LU100738B1 - Carpet backing layer composition - Google Patents
Carpet backing layer composition Download PDFInfo
- Publication number
- LU100738B1 LU100738B1 LU100738A LU100738A LU100738B1 LU 100738 B1 LU100738 B1 LU 100738B1 LU 100738 A LU100738 A LU 100738A LU 100738 A LU100738 A LU 100738A LU 100738 B1 LU100738 B1 LU 100738B1
- Authority
- LU
- Luxembourg
- Prior art keywords
- weight
- less
- carpet
- polyolefin
- layer composition
- Prior art date
Links
- 239000000203 mixture Substances 0.000 title claims abstract description 108
- 229920000098 polyolefin Polymers 0.000 claims abstract description 90
- 230000004927 fusion Effects 0.000 claims abstract description 37
- 239000003921 oil Substances 0.000 claims abstract description 30
- 239000002245 particle Substances 0.000 claims abstract description 26
- 238000000113 differential scanning calorimetry Methods 0.000 claims abstract description 8
- 239000011256 inorganic filler Substances 0.000 claims abstract description 8
- 229910003475 inorganic filler Inorganic materials 0.000 claims abstract description 8
- 238000000034 method Methods 0.000 claims abstract description 8
- VXNZUUAINFGPBY-UHFFFAOYSA-N 1-Butene Chemical compound CCC=C VXNZUUAINFGPBY-UHFFFAOYSA-N 0.000 claims description 35
- 239000001993 wax Substances 0.000 claims description 30
- QQONPFPTGQHPMA-UHFFFAOYSA-N Propene Chemical compound CC=C QQONPFPTGQHPMA-UHFFFAOYSA-N 0.000 claims description 28
- 239000000654 additive Substances 0.000 claims description 27
- 229920001577 copolymer Polymers 0.000 claims description 26
- 239000004711 α-olefin Substances 0.000 claims description 19
- 239000000463 material Substances 0.000 claims description 17
- TZCXTZWJZNENPQ-UHFFFAOYSA-L barium sulfate Chemical compound [Ba+2].[O-]S([O-])(=O)=O TZCXTZWJZNENPQ-UHFFFAOYSA-L 0.000 claims description 14
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 11
- -1 polypropylene Polymers 0.000 claims description 11
- 238000010438 heat treatment Methods 0.000 claims description 9
- KWKAKUADMBZCLK-UHFFFAOYSA-N 1-octene Chemical compound CCCCCCC=C KWKAKUADMBZCLK-UHFFFAOYSA-N 0.000 claims description 8
- 239000000835 fiber Substances 0.000 claims description 8
- 239000000155 melt Substances 0.000 claims description 8
- 239000010428 baryte Substances 0.000 claims description 6
- 229910052601 baryte Inorganic materials 0.000 claims description 6
- 238000001816 cooling Methods 0.000 claims description 6
- 238000004519 manufacturing process Methods 0.000 claims description 6
- 239000000454 talc Substances 0.000 claims description 6
- 229910052623 talc Inorganic materials 0.000 claims description 6
- 239000004743 Polypropylene Substances 0.000 claims description 5
- 238000007765 extrusion coating Methods 0.000 claims description 5
- 239000011521 glass Substances 0.000 claims description 5
- TVMXDCGIABBOFY-UHFFFAOYSA-N n-Octanol Natural products CCCCCCCC TVMXDCGIABBOFY-UHFFFAOYSA-N 0.000 claims description 5
- 229920001155 polypropylene Polymers 0.000 claims description 5
- 239000000377 silicon dioxide Substances 0.000 claims description 5
- 239000005995 Aluminium silicate Substances 0.000 claims description 4
- 150000001336 alkenes Chemical class 0.000 claims description 4
- WNROFYMDJYEPJX-UHFFFAOYSA-K aluminium hydroxide Chemical compound [OH-].[OH-].[OH-].[Al+3] WNROFYMDJYEPJX-UHFFFAOYSA-K 0.000 claims description 4
- 235000012211 aluminium silicate Nutrition 0.000 claims description 4
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 claims description 4
- VTHJTEIRLNZDEV-UHFFFAOYSA-L magnesium dihydroxide Chemical compound [OH-].[OH-].[Mg+2] VTHJTEIRLNZDEV-UHFFFAOYSA-L 0.000 claims description 4
- 239000000347 magnesium hydroxide Substances 0.000 claims description 4
- 229910001862 magnesium hydroxide Inorganic materials 0.000 claims description 4
- 238000005259 measurement Methods 0.000 claims description 4
- 239000010445 mica Substances 0.000 claims description 4
- 229910052618 mica group Inorganic materials 0.000 claims description 4
- 229910001570 bauxite Inorganic materials 0.000 claims description 3
- ZLNQQNXFFQJAID-UHFFFAOYSA-L magnesium carbonate Chemical compound [Mg+2].[O-]C([O-])=O ZLNQQNXFFQJAID-UHFFFAOYSA-L 0.000 claims description 3
- 239000001095 magnesium carbonate Substances 0.000 claims description 3
- 229910000021 magnesium carbonate Inorganic materials 0.000 claims description 3
- JRZJOMJEPLMPRA-UHFFFAOYSA-N olefin Natural products CCCCCCCC=C JRZJOMJEPLMPRA-UHFFFAOYSA-N 0.000 claims description 3
- BVKZGUZCCUSVTD-UHFFFAOYSA-L Carbonate Chemical compound [O-]C([O-])=O BVKZGUZCCUSVTD-UHFFFAOYSA-L 0.000 claims description 2
- 239000010459 dolomite Substances 0.000 claims description 2
- 229910000514 dolomite Inorganic materials 0.000 claims description 2
- 230000015572 biosynthetic process Effects 0.000 claims 1
- IAQRGUVFOMOMEM-UHFFFAOYSA-N butene Natural products CC=CC IAQRGUVFOMOMEM-UHFFFAOYSA-N 0.000 claims 1
- 238000009792 diffusion process Methods 0.000 claims 1
- 235000012239 silicon dioxide Nutrition 0.000 claims 1
- 239000000945 filler Substances 0.000 description 38
- 235000019198 oils Nutrition 0.000 description 28
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 description 23
- 229920000642 polymer Polymers 0.000 description 18
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 description 16
- 238000012545 processing Methods 0.000 description 15
- 125000004805 propylene group Chemical group [H]C([H])([H])C([H])([*:1])C([H])([H])[*:2] 0.000 description 14
- 230000000996 additive effect Effects 0.000 description 11
- 235000010216 calcium carbonate Nutrition 0.000 description 11
- 229910000019 calcium carbonate Inorganic materials 0.000 description 11
- 229960003563 calcium carbonate Drugs 0.000 description 10
- 238000012360 testing method Methods 0.000 description 10
- 239000004200 microcrystalline wax Substances 0.000 description 8
- 235000019808 microcrystalline wax Nutrition 0.000 description 8
- 229920005653 propylene-ethylene copolymer Polymers 0.000 description 8
- ZWEHNKRNPOVVGH-UHFFFAOYSA-N 2-Butanone Chemical compound CCC(C)=O ZWEHNKRNPOVVGH-UHFFFAOYSA-N 0.000 description 6
- 239000005977 Ethylene Substances 0.000 description 6
- 239000003063 flame retardant Substances 0.000 description 5
- 239000004215 Carbon black (E152) Substances 0.000 description 4
- 238000009826 distribution Methods 0.000 description 4
- 230000004907 flux Effects 0.000 description 4
- 229930195733 hydrocarbon Natural products 0.000 description 4
- 150000002430 hydrocarbons Chemical class 0.000 description 4
- PBKONEOXTCPAFI-UHFFFAOYSA-N 1,2,4-trichlorobenzene Chemical compound ClC1=CC=C(Cl)C(Cl)=C1 PBKONEOXTCPAFI-UHFFFAOYSA-N 0.000 description 3
- 239000000853 adhesive Substances 0.000 description 3
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- 238000009472 formulation Methods 0.000 description 3
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- 235000012254 magnesium hydroxide Nutrition 0.000 description 3
- 229960000816 magnesium hydroxide Drugs 0.000 description 3
- 238000002844 melting Methods 0.000 description 3
- 230000008018 melting Effects 0.000 description 3
- 239000002480 mineral oil Substances 0.000 description 3
- 235000010446 mineral oil Nutrition 0.000 description 3
- 229920000573 polyethylene Polymers 0.000 description 3
- 229920002959 polymer blend Polymers 0.000 description 3
- 239000003381 stabilizer Substances 0.000 description 3
- ZGEGCLOFRBLKSE-UHFFFAOYSA-N 1-Heptene Chemical compound CCCCCC=C ZGEGCLOFRBLKSE-UHFFFAOYSA-N 0.000 description 2
- LIKMAJRDDDTEIG-UHFFFAOYSA-N 1-hexene Chemical compound CCCCC=C LIKMAJRDDDTEIG-UHFFFAOYSA-N 0.000 description 2
- OWWRMMIWAOBBFK-UHFFFAOYSA-N 3,4-dimethylhex-1-ene Chemical compound CCC(C)C(C)C=C OWWRMMIWAOBBFK-UHFFFAOYSA-N 0.000 description 2
- WNEYWVBECXCQRT-UHFFFAOYSA-N 5-methylhept-1-ene Chemical compound CCC(C)CCC=C WNEYWVBECXCQRT-UHFFFAOYSA-N 0.000 description 2
- DFVOXRAAHOJJBN-UHFFFAOYSA-N 6-methylhept-1-ene Chemical compound CC(C)CCCC=C DFVOXRAAHOJJBN-UHFFFAOYSA-N 0.000 description 2
- RSWGJHLUYNHPMX-UHFFFAOYSA-N Abietic-Saeure Natural products C12CCC(C(C)C)=CC2=CCC2C1(C)CCCC2(C)C(O)=O RSWGJHLUYNHPMX-UHFFFAOYSA-N 0.000 description 2
- KFZMGEQAYNKOFK-UHFFFAOYSA-N Isopropanol Chemical compound CC(C)O KFZMGEQAYNKOFK-UHFFFAOYSA-N 0.000 description 2
- KHPCPRHQVVSZAH-HUOMCSJISA-N Rosin Natural products O(C/C=C/c1ccccc1)[C@H]1[C@H](O)[C@@H](O)[C@@H](O)[C@@H](CO)O1 KHPCPRHQVVSZAH-HUOMCSJISA-N 0.000 description 2
- 229910021502 aluminium hydroxide Inorganic materials 0.000 description 2
- 239000003963 antioxidant agent Substances 0.000 description 2
- 229940092690 barium sulfate Drugs 0.000 description 2
- 150000001875 compounds Chemical class 0.000 description 2
- 238000001938 differential scanning calorimetry curve Methods 0.000 description 2
- 238000001125 extrusion Methods 0.000 description 2
- 239000010881 fly ash Substances 0.000 description 2
- 239000004615 ingredient Substances 0.000 description 2
- 229940032007 methylethyl ketone Drugs 0.000 description 2
- 239000000178 monomer Substances 0.000 description 2
- YWAKXRMUMFPDSH-UHFFFAOYSA-N pentene Chemical compound CCCC=C YWAKXRMUMFPDSH-UHFFFAOYSA-N 0.000 description 2
- 229920005606 polypropylene copolymer Polymers 0.000 description 2
- 229920005989 resin Polymers 0.000 description 2
- 239000011347 resin Substances 0.000 description 2
- 238000000646 scanning calorimetry Methods 0.000 description 2
- 239000002904 solvent Substances 0.000 description 2
- 239000000725 suspension Substances 0.000 description 2
- 239000003017 thermal stabilizer Substances 0.000 description 2
- KHPCPRHQVVSZAH-UHFFFAOYSA-N trans-cinnamyl beta-D-glucopyranoside Natural products OC1C(O)C(O)C(CO)OC1OCC=CC1=CC=CC=C1 KHPCPRHQVVSZAH-UHFFFAOYSA-N 0.000 description 2
- 238000001644 13C nuclear magnetic resonance spectroscopy Methods 0.000 description 1
- RNFJDJUURJAICM-UHFFFAOYSA-N 2,2,4,4,6,6-hexaphenoxy-1,3,5-triaza-2$l^{5},4$l^{5},6$l^{5}-triphosphacyclohexa-1,3,5-triene Chemical compound N=1P(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP=1(OC=1C=CC=CC=1)OC1=CC=CC=C1 RNFJDJUURJAICM-UHFFFAOYSA-N 0.000 description 1
- PKXHXOTZMFCXSH-UHFFFAOYSA-N 3,3-dimethylbut-1-ene Chemical compound CC(C)(C)C=C PKXHXOTZMFCXSH-UHFFFAOYSA-N 0.000 description 1
- TXBZITDWMURSEF-UHFFFAOYSA-N 3,3-dimethylpent-1-ene Chemical compound CCC(C)(C)C=C TXBZITDWMURSEF-UHFFFAOYSA-N 0.000 description 1
- WFHXQNMTMDKVJG-UHFFFAOYSA-N 3,4-dimethylpent-1-ene Chemical compound CC(C)C(C)C=C WFHXQNMTMDKVJG-UHFFFAOYSA-N 0.000 description 1
- FEZKAPRRVNNJTK-UHFFFAOYSA-N 3,5-dimethylhex-1-ene Chemical compound CC(C)CC(C)C=C FEZKAPRRVNNJTK-UHFFFAOYSA-N 0.000 description 1
- QDMFTFWKTYXBIW-UHFFFAOYSA-N 3-Methyl-1-heptene Chemical compound CCCCC(C)C=C QDMFTFWKTYXBIW-UHFFFAOYSA-N 0.000 description 1
- PHHHEKOJKDYRIN-UHFFFAOYSA-N 3-ethyl-3-methylpent-1-ene Chemical compound CCC(C)(CC)C=C PHHHEKOJKDYRIN-UHFFFAOYSA-N 0.000 description 1
- DTNALCAUPPLROB-UHFFFAOYSA-N 3-ethyl-4-methylpent-1-ene Chemical compound CCC(C=C)C(C)C DTNALCAUPPLROB-UHFFFAOYSA-N 0.000 description 1
- OLGHJTHQWQKJQQ-UHFFFAOYSA-N 3-ethylhex-1-ene Chemical compound CCCC(CC)C=C OLGHJTHQWQKJQQ-UHFFFAOYSA-N 0.000 description 1
- YPVPQMCSLFDIKA-UHFFFAOYSA-N 3-ethylpent-1-ene Chemical compound CCC(CC)C=C YPVPQMCSLFDIKA-UHFFFAOYSA-N 0.000 description 1
- YHQXBTXEYZIYOV-UHFFFAOYSA-N 3-methylbut-1-ene Chemical compound CC(C)C=C YHQXBTXEYZIYOV-UHFFFAOYSA-N 0.000 description 1
- RITONZMLZWYPHW-UHFFFAOYSA-N 3-methylhex-1-ene Chemical compound CCCC(C)C=C RITONZMLZWYPHW-UHFFFAOYSA-N 0.000 description 1
- KLCNJIQZXOQYTE-UHFFFAOYSA-N 4,4-dimethylpent-1-ene Chemical compound CC(C)(C)CC=C KLCNJIQZXOQYTE-UHFFFAOYSA-N 0.000 description 1
- UFWIBUBEFUNVNI-UHFFFAOYSA-N 4,5-dimethyl-1-hexene Chemical compound CC(C)C(C)CC=C UFWIBUBEFUNVNI-UHFFFAOYSA-N 0.000 description 1
- OPMUAJRVOWSBTP-UHFFFAOYSA-N 4-ethyl-1-hexene Chemical compound CCC(CC)CC=C OPMUAJRVOWSBTP-UHFFFAOYSA-N 0.000 description 1
- BFGOGLKYJXQPJZ-UHFFFAOYSA-N 4-methylhept-1-ene Chemical compound CCCC(C)CC=C BFGOGLKYJXQPJZ-UHFFFAOYSA-N 0.000 description 1
- SUWJESCICIOQHO-UHFFFAOYSA-N 4-methylhex-1-ene Chemical compound CCC(C)CC=C SUWJESCICIOQHO-UHFFFAOYSA-N 0.000 description 1
- KZJIOVQKSAOPOP-UHFFFAOYSA-N 5,5-dimethylhex-1-ene Chemical compound CC(C)(C)CCC=C KZJIOVQKSAOPOP-UHFFFAOYSA-N 0.000 description 1
- JIUFYGIESXPUPL-UHFFFAOYSA-N 5-methylhex-1-ene Chemical compound CC(C)CCC=C JIUFYGIESXPUPL-UHFFFAOYSA-N 0.000 description 1
- 102100021202 Desmocollin-1 Human genes 0.000 description 1
- 101000968043 Homo sapiens Desmocollin-1 Proteins 0.000 description 1
- 101000880960 Homo sapiens Desmocollin-3 Proteins 0.000 description 1
- 235000019738 Limestone Nutrition 0.000 description 1
- 239000004677 Nylon Substances 0.000 description 1
- 206010033307 Overweight Diseases 0.000 description 1
- 229910019142 PO4 Inorganic materials 0.000 description 1
- 239000004698 Polyethylene Substances 0.000 description 1
- BGYHLZZASRKEJE-UHFFFAOYSA-N [3-[3-(3,5-ditert-butyl-4-hydroxyphenyl)propanoyloxy]-2,2-bis[3-(3,5-ditert-butyl-4-hydroxyphenyl)propanoyloxymethyl]propyl] 3-(3,5-ditert-butyl-4-hydroxyphenyl)propanoate Chemical compound CC(C)(C)C1=C(O)C(C(C)(C)C)=CC(CCC(=O)OCC(COC(=O)CCC=2C=C(C(O)=C(C=2)C(C)(C)C)C(C)(C)C)(COC(=O)CCC=2C=C(C(O)=C(C=2)C(C)(C)C)C(C)(C)C)COC(=O)CCC=2C=C(C(O)=C(C=2)C(C)(C)C)C(C)(C)C)=C1 BGYHLZZASRKEJE-UHFFFAOYSA-N 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- 229920013640 amorphous poly alpha olefin Polymers 0.000 description 1
- 230000000845 anti-microbial effect Effects 0.000 description 1
- 150000004945 aromatic hydrocarbons Chemical class 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 239000003139 biocide Substances 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 229920001400 block copolymer Polymers 0.000 description 1
- 150000001648 bromium Chemical class 0.000 description 1
- 229910052794 bromium Inorganic materials 0.000 description 1
- HHSPVTKDOHQBKF-UHFFFAOYSA-J calcium;magnesium;dicarbonate Chemical compound [Mg+2].[Ca+2].[O-]C([O-])=O.[O-]C([O-])=O HHSPVTKDOHQBKF-UHFFFAOYSA-J 0.000 description 1
- 125000004432 carbon atom Chemical group C* 0.000 description 1
- 239000006229 carbon black Substances 0.000 description 1
- 150000005323 carbonate salts Chemical class 0.000 description 1
- 238000012668 chain scission Methods 0.000 description 1
- 239000004927 clay Substances 0.000 description 1
- 229910052570 clay Inorganic materials 0.000 description 1
- 239000003245 coal Substances 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 230000000052 comparative effect Effects 0.000 description 1
- 230000001143 conditioned effect Effects 0.000 description 1
- 230000003750 conditioning effect Effects 0.000 description 1
- 238000011109 contamination Methods 0.000 description 1
- 238000004132 cross linking Methods 0.000 description 1
- 239000010779 crude oil Substances 0.000 description 1
- 238000002425 crystallisation Methods 0.000 description 1
- 230000008025 crystallization Effects 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 235000014113 dietary fatty acids Nutrition 0.000 description 1
- 239000002270 dispersing agent Substances 0.000 description 1
- 239000006185 dispersion Substances 0.000 description 1
- 229920001971 elastomer Polymers 0.000 description 1
- 239000000806 elastomer Substances 0.000 description 1
- 229920005674 ethylene-propylene random copolymer Polymers 0.000 description 1
- 239000000194 fatty acid Substances 0.000 description 1
- 229930195729 fatty acid Natural products 0.000 description 1
- 238000009408 flooring Methods 0.000 description 1
- 238000005227 gel permeation chromatography Methods 0.000 description 1
- 239000005337 ground glass Substances 0.000 description 1
- 239000012943 hotmelt Substances 0.000 description 1
- 229910010272 inorganic material Inorganic materials 0.000 description 1
- 239000011147 inorganic material Substances 0.000 description 1
- 230000001788 irregular Effects 0.000 description 1
- 238000002356 laser light scattering Methods 0.000 description 1
- 239000006028 limestone Substances 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 239000000314 lubricant Substances 0.000 description 1
- 239000004579 marble Substances 0.000 description 1
- 229910044991 metal oxide Inorganic materials 0.000 description 1
- 150000004706 metal oxides Chemical class 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 239000005445 natural material Substances 0.000 description 1
- 229920001778 nylon Polymers 0.000 description 1
- SSDSCDGVMJFTEQ-UHFFFAOYSA-N octadecyl 3-(3,5-ditert-butyl-4-hydroxyphenyl)propanoate Chemical compound CCCCCCCCCCCCCCCCCCOC(=O)CCC1=CC(C(C)(C)C)=C(O)C(C(C)(C)C)=C1 SSDSCDGVMJFTEQ-UHFFFAOYSA-N 0.000 description 1
- 239000012766 organic filler Substances 0.000 description 1
- 239000003960 organic solvent Substances 0.000 description 1
- 238000013021 overheating Methods 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 239000012188 paraffin wax Substances 0.000 description 1
- 235000019809 paraffin wax Nutrition 0.000 description 1
- 239000010690 paraffinic oil Substances 0.000 description 1
- 150000002978 peroxides Chemical class 0.000 description 1
- 235000019271 petrolatum Nutrition 0.000 description 1
- 239000003208 petroleum Substances 0.000 description 1
- 239000010452 phosphate Substances 0.000 description 1
- NBIIXXVUZAFLBC-UHFFFAOYSA-K phosphate Chemical compound [O-]P([O-])([O-])=O NBIIXXVUZAFLBC-UHFFFAOYSA-K 0.000 description 1
- XRBCRPZXSCBRTK-UHFFFAOYSA-N phosphonous acid Chemical compound OPO XRBCRPZXSCBRTK-UHFFFAOYSA-N 0.000 description 1
- OJMIONKXNSYLSR-UHFFFAOYSA-N phosphorous acid Chemical compound OP(O)O OJMIONKXNSYLSR-UHFFFAOYSA-N 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 239000000049 pigment Substances 0.000 description 1
- 239000004014 plasticizer Substances 0.000 description 1
- 229920013639 polyalphaolefin Polymers 0.000 description 1
- 230000000379 polymerizing effect Effects 0.000 description 1
- 229920005629 polypropylene homopolymer Polymers 0.000 description 1
- 239000010453 quartz Substances 0.000 description 1
- 239000011342 resin composition Substances 0.000 description 1
- 239000012798 spherical particle Substances 0.000 description 1
- 238000013112 stability test Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 239000010409 thin film Substances 0.000 description 1
- MGMXGCZJYUCMGY-UHFFFAOYSA-N tris(4-nonylphenyl) phosphite Chemical compound C1=CC(CCCCCCCCC)=CC=C1OP(OC=1C=CC(CCCCCCCCC)=CC=1)OC1=CC=C(CCCCCCCCC)C=C1 MGMXGCZJYUCMGY-UHFFFAOYSA-N 0.000 description 1
- BIKXLKXABVUSMH-UHFFFAOYSA-N trizinc;diborate Chemical class [Zn+2].[Zn+2].[Zn+2].[O-]B([O-])[O-].[O-]B([O-])[O-] BIKXLKXABVUSMH-UHFFFAOYSA-N 0.000 description 1
- 238000005292 vacuum distillation Methods 0.000 description 1
- 235000015112 vegetable and seed oil Nutrition 0.000 description 1
- 239000008158 vegetable oil Substances 0.000 description 1
- 235000013311 vegetables Nutrition 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 238000009736 wetting Methods 0.000 description 1
- 239000000080 wetting agent Substances 0.000 description 1
- UGZADUVQMDAIAO-UHFFFAOYSA-L zinc hydroxide Chemical class [OH-].[OH-].[Zn+2] UGZADUVQMDAIAO-UHFFFAOYSA-L 0.000 description 1
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
- D06N7/0076—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
- 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
- D06N2205/00—Condition, form or state of the materials
- D06N2205/06—Melt
Landscapes
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Laminated Bodies (AREA)
- Compositions Of Macromolecular Compounds (AREA)
Abstract
The present invention is related to a carpet backing layer composition, comprising: - 100 parts by weight of a polyolefin or a blend of polyolefins and optionally a blend of oils , wax and tackifiers , said polyolefin or polyolefin blend comprising at least 50% by weight of (co)polymerized C3 - C8 alfa- olefins - between 100 and 900 parts by weight of one or more inorganic filler(s) characterized by a volume median particle diameter (D50) comprised between 10 and 1000 urn; the backing layer composition being characterized in that the heat effusion within the temperature range of from 10 to 40°C (AH10-*40'0) is less than 12.5% of the heat effusion within the temperature range of from 10 to 170°C (AH10-*170"0), the heat of fusion being measured by Differential Scanning Calorimetry. The invention is further related to a carpet comprising a carpet backing layer obtained from the carpet backing layer composition and a method for the preparation of said carpet.
Description
1 DP.TASO.0178/LllJu100738
CARPET BACKING LAYER COMPOSITION
Field of the Invention [0001] The present invention relates to a composition for carpet backing, inparticular to a composition comprising a polyolefin and a filler. The present inventionalso relates to a carpet comprising the carpet backing composition and to a method formaking the carpet comprising the carpet backing composition.
Background of the Invention [0002] Most conventional carpets comprise a primary backing layer with fibertufts in the form of cut or uncut loops extending upwardly from the primary backinglayer and a secondary backing layer at the backside of the primary backing layer.
[0003] US2004/0052952 discloses a process for tuft and filament binding to an unfinished carpet, which comprises applying a coating composition which comprisesfrom 50% to 100% by weight of one or more substantially amorphous poly-alpha-olefins as a melt to the backside of the unfinished carpet in a coating weight amountof from 20 to 1,500 g/m2 to bind the tuft and filament to the unfinished carpet, whereinthe melt viscosity of the coating composition at 190°C is from 200 mPas to 20,000mPas.
The poly-alpha-olefin comprises polymerized monomer units of from 0% to 100% byweight of one or more alpha-olefins having 4 to 10 carbon atoms, from 0% to 100% byweight of propene and from 0% to 20% by weight of ethene.
The coating composition further comprises one or more of from 0% to 5% by weight ofa crystalline polyolefin, from 0% to 35% by weight of fillers or pigments, and from 0%to 15% by weight of a wax.
[0004] US 2008/0280093 discloses a carpet comprising: - a primary backing material; - a plurality of fibers attached to the primary backing material; and - an adhesive composition, wherein the adhesive composition comprises atleast one homogenously branched ethylene polymer characterized as havinga short chain branching distribution index of greater than or equal to 50%, anda filler in an amount comprised between 1 and 75 weight percent of the 2 DP.TASO.0178/LltJui oo738composition, wherein the adhesive composition has substantially penetratedand substantially consolidated the fibers.
Preferably the ethylene polymers are substantially amorphous or totallyamorphous
Representative examples of fillers include, but are not limited limestone(primarily CaCO3), marble, quartz, silica, and barite (primarily BaSO4).Suitable particle sizes range from about 1 to about 50 pm.
[0005] JPH05132870 discloses a resin composition for backing tile carpets,obtained by blending: - 100 parts by weight resin component composed of (A) 50-90 % by weightamorphous polyolefin and (B) 10-50 % by weight tackifier (e.g. natural rosin ora modified rosin) with (C) 0-30 parts by weight of crystalline polypropylene and - 25-900 parts by weight filler containing magnesium carbonate.
The particle size of MgCCh filler is between 1 and 500p, preferably between 10 and 300 pm.
The polyolefin can be a random copolymer of ethylene and propylene, wherein theethylene content is between 0 and 30% by weight.
[0006] US 2014/0017439 describes carpets comprising: - a primary backing layer having a face side and a back side; - a plurality of fibers attached to the primary backing layer; and - a second layer attached to the back side of the primary backing layer, comprisingat least one propylene-based elastomer, with limited crystallinity, comprising atleast about 60% by weight propylene-derived units and about 5 to about 25% byweight ethylene-derived units.
The backing layers may include up to 80% by weight, based on the total weight of thelayer, of organic and/or inorganic fillers. Suitable fillers are calcium carbonate,aluminum trihydrate, talc, among others.
[0007] US 7,741,397 discloses a polymer composition comprising anethylene/alpha-olefin interpolymer and a filler. The ethylene/alpha-olefin interpolymeris a block copolymer having a certain amount of crystallinity, and the filler, with aparticle size preferably comprised between 3.2 and 8 pm, is present in the polymer 3 DP.TASO.0178/LUJ u 100738composition in an amount comprised between 30 and 95%. The polymer compositioncan be used in automotive flooring applications.
[0008] US 2010/0285246 discloses a polyolefin for floor coverings, wherein thepolyolefin contains not more than 20% by weight of ethylene, either 70-100% by weightor not more than 20% by weight of propylene and/or either 70-100% by weight or notmore than 20% by weight of 1-butene or of another linear 1-olefin, with the sum of theproportions being 100% by weight, and the triad distribution for propene triadsdetermined by 13C-NMR has an isotactic proportion of 75-98% by weight, an atacticproportion of less than 20% by weight and a syndiotactic proportion of not more than20% by weight and/or the triad distribution for 1 -butene triads determined by 13C-NMRhas an isotactic proportion of 10-98% by weight, an atactic proportion of 1-85% byweight and a syndiotactic proportion of not more than 20% by weight.
The polyolefin may be mixed with not more than 80% by weight of inorganic and/ororganic, based on a hot melt formulation comprising polyolefin and filler.
[0009] WO2015/100073 discloses a carpet comprising: (a) a primary backing layer; (b) a plurality of fibers attached to the primary backing layer; and (c) a second layer attached to the back side of the primary backing layer, whereinat least one of the primary backing layer and the second layer comprises apolymer blend comprising: (i) a first propylene-based polymer, wherein the first propylene-based polymeris a homopolymer of propylene or a copolymer of propylene and ethylene or aC4 to C10 alpha-olefin; and (ii) a second propylene-based polymer, wherein the second propylene-basedpolymer is a homopolymer of propylene or a copolymer of propylene andethylene or a C4 to C10 alpha-olefin; wherein the second propylene-basedpolymer is different than the first propylene-based polymer; wherein the polymer blend has a melt viscosity, measured at 190°C, according toASTM D-3236, of about 500 to about 25,000 cP.
Any one of the layers can comprise a filler and/or additive. The filler may be present atup to about 80% by weight, based on the total weight of the layer. 4 DP .TASO.0178/LljJ u 100738The polymer blend may have a heat of fusion comprised between 5 J/g and less than90 J/g and a crystallization temperature of greater than 0°C and less than 110°C,[0010] US 2016/0102429 discloses a carpet backing composition comprising: (a) 10 to 50% by weight of a first polymer component, the first polymer componentcomprising an elastomeric polymer; (b) 50 to 90% by weight of a filler; and (c) 0.1 to 5% by weight of a compatibilizer, the compatibilizer providing free radicalsource to bond the first polymer component and the filler.
The filler comprises fly ash, ground glass, calcium carbonate, talc, clay, orcombinations thereof.
The first polymer component is a propylene-based copolymer having: - 75 to 95 % by weight propylene-derived units and about 5 to 25% by weight units derived from at least one of ethylene or a C4 to C12 alpha-olefin; - a heat of fusion, as determined by DSC, of about 75 J/g or less;. - a percent crystallinity of 2 to 65.
The composition may further comprise a second polymer component. The secondpolymer component can be a homo-polymer, such as a functionalized/modified homo-polymer, a copolymer, such as a functionalized/modified copolymer, an oligomer, ahydrocarbon tackifying resin, such as a functionalized/modified hydrocarbon tackifyingresin, or any combinations thereof.
[0011] Carpets, during their use, are subject to atmospheric fluctuations such aschanges in ambient temperature and humidity, which endanger their dimensionalstability. To remedy to the dimensional instability and to prevent curling, a flexiblebacking is indispensable; yet it is generally known that the flexibility of the polymer(s),forming the backing layer, is negatively influenced by the addition of filler and additives.Fillers are added to the formulation both for economical and performance reasons e.g.fire resistance.
[0012] The negative effect of filler on the flexibility of a polyolefin/filler blend,depends on the particle size of said filler and is proportional to it.
Otherwise, low particle size fillers negatively influence processing of the blend sincethey give rise to local overheating of the polyolefin causing degradation of the polymerresulting, dependent on the polymer composition, in either an increase in viscosity due 5 DP.TASO.0178/HtJu100738to peroxide-initiated crosslinking or a loss in physical properties of the backing layerdue to chain scission.
In particular, polymers containing high levels (more than 50% in weight) of ethene aresubject to a viscosity increase during high temperature processing due to crosslinkingdegradation, causing poor processing performances especially for high filledcompounds.
Contrary, polymers containing high level of C3 to C8 monomers have no tendency tocrosslink during hot processing
In addition, high amounts of low particle size filler negatively influence the adhesion ofthe backing layer to the unfinished carpet.
Aims of the invention.
[0013] The present invention aims to provide a carpet backing layer that does not present the drawbacks of the prior art carpet backing layers. It is the aim ofthe present invention to provide a carpet backing layer allowing the production ofcarpets showing a dimensional stability independent of atmospheric conditions, saidcarpet backing layer being applicable by a trouble-free process. A further aim is toprovide a method for the production of carpets, comprising said carpet backing layeras well as the carpet itself.
Summary of the Invention [0014] The present invention discloses a carpet backing layer compositioncomprising: - between at least 10% by weight and 50% by weight or less, preferably 40%by weight or less, more preferably 30% by weight or less, most preferably20% by weight or less of a semi-crystalline polyolefin or of a blend of two ormore semi-crystalline polyolefin(s) said polyolefin or blend of two or morepolyolefins being characterized in that the weight percentage of(co)polymerized C2 olefin is less than 50 and that the weight percentage ofC3 - C8 alfa olefins is 50 or more; and - between up to 90% by weight and 50% by weight or more, preferably 60%by weight or more, more preferably 70% by weight or more, most preferably80% by weight or more of one or more inorganic filler(s) characterized by avolume median particle diameter (D50) comprised between up to 1000 pmand at least 10 pm, preferably more than 20 pm, more preferably more than 6 DP.TAS0.0178/HIJU100738 50 pm and most preferably more than 100 pm, or even more than 200 pmas obtained from laser light scattering measurements according to ISO13320; the backing layer composition being characterized in that the heat of fusion within thetemperature range of from 10 to 40°C (ΔΗ10^40Χ) is less than 12.5%, preferably lessthan 10%, more preferably less than 5% of the heat of fusion within the temperaturerange of from 10 to 170°C (AH1tW70X), the heat of fusion being measured byDifferential Scanning Calorimetry.
[0015] Preferred embodiments of the present invention disclose one or more of the following features: - the polyolefin or blend of polyolefins has a Shore A hardness, according to ASTMD 2240 of at least 65, preferably of at least 70, more preferably of at least 75,most preferably of at least 80, even of at least 85 or even of at least 90; - the C3 - C8 alpha-olefin(s) of the one or more polyolefin(s) are selected from thegroup consisting of the isomers of C3 to C8 alpha-olefins and combinationsthereof; - the C3 - C8 alpha-olefin of the one or more polyolefin(s) is propene, 1-butene, 1-octene or a combination thereof; - the polyolefin is selected from the group consisting of polypropylene, poly-1-butene, propene-ethene copolymer, propene-1-butene copolymer, 1-butene-ethene copolymer, propene-1-butene-ethene copolymer and 1-octene-ethenecopolymer; - the inorganic filler is selected from the group consisting of talc, mica, calciumcarbonate, magnesium carbonate, dolomite, barite (barium sulfate), bauxite,magnesium hydroxide, aluminium hydroxide, kaolin, silica, glass, and anycombination thereof; - the carpet backing layer composition comprises one or more processingadditive(s) selected from the group consisting of waxes, oils and tackifiers; - the carpet backing layer composition comprises: • between at least 10% by weight and 50% by weight or less, preferably40% by weight or less, more preferably 30% by weight or less, mostpreferably 20% by weight or less of I, preferably of II, more preferably ofIII, most preferably of IV; and 7 DP.TASO.0178/LL|Lu 100738 • between up to 90% by weight and 50% by weight or more, preferably 60% by weight or more, more preferably 70% by weight or more, mostpreferably 80% by weight or more of one or more inorganic filler(s)characterized by a volume median particle diameter (D50) comprisedbetween up to 1000 pm and at least 10 pm, preferably more than 20 pm,more preferably more than 50 pm and most preferably more than 100pm, or even more than 200 pm as obtained from laser light scatteringmeasurements according to ISO 13320.; wherein: - I. comprises 20% by weight or more of one or more polyolefin(s) and 80% by weight or less of one or more processing additive(s); - II. comprises 25% by weight or more of one or more polyolefin(s) and75% by weight or less of one or more processing additive(s); - III. comprises 35% by weight or more of one or more polyolefin(s) and65% by weight or less of one or more processing additive(s); - IV. comprises 45% by weight or more of one or more polyolefin(s) and55% by weight or less of one or more processing additive(s); - the carpet backing layer composition comprises: • between at least 10% by weight and 50% by weight or less, preferably40% by weight or less, more preferably 30% by weight or less, mostpreferably 20% by weight or less of V, preferably of VI, more preferablyof VII; and • between up to 90% by weight and 50% by weight or more, preferably60% by weight or more, more preferably 70% by weight or more, mostpreferably 80% by weight or more of one or more inorganic filler(s)characterized by a volume median particle diameter (D50) comprisedbetween up to 1000 pm and at least 10 pm, preferably more than 20 pm,more preferably more than 50 pm and most preferably more than 100pm, or even more than 200 pm as obtained from laser light scatteringmeasurements according to ISO 13320.; wherein: - V. comprises 55% by weight or more of one or more polyolefin(s) and 45% by weight or less of or more processing additive(s); 8 DP.TASO.0178/LqLu100738 - VI. comprises 65% by weight or more of one or more polyolefin(s) and35% by weight or less of one or more processing additive(s); - VII. comprises 80% by weight or more of one or more polyolefin(s) and20% by weight or less of one or more processing additive(s); - the carpet backing layer composition is characterized by a melt viscosity at 160°Cin a rotational viscometer, according to ISO 11443, of from 10 Pas to 5000 Pas,preferably from 20 Pas to 2500 Pas, more preferably from 50 to 500 Pas.
[0016] The present invention further discloses a carpet comprising the carpetbacking layer composition of the present invention.
[0017] Preferred characteristics of the carpet according to the present inventioncomprise: - the backing layer has a surface density comprised between 1600 and 4000 g/m2,preferably between 1700 and 3500 g/m2, more preferably between 1800 and3000 g/m2, most preferably between 1900 and 2500 g/m2 and - the backing layer thickness is comprised between 0.4 and 4.0 mm, preferablybetween 0.5 and 3.5 mm, more preferably between 0.7 and 2.5 mm, mostpreferably between 0.8 and 2.0 mm.
[0018] The present invention further discloses a method of making a carpetcomprising: a) extrusion coating the carpet backing layer composition of the present, on theback side of a primary backing material, said primary backing material havinga face and a back side, a plurality of fibers attached to the primary backingmaterial and extending from the face side and exposed at the back side and b) cooling down the carpet layer composition and forming the carpet backinglayer.
[0019] Preferred embodiments of the method of making a carpet furtherdisclose: - the extrusion coating is performed at a temperature comprised between 130 and170°C, preferably between 140 and 160°C. - an additional step comprises subjecting the extrusion coated carpet backing layercomposition of step a) to a subsequent heat treatment at a temperaturecomprised between 130 and 170°C, preferably between 140 and 160°C for a time 9 DP.TASO.0178/LWU100738period comprised between 1 and 60 s, preferably between 5 and 30 s, morepreferably between 10 and 20 s, before cooling down in step b).
Detailed description of the invention [0020] According to the present invention there is provided a carpet backinglayer for carpet tiles and carpet rolls, showing an outstanding dimensional stability,independent of the ambient conditions, said carpet backing layer being obtained froma semi-crystalline polyolefin or a blend of semi-crystalline polyolefins, one or morefiller(s) and optionally of one or more compounds selected from the group consistingof waxes, oils, tackifiers and combinations thereof.
[0021] The polyolefin(s) for being used in the carpet backing layer of the presentinvention are obtained from polymerizing one or more C2 to C8 olefin.
[0022] In the case of using one polyolefin, said polyolefin comprises 50% byweight or more of (co)polymerized C3 to C8 alpha olefins.
[0023] In the case of using a blend of polyolefins, one or more of said polyolefinsmay comprise less than 50% by weight of (co)polymerized C3 - C8 alpha-olefins,provided that the blend of polyolefins comprises 50% by weight or more of C3 - C8alpha-olefins.
[0024] The (co)polymerized C3 to C8 alpha olefins are preferably selected fromthe group consisting of propene, 1-butene, 1-pentene, 1-hexene, 1-heptene, and 1-octene.
[0025] Alpha-olefins selected from the group consisting of isopentene, 3,3-dimethyl-1-butene, 3,3-dimethyl-1-pentene, 3,4-dimethyl-1 -pentene, 3-ethyl-1-pentene, 3-methyl-1 -hexene, 4,4-dimethyl-1 -pentene, 4-methyl-1 -hexene, 5-methyl-1-hexene, , 3-methyl-1 -heptene, 4-methyl-1 -heptene, 5-methyl-1-heptene, 6-methyl-1-heptene, 3.3-dimethyl-1 -hexene, 4,4-dimethy1 -hexene, 5,5-dimethyl-1 -hexene, 3,4-dimethyl-1-hexene, 3,5-dimethyl-1-hexene, 4,5-dimethyl-1 -hexene, 3-ethyl-1-hexene,4-ethyl-1-hexene, 5-ethyl-1-hexene, 3-methyl-4-ethyl-1 -pentene, 3-ethyl-4-methyl-1-pentene and 3-methyl-3-ethyl-1-pentene are optionally used.
[0026] Preferably the C3 to C8 alpha-olefin is propene, 1-butene, 1-octene or acombination thereof. 10 DP.TASO.0178/LqJu100738[0027] Preferably the polyolefin is a polypropylene homopolymer or a propylenebased copolymer.
[0028] Preferably the polyolefin is a polybutylene-1 homopolymer or a 1-butenebased copolymer; more preferably the polyolefin is a 1-butene based copolymer.
[0029] The propylene-based copolymer comprises 50% by weight or more,preferably 60% by weight or more, more preferably 70% by weight or more, mostpreferably 80% by weight or more or even 90% by weight or more of propylene-derivedunits, based on the total weight of the propylene-based copolymer. Correspondingly,the units derived from at least one of ethylene or a C4 to C8 alpha-olefin may bepresent in an amount of less than 50% by weight, preferably of less than 40% byweight, more preferably of less than 30% by weight, most preferably of less than 20%by weight or even of less than 10% by weight based on the weight of the propylene-based copolymer.
[0030] The 1-butene-based copolymer comprises 50% by weight or more,preferably 60% by weight or more, more preferably 70% by weight or more, mostpreferably 80% by weight or more of 1-butene-derived units, based on the total weightof the 1-butene-based copolymer. Correspondingly, the units derived from at least oneof ethylene, propylene or a C5 to C8 alpha-olefin may be present in an amount of lessthan 50% by weight, preferably of less than 40% by weight, more preferably of lessthan 30% by weight, most preferably of less than 20% by weight based on the weightof the 1-butene-based copolymer. Preferably the 1-butene-based copolymercomprises less than 85% by weight of polymerized 1-butene and 15% by weight ormore of polymerized propene and/or ethene, the weight percentage of ethene beingunder 50.
[0031] Preferably the polyolefin is selected from the group consisting ofpolypropylene, propene-ethene copolymer, propene-1-butene copolymer, 1-butene-ethene copolymer propene-1-butene-ethene copolymer and 1-octene-ethenecopolymer.
[0032] Preferably the polyolefin comprises less than 50% by weight ofpolymerized ethene. 11 DP.TASO.0178/LUui 00738[0033] In the case of using a blend of polyolefins, one or more of said polyolefinsmay comprise more than 50% by weight of (co)polymerized ethene, provided that theblend of polyolefins comprises less than 50% by weight of ethene.
[0034] The polyolefin or polyolefin blend is a semi-crystalline polyolefin orpolyolefin blend characterized by: - a heat of fusion (AHf) of 75 J/g or less, preferably of 70 J/g or less, morepreferably 50 J/g or less, most preferably 45 J/g or less or even 35 J/g or lessand of more than 10 J/g, preferably of more than 20 J/g, more preferably of morethan 25 J/g; - a melting peak temperature comprised between 20 and 160°C, preferablybetween 30 and 150°C, more preferably between 40 and 140°C; the heat of fusion (AHf) and the melting peak temperature being determined byDifferential Scanning Calorimetry (DSC) with a heating gradient of 10°C/minute. Themelting peak temperature is determined at the peak in the DSC curve. For thedetermination of the heat of fusion (AHf) and the melting peak temperature, samplesof the polyolefin or polyolefin blend are first stored for 48 hours at a temperature of14°C and subsequently are cooled down, at gradient of 10°C/minute, to a temperatureof 0°C. After 5 minutes at 0°C the samples are heated, at a heating gradient of10°C/minute for recording the DSC curve. .
[0035] The polyolefin further is preferably characterized by: - a number average molecular weight (Mn) comprised between 2,500 and250,000 g/mole, preferably between 10,000 and 250,000 g/mole, morepreferably between 25,000 and 200,000 g/mole; - a polydispersity (DP) comprised between 1.5 and 20, preferably between 1.5and 15, more preferably between 1.5 and 5, most preferably between 1.8 toabout 3, or even between 1.8 to about 2.5; as determined by Gel Permeation Chromatography in 1,2,4-trichlorobenzene, againstpolystyrene standards.
[0036] Preferably the polyolefin or blend of polyolefin is further characterized bya Shore A hardness, according to ASTM D 2240, of at least 65, preferably of atleast 70, more preferably of at least 75, most preferably of at least 80, even of atleast 85 or even of at least 90. 12 DP.TASO.0178/Ll|Lui 00738[0037] To the one or more polyolefin(s) is/are optionally blended: - tackifiers comprising at least one hydrocarbon, wherein the hydrocarboncomprises an aliphatic hydrocarbon, a cycloaliphatic hydrocarbon, an aromaticmodified aliphatic hydrocarbon, an aromatic and aliphatic hydrocarbon modifiedwith at least one fatty acid ester or any combination thereof. Commerciallyavailable examples of the hydrocarbon tackifier include, e.g., Escorez™(Escorez 1102 and 5600) (ExxonMobil Corp.), and Struktol™ TR016 (StruktolCompany of America); and/or Regalite (Regalite 1090) from EastmannTackifiers could be hydrotreated or not; - waxes selected from microcrystalline waxes, polyethylene waxes, Fischer-Tropsch waxes, paraffin waxes, polypropylene waxes or combinations thereof.Preferably microcrystalline waxes and/or polypropylene waxes may be used.Commercially available waxes include but are not limited to Sasolwax® C80(Sasol) and A-C® 1660 (Honeywell); and/or Microcrystalline Wax LMP, orMicrocriytalline Wax HMP from Shell; and/or MMP Wax from Alpha - oils, for example oils selected from vegetable and derivatized vegetable oils,hydrotreated heavy naphthenic petroleum oils, paraffinic oils or combinationsthereof may be used. Commercially available examples of naphthenic oils areKN 4006 and KN 4008 (KunLun Lubricant Company of Petrochina) and LP 150and LP 350 (Kukdong Oil and Chemicals) and/or Finavestan 360 B from Totaland/or processing oil 6116 WOP from PetroCenter. Preferably, oils are basedon paraffinic hydrotreated to minimize the smell of the compound.
[0038] To the one or more polyolefin(s), optionally comprising one or more oil(s)and/or one or more wax(es) and/or one or more tackifier(s), are added one or morefillers selected from the group consisting coal fly ash, carbonate salts such asmagnesium carbonate, calcium carbonate and calcium-magnesium carbonate, bariumsulfate, carbon black, metal oxides, inorganic material, natural material, aluminatrihydrate, magnesium hydroxide, aluminum hydroxide, bauxite, talc, mica, barite,kaolin, silica, post-consumer glass, or post-industrial glass, synthetic and natural fiber,or any combination thereof. Preferably, the filler comprises talc, mica, calciumcarbonate, barite, kaolin, silica, glass, or any combination thereof.
[0039] The one or more fillers are characterized by a volume median particlediameter (D50) comprised between up to 1000 pm and more than 10 pm, preferably 13 DP.TASO.0178/LUu 100738more than 20 pm, more preferably more than 50 pm and most preferably more than100 pm or even more than 200 pm as obtained from laser light scatteringmeasurements according to ISO 13320.
[0040] The technique of laser diffraction is based on the principle that particlespassing through a laser beam will scatter light at an angle that is directly related to theirsize: large particles scatter at low angles, whereas small particles scatter at highangles. The laser diffraction is accurately described by the Fraunhofer approximationand the Mie theory, with the assumption of spherical particle morphology.
[0041] Concentrated suspensions, comprising about 1.0 % by weight of fillerparticles, are prepared, using suitable wetting and/or dispersing agents.
Suitable solvents are for example water or organic solvents such as for exampleethanol, isopropanol, octane or methyl ethyl ketone. A sample presentation systemensures that the material under test passes through the laser beam as a homogeneousstream of particles in a known, reproducible state of dispersion.
[0042] Typically the particle size distribution is measured by laser light scatteringusing the particle size analyzer (HORIBA 920) from (Horiba Scientific) according toISO 13320.
Particle size measurements are performed on pure solvent, e.g. 150 ml of methyl ethylketone, to which a concentrated suspension of filler is added drop by drop until theconcentration of filler is such that a transmission, as displayed by the particle sizeanalyzer is comprised between 75 and 90%.
[0043] The carpet backing layer of the present invention thus comprises acomposition comprising: - between at least 10 % by weight and 50% by weight or less, preferably 40% byweight or less, more preferably 30% by weight or less of a semi-crystallinepolyolefin or of a blend of two or more semi-crystalline polyolefin(s)characterized in that the polyolefin or blend of polyolefins has a weightpercentage of (co)polymerized C3 - C8 alfa-olefins of 50 or more; - between up to 90% by weight and 50% by weight or more, preferably 60% byweight or more, more preferably 70% by weight or more of one or moreinorganic filler(s) characterized by a volume median particle diameter (D50)comprised between up to 1000 pm and more than 10 pm, preferably more than 14 DP.TASO.0178/LLtu10073820 pm, more preferably more than 50 pm and most preferably more than 100pm, or even more than 200 pm as obtained from laser light scatteringmeasurements according to ISO 13320.; the backing layer composition being characterized in that the heat of fusion withinthe temperature range of from 10 to 40°C (ΔΗ10-40"0) is less than 12.5%, preferablyless than 10%, more preferably less than 5% of the heat of fusion within thetemperature range of from 10 to 170°C (AH1M70’c), the heat of fusion beingmeasured by Differential Scanning Calorimetry.
[0044] For the determination of the percentage of the heat of fusion, samples ofthe backing layer composition, after being compounded, are first stored for 48 hoursat a temperature of 14°C and subsequently are cooled down, at gradient of10°C/minute, to a temperature of 0°C. After 5 minutes at 0°C the heat of fusion isdetermined by heating the samples, at a heating gradient of 10°C/minute, to atemperature of 170°C. The heat of fusion within the temperature range of from 10 to40°C (ΔΗ1ίΜ0Χ) is determined from integrating the heat flux in said temperaturerange.
[0045] The carpet backing layer further may comprise one or more wax(es),oil(s) and/or tackifier(s), substituting 80% by weight or less, advantageously 75% byweight or less, advantageously 65% by weight or less, advantageously 55% by weightor less, advantageously 45% by weight or less, advantageously 35% by weight or less,advantageously 20% by weight or less, of the semi-crystalline polyolefin or of the blendof semi-crystalline polyolefins, the polyolefin part in the carpet backing formulation thusbeing transformed into: - 20% by weight or more of one or more polyolefin(s) and 80% by weight or less or more or more wax(es), oil(s) and/or tackifier(s) (mixture or blend I); - 25% by weight or more of one or more polyolefin(s) and 75% by weight or less or more or more wax(es), oil(s) and/or tackifier(s) (mixture or blend II); - 35% by weight or more of one or more polyolefin(s) and 65% by weight or less or more or more wax(es), oil(s) and/or tackifier(s) (mixture or blend III) - 45% by weight or more of one or more polyolefin(s) and 55% by weight or less or more or more wax(es), oil(s) and/or tackifier(s) (mixture or blend IV); 15 DP.TASO.0178/LQJu 100738 - 55% by weight or more of one or more polyolefin(s) and 45% by weight or less or more or more wax(es), oil(s) and/or tackifier(s) (mixture or blend V); - 65% by weight or more of one or more polyolefin(s) and 35% by weight or less or more or more wax(es), oil(s) and/or tackifier(s) (mixture or blend VI); - 80% by weight or more of one or more polyolefin(s) and 20% by weight or less or more or more wax(es), oil(s) and/or tackifier(s) (mixture or blend VII).
[0046] For this particular case the carpet backing composition comprises acomposition comprising: - between at least 10% by weight and 50% by weight or less, preferably 40% byweight or less, more preferably 30% by weight or less of a mixture or an blendof I, II, III, IV, V, VI or VII; - between up to 90% by weight and 50% by weight or more, preferably 60% byweight or more, more preferably 70% by weight or more of one or moreinorganic filler(s).
[0047] The inventors have observed that the heat of fusion of each composingcomponent of the carpet backing composition is influenced to a certain degree by theother composing components, yet the thermal properties of the complete carpetbacking composition is determining for the dimensional stability of the derived carpetbacking layer and thus for finished carpet.
[0048] When tackifiers are used in the carpet baking composition of the presentinvention they preferably are used in combination with one or more oil(s) and/or withone or more waxe(s). The inventors have observed that the use of tackifiers as such(= without oil(s) and /or waxe(s)) has a negative effect on the dimensional stability ofderived carpet backing layer.
[0049] The inventors have observed as well that the use of wax as the onlypartial substitute for the polyolefin or polyolefin blend may have a negative effect onthe dimensional stability of derived carpet backing layer.
[0050] The inventors have also observed that for a polyolefin or a polyolefinblend characterized by a borderline Shore hardness (65 - 70) and a borderline heat of 16 DP.TASO.0178/LI4ui 00738fusion (AHf around 25 J/g), waxe(s), oil(s) and tackifier(s) preferably are omitted in thecarpet backing composition.
[0051] The inventors have found that: - the weight percentage of (co)polymerized C3 - C8 alpha-olefin in thepolyolefin(s); - the weight percentage and particle size of the filler(s) - and the type and weight percentage of waxe(s), oil(s) and/or tackifier(s); are key for the value of the heat of fusion of the backing layer composition in thetemperature range of from 10 to 40°C (ΔΗ10-40Χ) relative to the value of the heat offusion in the temperature range of from 10 to 170°C (ΔΗ10_>170°°); a relative value ofless than 12.5% in turn being the main determining characteristic for: - getting the right yield strength of the carpet backing layer resulting in a carpetcharacterized by a satisfactory handling and dimensional stability; - limiting thermal degradation of the polyolefin(s) to a strict minimum; - good dimensional stability; - guaranteeing good adhesion of the backing layer composition to the unfinishedcarpet.
[0052] The inventors have experienced personally that a limited number ofexperiments allow the one skilled in the art to obtain the right combination ofpolyolefin(s), filler(s), wax(es), oil(s) and tackifier(s) that results in a backing layercomposition with a heat of fusion, in the temperature range of from 10 to 40°C(ΔΗ10^40°°), of less than 12.5%, or even less than 10% or even less than 5%, of theheat of fusion in the temperature range of from 10 to 170°C (AH1(M70'c), ensuring along term dimensional stability of the derived carpet tiles.
[0053] The composition according to the present invention can optionally contain oneor more further additives, such as, antimicrobial, biocides, antioxidants, thermalstabilizers, flame retardants, or any combination thereof. Preferably, the compositionincludes at least a flame retardant, a thermal stabilizer or a combination thereof.
[0054] A stabilizer can for example be added to the composition to provide heatstability. The stabilizer can be used to minimize degradation caused by exposure toheat and oxygen, including conditions encountered in the manufacture of a productcontaining the composition of the present invention. 17 DP.TASO.0178/LUlu100738[0055] Particularly preferred stabilizers are for example sterically hindredphenolic antioxidants such as Irganox 1010 and Irganox 1076 (BASF) and stabilizersfrom the phosphonite or phosphite type such as Doverphos® S-9228 (Dover Chem.Corp) or Weston® TNPP (Addivant).
[0056] Flame retardants preferably are selected from halogenated and non-halogenated flame retardants, zinc borates, aluminium hydroxides, magnesiumhydroxide, bromium oxides and zinc hydroxides. Liquid flame retardants can also beused for instance phosphate plasticizers.
[0057] The composition according to the present invention optionally comprisesbetween 0.1 % and 5% of the one or more further additives.
[0058] The compositions according to the present invention are characterizedby: - a melt viscosity at 160°C in a rotational viscometer, according to ISO11443:2005, of from 10 Pas to 5000 Pas, preferably from 20 Pas to 2500 Pas,more preferably from 50 to 500 Pas; - an open time of not more than 300 seconds, preferably not more than 200seconds, more preferably not more than 150 seconds and most preferably notmore than 120 seconds, with further preferred ranges being not more than 100seconds, not more than 60 seconds, not more than 45 seconds, not more than30 seconds, not more than 20 seconds, and in particular 1-30 seconds, whereinthe open time stands for the period of time during which the composition isprocessable i.e. does not solidify or partially solidify, so that a potential blockageand contamination of the application equipment is circumvented.
[0059] The composition according to the present invention preferably iscompounded in a suitable heated mixer, for example in a twin screw or a single screwextruder, at an internal temperature comprised between 130 and 170°C, preferablebetween 140 and 160°C.
By internal temperature it is meant the real temperature of the melt and not the settemperatures of the equipment for preparing and processing of said melt.
[0060] The melt is applied, by extrusion coating, on the back side of a firstbacking material, said first backing material having a face and a back side, a plurality 18 DP.TASO.0178/LUlu100738of fibers attached to the first backing material and extending from the face of the firstbacking material and exposed at the back side of the first backing material.
[0061] The melt blended composition, standing at a temperature comprisedbetween 130 and 170°C, preferable between 140 and 160°C, is applied in the form ofa thin film on the back side of the first backing material, forming the carpet backinglayer upon cooling, with a layer thickness comprised between 0.4 and 4.0 mm,preferably between 0.6 and 3.0 mm, more preferably between 0.8 and 2.0 mm,corresponding to a surface density comprised between 1600 and 4000 g/m2, preferablybetween 1700 and 3500 g/m2, more preferably between 1800 and 3000 g/m2, mostpreferably between 1900 and 2500 g/m2.
[0062] The extrusion coated carpet backing layer composition optionally issubjected to a subsequent heat treatment at a temperature comprised between 130and 170°C, preferably between 140 and 160°C for a time period comprised between 1and 60 s, preferably between 5 and 30 s, more preferably between 10 and 20 s, beforecooling down.
[0063] The carpets may be produced and applied as tiles or as roles.
[0064] The carpets thus obtained prove satisfactory dimensional stability toprevent curling upon varying atmospheric temperature and humidity conditions.
Examples [0065] The following illustrative examples are merely meant to exemplify thepresent invention but is not destined to limit or otherwise define the scope of thepresent invention.
[0066] In table 1 to 3 the influence of filler content, particle size of the filler andadditive content on the AH1O_>4O°C heat of fusion percentage (100 x AH1tM0=c /^I_|io-i7o°c) of the carpet backing layer composition is illustrated. The amounts ofpolyolefins, additives and fillers are given in parts.
Example Vestoplast 708Shore A : 67 Vestoplast 408Shore A: 94 Carbocia 310 Additives %weightFiller 100 xAH10^40”c / ΔΗ10-170"0) 1 100 100 50 0 2 80 100 20 50 8.5 3 100 200 67 3.5 4 65 300 35 75 5 5 65 400 35 80 11.2 6 65 400 35 80 5.3
Table 1. 19 DP.TASO.0178/LUlu100738 [0067]
Example Vistamax6502Shore A :71 Vistamax8880Shore A :93 Licocene1602Shore A:82 Carbocia 310 Additives %weightFiller 100 x ΔΗ10-40’0 / ΔΗ10^170°°) 7 100 200 67 5.3 8 100 200 67 7.3 9 80 100 20 50 12.9 10 80 100 20 50 10.8
Table 2.
[0068] In table 2, example 9 is comparative because of the (100 x ΔΗ10^40'0 I5 AH1tW70°c) value of the backing layer composition being above 12.5%.
[0069] In:
Example 2, 9 and 10 the additive is LMP wax, a microcrystalline hydrogenatedmicrowax derived from the residues of the vacuum distillation of crude oil from Shell;Example 4 to 6 the 35 parts of additives comprise 20 parts of tackifier, 5 parts of 10 mineral oil and 10 parts of LMP wax, wherein the tackifier is Escorez 1102 or Escorez5600 from ExxonMobil and the mineral oil is Processing oil 6116 WOP fromPetroCenter.
Example Vestoplast 408 Durcal10 BL Omyacarb130GU Carbocia 310 Carbocia1300 %weightFiller 100 x ΔΗ10-40"0 / ΔΗ10^170"0) 11 100 100 50 3 12 100 150 60 2.9 13 100 100 50 2.8 14 100 100 50 2.7 15 100 100 50 2.4 16 100 150 60 2.7 17 100 100 50 2.7 18 100 150 60 2.7
Table 3. 15
Example Polyolefin 1(parts) Polyolefin 2(parts) Additivesparts Filler(parts) %weightFiller 100 x ΔΗ10^40°° / ΔΗ1°^170°°) 19 Vestoplast 508 (20) Vestoplast 408 (45) 35 Carbocia310(400) 80 0 20 Vestoplast 508(20) Vestoplast 408(45) 35 Carbocia310(565) 85 10.2 20 DP.TASO.01 78/LUlu1 OO738 21 Licocene 2602 (20) Licocene 3602 (20) 60 Carbocia310(450)Baryte(450) 90 4.9 22 Vestoplast 408 (32.5) Vistamax 8880 (32.5) 35 Carbocia310(400) 80 6.9 23 Engage 8100 (60) Vistamax 8880 (40) Carbocia310(200) 67 0 24 Engage 8100 (12.5) Vistamax 8880 (12.5) 75 Carbocia310(300) 75 8.7 25 Engage 8100 (10) Vistamax 8880 (10) 80 Carbocia310(300) 75 4.05 26 Vestoplast 708 41.375 Vestoplast 508 41.375 17.25 BL20250 71.4 16.7
Table 4 [0070] In:
Example 19, 20 and 22, the 35 parts of additives comprise 20 parts of tackifier, 5 partsof mineral oil and 10 parts of MMP wax from Alpha ;
Example 21, the 60 parts of additives comprise 40 parts of tackifier, 10 parts of oil and10 parts of MMP wax;
Example 24, the 75 parts of additives comprise 25 parts of tackifier, 25 parts of oil and12.5 parts of HMP Microcrystalline wax from Shell and 12.5 parts of MMP waxfrom Alpha;
Example 25, the 80 parts of additives comprise 25 parts of tackifier, 30 parts of oil and25 parts of HMP Microcrystalline wax.
Example 26, the 17.25 parts of additives consist of tackifier only.
[0071] In table 1 to 4: - Carbocia 310 is calcium carbonate with a volume median particle diameter(D50) of 200 pm; - Durcal 10 is calcium carbonate with a volume median particle diameter (D50) of10 pm; - BL is calcium carbonate with a volume median particle diameter (D50) of 30 pm; - Omyacarb 130 GU is calcium carbonate with a volume median particle diameter(D50) of 150 pm; - Carbocia 1300 is a calcium carbonate with a volume median particle diameter(D50) of 650 pm; 21 DP.TASO.0178/LU L(J100738 - Vestoplast 408 is a high 1-butene, propylene ethylene copolymer; having a
Shore A at 94; a heat of fusion (AHf) of 0.76 J/g in the temperature range offrom 33 to 49°C, with a peak at 41 °C, and 40.86 J/g in the temperature rangeof from 72 to 115°C with a peak at 104.8°C. - Vestoplast 508 is a high 1-butene, propylene ethylene copolymer; having a
Shore A at 74; a heat of fusion (AHf) of 23.94 J/g in the temperature range offrom 26 to 80°C with a peak at 43°C. - Vestoplast 708 is a high 1-butene, propylene ethylene copolymer, having a
Shore A at 67; a heat of fusion (AHf) of 24.9 J/g in the temperature range offrom 29 to 117°C with a peak at 42°C. - Vistamaxx 8880 is a metallocene propylene ethylene copolymer having a Shore A at 93; a heat of fusion (AHf) of 43.4 J/g in the temperature range of from 22 to120°C with a peak at 48 and at 89°C. - Vistamax 6502 is a metallocene propylene ethylene copolymer, having a Shore A at 71 ; a heat of fusion (AHf) of 25.82 J/g in the temperature range of from 27to 110°C with a peak at 45.9°C. - Licocene 1602 is a metallocene propylene ethylene copolymer having a Shore A at 82; a heat of fusion (AHf) of 34.08 J/g in the temperature range of from 30to 95°C with a peak at 55 and at 72.3°C). - Licocene 2602 is a metallocene propylene ethylene copolymer, having a Shore A at 90; a heat of fusion (AHf) of 76.3 J/g in the temperature range of from 24 to102°C with a peak at 43 and at 83°C. - Licocene 3602 is a metallocene propylene ethylene copolymer, having a Shore A at 97; a heat of fusion (AHf) of 56 J/g in the temperature range of from 28 to 117°C with a peak at 100.35°C. - Engage 8100 is an ethylene-octene copolymer having a Shore A at 73; a heatof fusion (AHf) of 36 J/g in the temperature range of from 32 to 90°C with a peakat 40 and at74°C). - LMP wax is a microcrystalline wax from Shell having a heat of fusion (AHf) of 156 J/g in the temperature range of from 12to 75°C (peak 48°C). - MMP wax is a microcrystalline wax from Shell having a heat of fusion (AHf) of 158 J/g in the temperature range of from 17 to 85°C (peak 49.6°C). 22 DP.TASO.0178/LUlu100738 - HMP wax is a microcrystalline wax from Shell having a heat of fusion (AHf) of232.8 J/g in the temperature range of from 30 to 95°C (peak 77.3°C). wherein: - the heat of fusion (AHf) is determined by DSC, with a “DSC1 STARe System”from Mettler Toledo, wherein the polyolefin, the processing additive or thecompounded backing layer composition first is stored on a metallic cooled plateat 14°C during 48 hours and subsequently cooled down, at gradient of10°C/minute, to a temperature of 0°C. After 5 minutes at 0°C the heat of fusionis determined by heating the samples, at a heating gradient of 10°C/minute, toa temperature of 170°C. for the particular case of an irregular baseline around 10°C, samples arecooled down to a temperature of -10 or -20°C and DSC measurements arestarted from thereon, thus ensuring an unaffected and reproducible fusionheat value. for the particular case where there is heat flux is beyond 170°C, DSC isrecorded till a temperature of 10 to 20° beyond 170°C, and heat of fusionvalues are obtained from integrating the heat flux from 10°C till thetemperature where there is no more heat flux. The volume of samples is inthe range of from 5 to 10 pliter corresponding to approximatively 5 to 25 mg; - the Shore A hardness—is measured on the polyolefin or polyolefin blend, aftermelting and cooling to 23°C at 10°C/min. and conditioning for 48 hours at 23°C; [0072] In table 1 and 2 the influence of the filler content, Shore A hardness ofthe polyolefin and additive addition is illustrated.
[0073] In table 3 the influence of filler content and particle size is illustrated(examples 11 to 18). Example 12 is represented by way of comparison.
[0074] In table 4 a blend of polyolefins at high filler concentration is illustrated inexamples 19 to 22. In the same table, examples 23 to 25 illustrate a polyolefin blendwherein one of the polyolefins (Engage 8100) has a copolymerized ethene weightpercentage which is 62. In a mixture with Vistamaxx 8880 having a copolymerizedethene weight percentage of 6, the polymer blends are characterized by: - an ethene percentage of 40 and a Shore A hardness of 80 for example 23, 23 DP.TASO.0178/LUlu100738 - an ethene percentage of 34 and a Shore A hardness of 85 for example 24 and 25.
Further, examples 24 and 25 illustrate carpet backing compositions comprising highweight percentages of additives.
Example 9 illustrates the influence of using wax as such, i.e. not in combination withoil(s) and/or tackifier(s).
Example 26 illustrates the influence of using tackifier as such, i.e. not in combinationwith oil(s) and/or wax(es).
Example 27 [0075] Dimensional changes were evaluated for straight stitch loop level 500 x 500 mm square test tiles wherein: - the weight of the tufted nylon yarns is 900 g/m2 with a tuft density is 12needles per inch; and, - the backing layer has a density of 2200 g/m2 and a thickness of 1.5 mm;the thickness is an indicative value as the weight needed is required.
[0076] The carpet test tiles first were conditioned for 100 hours at a temperatureof 10°C and a relative humidity of 25%. The dimensional stability test was performedby installing 25 square carpet test tiles with 50 cm side in a 6.25 m2 square with 2.5 mside, wherein the first side of the 6.25 m2 square consists of 5 carpet test tiles in themachine direction while the second side of the 6.25 m2 square, forming a right anglewith the first side, consists of 5 carpet test tiles in the cross direction. The 6.25 m2square was further filled with strips of tiles, in the machine direction, parallel to the firstside corresponding to parallel strips of tiles in the cross direction, parallel with thesecond side. The tiles contacting each other, side by side, were blocked at the edgesof the 6.25 m2 square, ensuring that each dimensional variation of the individual tilesimplies internal stresses that become visible through doming or curling Subsequentlythe test panels were subjected for 80 hours at a temperature of 40°C and a relativehumidity of 65%, whereupon curling was measured.
[0077] The carpet test tiles comprising a backing layer with a (100 x ΔΗ10^40"01AH1M70’c) value of less than 12.5%, show an acceptable dimensional change, i.e.less than 1 mm lifting at the edges of the tile. 24 DP.TASO.0178/LUlu100738[0078] The inventors further have observed that for a backing layer compositionwith: - a (100 X AH1[MO“C ! ΔΗ1°->170°°) value of less than 5% no lifting at the edges of the tiles is observed; - a (100 X AH1iM0”c I AH1[M70"c) value comprised between 5 and less than 10%, lifting at the edges between 0 and less than 0.5 mm is observed; - a (100 X AH1O^4O°C I AH1°-*17O°C) value comprised between 10 and less than 12.5%, a lifting at the edges between 0.5 and less than 1 mm is observed.
[0079] The carpet test tiles comprising the backing layer with a (100 x ΔΗ1Μ0’°I AH1[W70"c) value of 12.5% or more, as in examples 9 and 26, which arecomparative examples, show an unacceptable dimensional change, i.e. a lifting at theedges of the tile between 1 mm and less than 2 mm for example 9 and between 2 mmand less than 7 mm for example 26.
[0080] The inventors have observed that the heat of fusion of each ingredient(filler included) may be strongly influenced by presence of the other ingredients of thecarpet backing layer composition; the thermal properties has to be measured on thecompleted carpet backing layer composition.
[0081] The carpet test tiles comprising the backing layer according to theinvention prove to have sufficient stiffness for showing an outstanding dimensionalstability under varying temperature and/or humidity conditions.
Claims (14)
Priority Applications (10)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| LU100738A LU100738B1 (en) | 2018-03-19 | 2018-03-19 | Carpet backing layer composition |
| EP18733913.0A EP3652376B1 (en) | 2017-07-14 | 2018-07-03 | Carpet backing layer composition |
| JP2020500831A JP7381445B2 (en) | 2017-07-14 | 2018-07-03 | carpet support layer composition |
| PCT/EP2018/067966 WO2019011725A1 (en) | 2017-07-14 | 2018-07-03 | Carpet backing layer composition |
| CN201880044094.9A CN110869552B (en) | 2017-07-14 | 2018-07-03 | Carpet backing layer composition |
| RU2020102698A RU2745052C1 (en) | 2017-07-14 | 2018-07-03 | Composition of carpet base layer |
| US16/630,763 US11326068B2 (en) | 2017-07-14 | 2018-07-03 | Carpet backing layer composition |
| KR1020207003028A KR102637062B1 (en) | 2017-07-14 | 2018-07-03 | Carpet backing layer composition |
| SG11202000033VA SG11202000033VA (en) | 2017-07-14 | 2018-07-03 | Carpet backing layer composition |
| UAA202000760A UA125189C2 (en) | 2017-07-14 | 2018-07-03 | Carpet backing layer composition |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| LU100738A LU100738B1 (en) | 2018-03-19 | 2018-03-19 | Carpet backing layer composition |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| LU100738B1 true LU100738B1 (en) | 2019-10-01 |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| LU100738A LU100738B1 (en) | 2017-07-14 | 2018-03-19 | Carpet backing layer composition |
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| Country | Link |
|---|---|
| LU (1) | LU100738B1 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US11326068B2 (en) * | 2017-07-14 | 2022-05-10 | Tarkett Gdl | Carpet backing layer composition |
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|---|---|---|---|---|
| EP0518014A1 (en) * | 1991-05-27 | 1992-12-16 | Hüls Aktiengesellschaft | Mouldable floor carpets |
| JPH10276888A (en) * | 1997-04-10 | 1998-10-20 | Ube Rekisen Kk | Backing material for car floor carpet and car floor carpet mat using the same |
| JP3030124B2 (en) * | 1991-07-04 | 2000-04-10 | 住江織物株式会社 | Tile carpet and resin composition for lining the same |
| US20160032521A1 (en) * | 2014-07-30 | 2016-02-04 | Milliken & Company | Carpet Tile With Polyolefin Secondary Backing |
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2018
- 2018-03-19 LU LU100738A patent/LU100738B1/en active IP Right Grant
Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP0518014A1 (en) * | 1991-05-27 | 1992-12-16 | Hüls Aktiengesellschaft | Mouldable floor carpets |
| JP3030124B2 (en) * | 1991-07-04 | 2000-04-10 | 住江織物株式会社 | Tile carpet and resin composition for lining the same |
| JPH10276888A (en) * | 1997-04-10 | 1998-10-20 | Ube Rekisen Kk | Backing material for car floor carpet and car floor carpet mat using the same |
| US20160032521A1 (en) * | 2014-07-30 | 2016-02-04 | Milliken & Company | Carpet Tile With Polyolefin Secondary Backing |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US11326068B2 (en) * | 2017-07-14 | 2022-05-10 | Tarkett Gdl | Carpet backing layer composition |
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