in a bath containing the repellent finish at the desired concentration and then squeezed to reduce the impregnation to the required level, is more convenient than spray coating or foam coating. preferable. Spray coating and foam coating are suitable if the amount of active ingredient in the repellent finish is carefully controlled so as not to leave small portions that are insufficient to provide the desired impermeability. A second important difference between the carpet and the underlay is that the repellent finish is applied to the underlay either before or after the application of the adhesive. In the case of carpets, the adhesive latex is applied to the primary backing prior to the repellent finish, otherwise reducing the product impermeability. The adhesive latex must soak into the carpet backing, for example by a roller, to secure the tuft. A possible explanation for this difference is that the infiltration of latex into the carpet after it has been treated with a repellent finish in this way creates channels for the passage of liquids and therefore impermeability is reduced. After both the repellent finish was applied, dried and cured, Test Methods 1 and 2 measured the oil and water impermeability of the underlay mat, while Test Methods 3 and 4 used the underlay mat. The oil and water repellency of the mat is measured. The oil repellency rating from Test Method 3 correlates strongly with the desired properties that are substantially impermeable to liquids, as measured by Test Method 1. Similarly, the water repellency rating from Test Method 4 correlates strongly with the desired property of being substantially impermeable to water as measured by Test Method 2. Repellency testing methods 3 and 4 may be easier to use on certain samples. Test methods 1 and 2 are used for repellent finished underlays. The present invention is more specifically described by the following test methods and examples. Test method Test method 1. Oil Impermeable The underlay sample is placed on a white absorbent paper towel with the adhesive side down. 20 ml of S.I. adjusted to room temperature of 24 ° C. + / − 3 ° C. (75 ° F. + / − 5 ° C.). A. E. 10W30 motor oil is poured into the underlay sample through an approximately 4 cm diameter cylinder and from a height of approximately 6 cm to create a circular pool of liquid. The cylinder is removed and the sample is not disturbed for 30 minutes. The underlay is removed, and the diameter of any oil spot on the towel is measured. A sample is said to be substantially impermeable to oil if no or very little oil passes through the underlying sample. The diameter of any oil spot on the paper towel that has passed through the underlay is measured. 2. An oil spot diameter of 54 cm (1 inch) or less is required because the underlay is substantially impervious to oil. Test method 2. Water Impermeable The underlay sample is placed adhesive side down on a white absorbent paper towel. 20 ml of water conditioned at room temperature of 24 ° C. + / − 3 ° C. (75 ° F. + / − 5 ° F.) was poured into the underlay sample through a cylinder about 4 cm in diameter and from a height of about 6 cm into a circle. Make a pool of liquid. The cylinder is removed and the sample is not disturbed for 30 minutes. The underlay is removed, and the diameter of any water spot on the towel is measured. A sample is said to be substantially impervious to water if no or very little water passes through the underlying sample. The diameter of any water spot on the paper towel that has passed through the underlay is measured. 2. A wet spot diameter of 54 cm (1 inch) or less is required because the underlay is substantially impervious to water. Test method 3. Oil repellency AATCC test method No. 118-1989 After appropriate adjustment, the underlying specimen is placed on a flat horizontal surface with the adhesive side down. Three drops of the selected oil or mixture of oils are dripped on the fabric and left for 30 seconds. If no penetration occurs, the fabric is judged to "pass" this level of oil repellency and the next higher numbered mixture is tested. The fabric grade is the highest numbered oil mixture that does not wet or penetrate the fabric. The test oil compositions are as follows: A rating of 0 indicates no oil repellency; a rating of 3 or higher is desired. Test method 4. Water repellency DuPont "TEFLON" Standard Test Method No. 311.56 After appropriate adjustment, the underlying specimen is placed on a flat horizontal surface with the adhesive side down. Three drops of the selected water / isopropanol mixture are dripped on the fabric and left for 10 seconds. If no penetration occurs, the fabric is determined to "pass" this level of water repellency, and the next higher numbered test liquid is tested. The fabric grade is the highest numbered test liquid that does not wet the fabric. The water / isopropanol mixture has the following composition: A rating of 0 indicates no water repellency and a rating of 6 indicates maximum water repellency. Three or more test grades are desired. Control-Underlay without repellent finish Needle-punched polyester non-woven fabric (approximately 0.14 kg / m ^Two , 4 ounces / square yard) was sprayed with Air Products Pressure Sensitive Adhesive # 625 on both the top and bottom surfaces to a total wet weight of 20 wt% of the adhesive solution. The treated fabric was dried at 132 ° C. (270 ° F.) for 3 minutes to give a repellent finished underlay containing 10% by weight of the adhesive active. The following test results were obtained before and after application of the adhesive on the fabric using the test methods described above. The results for test methods 1 and 2 are listed in cm. The control underlay is not sufficient for all tests and is not substantially impermeable to either water or oil. Examples 1 to 12 Preparation of Underlays Continuously Treated with Repellent Finish, then Adhesive, and Tested for Oil and Water Impermeableness Non-woven needle-punched polyester (approximately 0.14 kg / m ^Two , 4 ounces / square yard) with the repellent solution shown in Table 2 and reducing the liquid to 200% by weight of the fabric by squeezing. The treated fabric was dried at 82 ° C. (180 ° F.) for 10 minutes and cured at 149 ° C. (300 ° F.) for 3 minutes to give a fabric having the content shown in Table 2 of the repellent active. The fabric was then sprayed with Air Products Pressure Sensitive Adhesive # 625 (Air Products, Allentown, PA) on both the top and bottom surfaces to a total impregnation of 20% by weight solution. The treated fabric was dried at 132 ° C. (270 ° F.) for 3 minutes to provide a fabric containing 10% by weight of the adhesive active. The following test results were obtained using the test method described above. The results for test methods 1 and 2 are listed in cm. Testing has shown that underlays treated with repellents G and H, like Octowax 321, are substantially impervious to water, and all other treated underlays are substantially impermeable to oil and water. Showed to be permeable. ^* The repellent finishes used were as follows: A-Polyfluoroorganic compound B prepared by reacting a polyisocyanate as disclosed in EP-A-453641A with a fluoroalcohol and water. Fluoroalkyl citrate-urethane and polymethyl methacrylate blends C disclosed in U.S. Pat. No. 3,923,715 C. Polyisocyanates and fluoroalcohols disclosed in U.S. Pat. No. 4,958,039 And fluorocarbonylimino biuret D prepared by reaction with monochlorohydrin-fluoroalkyl citrate urethane, fluoroalkyl methacrylate / 2-ethylhexyl methacrylate / 2-hydroxy disclosed in U.S. Pat. No. 4,595,518. Formulation of ethyl methacrylate / N-methylol acrylamide copolymer, fluoroalkyl methacrylate / lauryl methacrylate / N-methylol acrylamide copolymer, dimethylaminoethyl methacrylate / acrylic acid copolymer, and chloroprene / dichlorobutadiene copolymer FC-1355 Minnesota Anionic emulsion of fluoroaliphatic polymer available from 3M of Minneapolis as FC-1355 FC-1367-Anionic emulsion of a fluoroaliphatic polymer available as FC-1367 from 3M of Minneapolis, Minnesota E-US Patent No. 4 Fluoroalkyl acrylate / hexadecyl methacrylate / octadecyl methacrylate / vinylidene chloride disclosed in U.S. Pat. Formulation of copolymer F-wax, diethylaminoethyl methacrylate / hexadecyl methacrylate / octadecyl methacrylate copolymer and fluoroalkyl methacrylate copolymer of the type disclosed in U.S. Pat. No. 4,595,518 G-hydrocarbon wax Dispersion H-hydrocarbon wax stearyl methacrylate / diethylaminoethyl methacrylate copolymer of melamine and behenic acid ester of melamine Examples 13 to 19 Preparation of Underlay Continuously Treated with Adhesive and then Repellent Finish and Testing for Oil and Water Permeability Needle-punched polyester nonwoven (approximately 0.14 kg / m ^Two Oz / square yard) was sprayed with Air Products Pressure Sensitive Adhesive # 625 (Air Products, Allentown, PA) on both the top and bottom surfaces to a total wet out of 20% by weight solution. The treated fabric was dried at 132 ° C. (270 ° F.) for 3 minutes to provide a fabric containing 10% by weight of the adhesive active. The fabric was then impregnated with the water repellent solution and the liquid reduced to 200% by weight of the fabric by squeezing. The treated fabric was dried at 82 ° C. (180 ° F.) for 10 minutes and cured at 149 ° C. (300 ° F.) for 3 minutes to obtain a fabric having the content shown in Table 3 of the repellent active. The following test results were obtained using the test method described above. The results for test methods 1 and 2 are given in cm. Repellent finishes A to G are as set forth in Examples 1-12. Tests have shown that the underlay treated with Repellent G is substantially impermeable to water, and all other treated underlays are substantially impermeable to oil and water. Indicated. Examples 20 to 22 Preparation of a dried and cured treated underlay that is continuously treated with a repellent finish followed by an adhesive and then combined and tested for oil and water permeability Needle punched polyester nonwoven fabric (approx. 14kg / m ^Two , 4 ounces / square yard) with the indicated repellent solution and squeezing to reduce the liquid to 200% by weight of the fabric. The fabric was then sprayed on both the top and bottom surfaces with Air Products Pressure Sensitive Adhesive # 625 (Air Products, Allentown, PA) to a total soak of 200% by weight solution. The treated fabric was dried at 132 ° C. (270 ° F.) for 3 minutes to provide a fabric containing about 25% by weight of the adhesive active and having the content shown in Table 4 of the repellent active. The following test results were obtained using the test method described above. The results for test methods 1 and 2 are given in cm. Repellent finishes D, F and G were as revealed in Examples 1-12. Tests have shown that the underlay treated with the repellents F and G is substantially impermeable to water. The underlay treated with Repellent D was substantially impermeable to oil and water. Examples 23 to 62 Examples 23-62 illustrate the application of a water impervious underlay fabric to a carpet and compared to a control sample of a carpet without an impermeable underlay. The water impervious underlays used are listed in Table 5. Examples 24-26 were "TYPAR" available from Norville Industrials, Dalton, Georgia. Example 27 is described in E. M. Wilmington, Del. I. "TYVEK" available from du Pont de Nemours and Company. Example 28 was a commercially available meltblown polypropylene nonwoven fabric. Examples 29-38 are described in E. M., Wilmington, Del. I. "SONTA RA" available from du Pont de Nemours & Co. Examples 39-46 are nonwoven RB400 (130 g / m2) obtained from Synthetic Industries, Ringold, Georgia. ^Two ) And RB406 (150 g / m ^Two )Met. Examples 47-62 were various commercially available woven and knitted fabrics purchased at Walmart, Chattanooga, TN. Some fabrics did not require an oil or water repellent treatment and others were treated with the repellents listed in Table 5. Repellents D and E identified in Examples 1 to 12 were used. Both are available from EIdu Pont de Nemours & Company in Wilmington, Delaware. For the treatment of the underlay, the chemicals were spray applied and the underlay fabric was dried at 82 ° C (180 ° F) for 3 minutes and cured at 148 ° C (300 ° F). Water impervious underlays are available from St. Minnesota. Using 3M Super 77 Spray Adhesive available from 3M Company of Paul, and on both the fabric and the back of the carpet, before gluing the two surfaces together according to the adhesive packaging instructions, apply 15 to each surface. The coating was applied by spraying for ２０20 seconds and adhered to the back of the carpet. For all Examples 23-62, carpet from Coronet Mills, Dalton, Georgia, style name "Torrey Pines Plus", 1.02 kg / m treated with DuPont's "Stainmaster" stain and sewage agent. ^Two (30 oz / yd ^Two ) The underlay was fixed to the nylon carpet. For Examples 38, 42 and 46, the underlay is sprayed with an adhesive, fixed to the back of the carpet, then treated with a repellent, and subsequently dried and cured as described above. The water impermeability, oil repellency, and water repellency tests, Test Methods 2-4 described above, were performed on the carpet samples. The data obtained is summarized in Table 5. The results for test method 2 are given in cm.

────────────────────────────────────────────────── ─── Continuation of front page    (72) Inventors Greenwood, Edward, James             .             United States 19707-1209 Delaware             Hokkesin Rafael Road, A             twenty three (72) Inventors Mataniak, Joyce, Monson.             United States 19707-1809 Delaware             Hockesin Cheltenham Road A               117

Claims (1)

[Claims] 1. a) Pile thread tufted surface and water permeable latex applied A primary lining having a back surface,     b) an optional permeable secondary lining having a front and a back surface, the front of the secondary lining A secondary lining whose surface is bonded to the back of the primary lining,     c) an underlay having a front surface and a back surface, wherein the undersurface has a secondary lining or Is bonded to one of the backs of the primary lining with an adhesive, and the underlay is a non-latex Comprising a fabric, said fabric being substantially impermeable to liquids A tufted pile carpet with an underlay,   The carpet is substantially impermeable to liquids. Ted pile carpet. 2. The underlay is made of polyester, polyolefin, polytrimethylene terephthalate. Polyester, nylon, wool, cotton, acrylic, jute, mixtures thereof, The car according to claim 1, wherein the car is a mixture with a cellulose derivative. Pets. 3. The adhesive used to secure the underlay should be at least 8.9 kg / m The carpet of claim 1, wherein the carpet provides a bond strength of: 4. The adhesive immediately contacts the underlay to the primary or secondary lining The carpet according to claim 1, wherein the carpet is bonded. 5. The adhesive, when wet with a liquid, can be used to remove the underlay and primary or secondary backing. The carpet of claim 1, wherein the carpet remains in close contact with the ground. 6. The pile yarn is made of polyamide, polyester, polyolefin, polytrim. In Tylene terephthalate, wool, cotton, acrylic, or mixtures thereof The carpet according to claim 1, wherein: 7. The underlay may be in or on top of a fluorochemical, silicone, wax, Coss emulsion, natural oil, alkyl acrylate resin, hydrophobic alkyl methacrylate It has a repellent finish containing a related resin or a mixture thereof. The carpet according to claim 1, wherein 8. The fluorochemical is polyvinylidene fluoride; polytetrafluoroethylene Len; perfluoroalkylethyl acrylate; perfluoroalkylethyl Methacrylates; mixtures thereof; and the compounds and polymers, Alkyl acrylate, polyalkyl methacrylate, wax emulsion, And vinylidene chloride, vinylidene fluoride, tetrafluoroethylene, perfluoro Polyalkylethyl acrylate and perfluoroalkylethyl methacrylate Claims: selected from the group consisting of blends of a salt with a copolymer. 7. The carpet according to 7. 9. The fluorochemical is a fluoroalkyl citrate urethane, fluoro Alkyl methacrylate / 2-ethylhexyl methacrylate / 2-hydroxy Ethyl methacrylate / N-methylol acrylamide copolymer, fluoroa Ruky methacrylate / lauryl methacrylate / N-methylol acrylamide Copolymer, dimethylaminoethyl methacrylate / acrylic acid copolymer, Chloroprene / dichlorobutadiene copolymer, and blends thereof The carpet according to claim 7, wherein the carpet is selected from a group.