WO1998025984A1 - Preparation selon un processus de melange continu et en ligne de formulations utilisees dans la fabrication de couches de support de moquettes a base de polyurethanne reactif et comportant des matieres de charge - Google Patents

Preparation selon un processus de melange continu et en ligne de formulations utilisees dans la fabrication de couches de support de moquettes a base de polyurethanne reactif et comportant des matieres de charge Download PDF

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Publication number
WO1998025984A1
WO1998025984A1 PCT/US1997/020848 US9720848W WO9825984A1 WO 1998025984 A1 WO1998025984 A1 WO 1998025984A1 US 9720848 W US9720848 W US 9720848W WO 9825984 A1 WO9825984 A1 WO 9825984A1
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Prior art keywords
filler
polyurethane
mixture
isocyanate
reactive
Prior art date
Application number
PCT/US1997/020848
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English (en)
Inventor
Sol M. Mirasol
Debkumar Bhattacharjee
Original Assignee
The Dow Chemical Company
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Filing date
Publication date
Application filed by The Dow Chemical Company filed Critical The Dow Chemical Company
Priority to AU54390/98A priority Critical patent/AU5439098A/en
Publication of WO1998025984A1 publication Critical patent/WO1998025984A1/fr

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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G18/00—Polymeric products of isocyanates or isothiocyanates
    • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
    • C08G18/08—Processes
    • C08G18/0895—Manufacture of polymers by continuous processes
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G18/00—Polymeric products of isocyanates or isothiocyanates
    • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
    • C08G18/08—Processes
    • C08G18/0838—Manufacture of polymers in the presence of non-reactive compounds
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/12—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins
    • D06N3/14—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins with polyurethanes
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
    • D06N7/0071—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing
    • D06N7/0073—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing the back coating or pre-coat being applied as an aqueous dispersion or latex
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
    • D06N7/0071—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing
    • D06N7/0086—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing characterised by the cushion backing, e.g. foamed polyurethane
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2203/00—Macromolecular materials of the coating layers
    • D06N2203/06—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D06N2203/068—Polyurethanes
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2205/00—Condition, form or state of the materials
    • D06N2205/18—Scraps or recycled materials
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2205/00—Condition, form or state of the materials
    • D06N2205/20—Cured materials, e.g. vulcanised, cross-linked
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
    • Y02P70/50—Manufacturing or production processes characterised by the final manufactured product
    • Y02P70/62—Manufacturing or production processes characterised by the final manufactured product related technologies for production or treatment of textile or flexible materials or products thereof, including footwear

Definitions

  • the present invention relates to polymer-backed articles.
  • the present invention particularly relates to polyurethane-backed articles, latex-backed articles, and to a process used in making same.
  • Articles having attached polyurethane foam layers are well known.
  • carpets and other substrates having attached polyurethane foam layers as backing are described in U.S. Patent Nos.: 3,755,212; 3,821,130; 3,862,879; 4,022,941; 4,171,395; 4,278,482; 4,286,003; 4,296,159; 4,405,393; 4,483,894; 4,512,831; 4,515,646; 4,595,436; 4,611,044; 4,657,790; 4,696,849; 4,853,054; 4,853,280 and, 5,104,693.
  • a filler material is used to prepare a polyurethane formulation for carpet backing.
  • the filler can replace some of the polymer required to prepare a polyurethane backed article, while maintaining bulk in the article. This can lower the cost of production of the article, since materials used as fillers are typically less expensive than the polymer material that is being replaced.
  • Cost reduction can be an incentive for increasing the volume of filler material incorporated into a polymer formulation.
  • the amount of filler can be limited, however, by process parameters which are adversely affected by a high loading of filler.
  • the viscosity of a polyol mixture that includes a high concentration of filler can be increased such that the transport of the polyol mixture through a process line can be difficult or impossible.
  • the difficulty can be exacerbated by contacting the polyol mixture with a polyisocyanate. Attempts to deliver the resulting reactive mixture to a carpet surface can produce line plugging. High viscosity also hinders the ability to properly place the resultant reactive mixture within a textured textile fabric.
  • Non-reactive solvents or diluents can be useful in lowering the viscosity of highly filled polyol mixtures. Use of such diluents is known. However, use of a non- reactive diluent is not without problems. Adding a non-reactive diluent to lower the viscosity of a highly-filled polyol mixture can result in additional process steps to remove the diluent from the final product. Additional process steps or equipment can be required to capture volatile solvent emissions, recover or recycle used diluent, or otherwise dispose of used diluent. In addition, there is extra cost associated with supplying the diluent. These additional measures can add cost to a production process and defeat the purpose of a cost-saving measure.
  • the present invention is a process for preparing a polyurethane- forming reactive mixture useful for preparing a polyurethane-backed article comprising simultaneously metering: (a) an isocyanate-reactive material;
  • the present invention is a process for preparing polyurethane- backed article comprising the steps: (i) simultaneously metering:
  • step (c) a filler; to a means for mixing (a), (b), and (c), thereby forming a polyurethane-forming reactive mixture, wherein the means for mixing (a), (b), and (c) is a low-shear or no-shear mixer; (ii) delivering the reactive mixture of step (i) to a pump;
  • the present invention is a polyurethane-forming reactive mixture
  • a polyurethane-forming reactive mixture comprising: (a) an isocyanate-reactive material; (b) a polyisocyanate; and (c) a filler; wherein the filler is included at a concentration of at least about 300 parts per 100 parts of isocyanate-reactive material, and wherein the mixture is obtained according to the process comprising simultaneously metering: (a) an isocyanate-reactive material; (b) a polyisocyanate; and
  • the present invention is a continuous mixing process, useful for preparing an article having a filled polymer backing, comprising the steps of: (i) simultaneously metering: (a) an aqueous polymer dispersion; and
  • step (b) a filler; to a means for mixing (a) and (b), thereby forming an aqueous polymer/filler dispersion, wherein the means for mixing (a), and (b) is a low-shear or no-shear mixer; (ii) delivering the aqueous dispersion of step (i) to a pump; (iii) pumping the polymer composition to form a coat on a surface of a substrate.
  • the present invention has several benefits. For example, use of the present invention can: (1) reduce the cost of producing articles having attached polymer cushions; (2) eliminate the requirement for additional warehouse space to store blends of polyol and filler for preparing polyurethane-backed articles; and (3) provide flexibility to a carpet or textile fabric manufacturer with respect to the amount and identity of filler incorporated into a particular carpet or textile backing.
  • the present invention is a method for preparing a highly- filled polyurethane-forming reactive mixture.
  • the polyurethane-forming reactive mixture of the present invention comprises: an isocyanate reactive material, for example a polyol as described herein; a polyisocyanate; a filler; and, optionally, a filler wetting agent.
  • an isocyanate reactive material for example a polyol as described herein
  • a polyisocyanate for example a polyol as described herein
  • a polyisocyanate for example a polyol as described herein
  • a filler for example a polyisocyanate
  • filler wetting agent e.g., a filler wetting agent
  • the terms "isocyanate” and “polyisocyanate” can be used interchangeably.
  • the term "highly-filled” as used herein refers to a mixture having at least 300 parts of filler per 100 parts of an isocyanate reactive material. Highly-filled mixtures can be
  • a polyisocyanate is used as a reactive diluent to facilitate the transfer of a polyurethane-forming reactive mixture, without premature viscosity build-up in the mixture.
  • the process of the present invention comprises the mixing of at least three separate streams to form a single reactive stream that can be used to prepare a polyurethane foam.
  • the first stream (SI) includes an isocyanate reactive material such as, for example, an active hydrogen containing compound.
  • Active hydrogen containing compounds are compounds having active hydrogen functionality, wherein at least one hydrogen atom is bonded to an electronegative atom such as sulfur, nitrogen, or oxygen.
  • Active hydrogen containing compounds described herein can contain any combination of hydroxyl , amino, and mercaptyl functionality in addition to other active hydrogen groups and can be reacted with isocyanate groups to form a polyurethane-forming reactive mixture useful for preparing a carpet backing under conditions suitable for carrying out the reaction.
  • Isocyanate-reactive compounds suitable for the practice of the present invention are well-known to those skilled in the art of preparing polyurethane-backed carpets, and are not unique to the present invention.
  • a polyol is an example of an isocyanate-reactive compound of the present invention.
  • a polyol of the present invention can have an average equivalent weight of from 500 to 5000, preferably from 750 to 2500, and more preferably from 750 to 2000.
  • the average equivalent weight of a compound can be determined by dividing the average molecular weight of the compound by the functionality of the compound.
  • polyether polyols While a wide range of materials can be used, polyether polyols are preferred based on their performance and wide availability. Polymers of propylene oxide which are at least partially end-capped with ethylene oxide are particularly preferred.
  • a polyurethane-forming reactive mixture of the present invention also includes a polyisocyanate material added as a second stream (S2).
  • S2 a polyisocyanate material added as a second stream
  • the identity of a polyisocyanate used in the present invention is not critical.
  • the polyisocyanate can be aliphatic or aromatic.
  • Aromatic polyisocyanates suitable for use herein include, for example: phenyl diisocyanate; 2,4-toluene diisocyanate; 2,6-toluene diisocyanate; ditoluene diisocyanate; naphthalene 1 ,4-diisocyanate; 2,4'- or a combination thereof 4,4'-diphenylmethane diisocyanate (MDI); polymethylene polyphenylenepolyisocyanates (polymeric MDI); like compounds, and mixtures thereof.
  • MDI 4,4'-diphenylmethane diisocyanate
  • MDI polymethylene polyphenylenepolyisocyanates
  • Suitable aliphatic polyisocyanates include, for example: 1 ,6-hexamethylene diisocyanate; isophorone diisocyanate; 1 ,4-cyclohexyl diisocyanate; like compounds and mixtures thereof.
  • Prepolymers prepared by reacting a polyol or chain extender with a polyisocyanate are suitable, as well.
  • a polyisocyanate can be used in an amount suitable to prepare a polyurethane- forming composition with an isocyanate index of from 85 to 130.
  • the isocyanate index can be calculated by multiplying the ratio of isocyanate equivalents to active hydrogen equivalents by 100.
  • the isocyanate index is in the range of from 85 to 115.
  • the present invention includes a filler material added as a third stream (S3).
  • S3 is typically added as a dry stream.
  • the filler material can be a conventional filler, such as, for example: milled glass, calcium carbonate, aluminum trihydrate (ATH), talc, bentonite, antimony trioxide, kaolin.
  • the filler material can also be recycled waste material from a carpet manufacturing process.
  • recycled waste material can include: fibrous materials such as lint from a fabric shearing process; and polymer waste that is ground to particle sizes less than 2 mm, including rubber from tires, and polyurethane from carpet underlays.
  • the filler can be fly ash, or any filler or mixture of fillers known to be useful in the art of preparing filled polymers. Any amount of filler can be used in the practice of the present invention, with the caveat that the viscosity of the reactive mixture cannot be too high to allow transfer of the mixture through the process, or result in defective polyurethane coatings, or result in obtaining articles of poor quality.
  • the concentration of filler to be used can be determined by various factors, including the end-use application of the article, the cost of producing the article, or the affect of the filler on the color, texture, or other physical properties of the article. The amount of filler to be used can also depend on process parameters.
  • filler can be loaded at concentrations greater than 300 parts of filler per 100 parts of an isocyanate reactive material to prepare a highly-filled polyurethane.
  • the filler is present at a concentration of from 300 to 1000 parts of filler per 100 parts of isocyanate-reactive material. More preferably the filler is loaded at a concentration of from 300 to 900 parts per 100 parts. Most preferably the filler is loaded at a concentration of from 300 to 800 parts per 100 parts of isocyanate-reactive material.
  • the present invention optionally includes a filler wetting agent.
  • a wetting agent generally performs the function of compatiblizing the filler with the other components of a polyurethane-forming composition.
  • a wetting agent can be particularly useful in preparing a highly-filled polyurethane mixture.
  • Useful filler wetting agents can include ethoxylated phosphate esters in an organic carrier. Examples of suitable wetting agents include: Maphos* 56 (Trade Designation of PPG/Mazer Chemicals), Pegafax* 410 (Trade Designation of Borgwarner Chemicals), and Code 5027 ® ( ® Trade Designation of Fibro Chem, Inc.). Organosilane compounds and organotitanate compounds are suitable, as well.
  • a wetting agent can be included in a polyurethane-forming mixture of the present invention at a concentration of at least about 0.5 parts per 100 parts of filler, by weight.
  • the filler wetting agent is included at a concentration of from 0.5 to 1.5 parts per 100 parts of filler, more preferably from 0.75 to 1.25 parts per 100 parts of filler.
  • the wetting agent can be included in either SI or S2.
  • the wetting agent can alternatively can be added to both streams, as a separate stream, or added after obtaining the mixture in a subsequent step.
  • the present invention is a process by which SI, S2, and S3 are combined to form a single reactive stream fRS) useful for preparing a polyurethane carpet backing.
  • a mixer suitable for the practice of the present invention is a low-shear type mixer, wherein mixing results in a thermal rise of less than 40°F.
  • the observed thermal rise is less than 35 °F, mure preferably less than 30°F.
  • thermal rise is the difference between the temperature of: (1) SI, S2, and S3 as measured before mixing; and (2) RS immediately after mixing.
  • a thermal rise outside of this range can result in a significant viscosity increase in the mixture due to a heat-catalyzed acceleration of the polyurethane-forming reaction.
  • Mixers suitable for the practice of the present invention are known and are available commercially. Suitable low-shear mixers can be obtained from Bepex Corp., Oakes Corp., and Krupp Industrietechnik.
  • a no-shear mixer can be suitable for the prac tice of the present invention.
  • a suitable no- shear mechanical mixing device is described in U.S. Patent No. 5,480,589.
  • a means for cooling the reactive mixture can be provided such that a thermal rise of less than 40°F is observed.
  • a mixer fitted with a cooling reservoir contacting the mixing chamber can be used to cool RS as it is obtained.
  • RS can be cooled in . ⁇ temperature-controlled pipeline to maintain a desirable temperature in the reactive mi, ture as it comes out of the mixer.
  • the reactive mixture of the present invention can be optionally combined in a subsequent step with other materials to obtain a polyurethane-forming composition useful for preparing polyurethane carpet backing.
  • RS can be combined with a catalyst, a filler wetting agent, a chain extender, a surfactant, a blowing agent, a flame retardant, pigments, antistatic agents, reinforcing fibers, antioxidants, preservatives, water scavengers, acid scavengers,.
  • Catalysts useful in the preparation of polyurethane carpet backings are known. Suitable catalysis include tertiary amines, and organometallic compounds, like compounds and mixtures thereof.
  • suitable catalysts include di-n-butyl tin bis(mercaptoacetic acid isooctyl ester), dimethyltin dilaurate, dibutyltin dilaurate, dibutyltin sulfide, stannous octoate, lead octoate, ferric acetylacetonate, bismuth carboxylates, triethylenediamine, N-methyl morpholine, like compounds and mixtures thereof.
  • blowing agents examples include gases such as air, carbon dioxide, nitrogen, argon, helium,; liquids such as water, volatile halogenated alkanes such as the various chlorfiuoromefhanes and chlorfluoroethanes; azo-blowing agents such as azobis(formamide).
  • gases such as air, carbon dioxide, nitrogen, argon, helium,; liquids such as water, volatile halogenated alkanes such as the various chlorfiuoromefhanes and chlorfluoroethanes; azo-blowing agents such as azobis(formamide).
  • gases such as air, carbon dioxide, nitrogen, argon, helium
  • liquids such as water, volatile halogenated alkanes such as the various chlorfiuoromefhanes and chlorfluoroethanes
  • azo-blowing agents such as azobis(formamide).
  • polyurethane-backed carpets In preparing polyurethane-backed carpets according to this invention, the individual components of the polyurethane-forming composition are mixed and applied as a layer of preferably uniform thickness onto one surface of the carpet substrate.
  • conventional mixers are suitable for combining RS with optional components to form a polyurethane-forming composition of the present invention.
  • a polyurethane-forming composition of the present invention can be obtained using equipment such as an Oakes or Firestone foamer, for example.
  • a polyurethane-forming composition of the present invention can be applied to a surface of a carpet substrate and cured to a tack-free state.
  • the polyurethane-forming composition is applied to the backstitch of a tufted carpet substrate.
  • the polyurethane- forming composition is typically applied to the carpet substrate before any substantial curing occurs, using equipment such as a doctor knife, air knife, or extruder to apply and gauge the layer.
  • the polyurethane-forming composition can be formed into a layer on a moving belt or other suitable apparatus and partially cured, then married to the carpet substrate using equipment such as a double belt (also known as double band) laminator or a moving belt with an applied foam cushion.
  • the amount of polyurethane-forming composition used can vary widely, from 5 to 500 ounces per square yard, depending on the characteristics of the textile.
  • the layer is cured using heat from any suitable heat source such as an infrared oven, a convection oven, or heating plates. A temperature of from 100°C to 170°C, and a time of from 1 minute to 60 minutes are suitable for curing the polyurethane.
  • a polyurethane backed carpet can include a precoat and a laminate coat applied to the back of a ca ⁇ et substrate.
  • a backed ca ⁇ et can optionally include an attached foam cushion that is applied to a ca ⁇ et substrate.
  • ca ⁇ ets having attached cushions are prepared by tufting or weaving yarn into a primary backing, applying an adhesive precoat to the primary backing to bind the tufted material into the backing, and then applying a polyurethane foam cushion.
  • Use of any of the polyurethane coats can be optional in the practice of the present invention, as long as at least one coat of polyurethane is applied to a ca ⁇ et substrate.
  • application of a separate polyurethane precoat can be eliminated by application of a sufficient amount of a laminate coat, such that the laminate coat soaks into the carpet weave and performs the function of both a precoat and a laminate coat.
  • a polyurethane foam coat can be applied in an amount sufficient to eliminate separate application of a polyurethane precoat or a combination thereof laminate coat.
  • a polyurethane-forming composition of the present invention can be used to coat a variety of substrates.
  • the composition of the present invention can be used to coat textiles such as: broadloom ca ⁇ et; ca ⁇ et tile; automotive ca ⁇ et; fabrics for automotive trim; paneling and trunk liners; synthetic playing surfaces; tennis ball covers; drapery fabrics; wall-covering fabric; woven and non-woven scrim.
  • the present invention is method of preparing a filled polymer composition that is useful for making polymer-backed articles.
  • a filled polymer composition can be prepared according to the same process used to prepare a polyurethane-forming composition, except that in place of SI and S2, an aqueous polymer dispersion (APD) can be combined with S3 to obtain an aqueous polymer/filler dispersion (PFD).
  • Aqueous polymer dispersions suitable for use in the practice of the present invention are not unique to the present invention, and are known in the art of preparing water-born polymer emulsions.
  • Aqueous polymer dispersions suitable for use in the present invention can be water emulsions of: styrene-butadiene copolymers (SB latex), ethylene-vinyl acetate copolymers (EVA latex), and styene- vinylidene chloride-butadiene tripolymer (SVB latex), for example.
  • SB latex styrene-butadiene copolymers
  • EVA latex ethylene-vinyl acetate copolymers
  • SVB latex styene- vinylidene chloride-butadiene tripolymer
  • An aqueous polymer dispersion used herein can be prepared by any method known in the art of preparing aqueous polymer dispersions. Such methods are described in U.S. Patent No. 3,962,170, for example.
  • a PFD of the present invention can be used to coat a variety of substrates.
  • PFD can be used in the same manner as polyurethane-forming formulations in applications described hereinabove.
  • a PFD of the present invention can be used to coat textiles such as: broadloom ca ⁇ et; ca ⁇ et tile; automotive ca ⁇ et; fabrics for automotive trim; paneling and trunk liners; synthetic playing surfaces; tennis ball covers; drapery fabrics; wall-covering fabric; woven and non-woven scrim.
  • Voranol ® 9120 polyol ( ® Trademark of the Dow Chemical Co.) and dipropylene glycol; 229.6 g/min of Isonate 7594 isocyanate; 16.1 g/min of Code 5027 ® ( ® Trademark of Fibro Chem, Inc.); and 1619.4 g/min of WF75 (CaCO 3 filler available from Georgia Marble Co.).
  • the components were mixed in the Extrud-O-Mix to form a reactive mixture.
  • the reactive mixture exits the mixer into a receiver for a Roper model pump that delivers the material to a Kenics static mixer, where a 10 wt percent solution of Fomrez ® ( ® Trademark of the Witco Chemical Co.) UL6 catalyst in Voranol ® 9287 polyol ( ® Trademark of the Dow Chemical Co.) was added at a rate of 0.9 g/min.
  • the catalyzed polyurethane-forming composition was then applied to the back of a contract level loop grade of Structures II ca ⁇ et (available from Shaw industries) and was cured in an oven for 8 minutes at 149°C.
  • the results of testing the ca ⁇ et were: coating weight - 1349 g/m 2 ; tuft bind - 8.7 Kg; edge curl - 0.6 cm; edge ravel - 1.27 Kg; and, hand punch - 13.3 Kg.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Dispersion Chemistry (AREA)
  • Manufacturing & Machinery (AREA)
  • Health & Medical Sciences (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Polyurethanes Or Polyureas (AREA)

Abstract

Cette invention concerne un processus continu de préparation de formulations qui sont utilisées dans la fabrication de couches de support de moquettes à base de polymères comportant des matières de charge. Cette invention fait plus particulièrement appel à un polyisocyanate qui est utilisé en qualité de diluant réactif lors du processus continu de préparation de polymères de polyuréthanne comportant des matières de charge. Cette invention permet de produire des couches de support de moquettes qui comprennent des quantités importantes de matières de charge.
PCT/US1997/020848 1996-12-10 1997-11-05 Preparation selon un processus de melange continu et en ligne de formulations utilisees dans la fabrication de couches de support de moquettes a base de polyurethanne reactif et comportant des matieres de charge WO1998025984A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU54390/98A AU5439098A (en) 1996-12-10 1997-11-05 Preparation of filed reactive polyurethane carpet backing formulations using an in-line continuous mixing process

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US3312796P 1996-12-10 1996-12-10
US60/033,127 1996-12-10

Publications (1)

Publication Number Publication Date
WO1998025984A1 true WO1998025984A1 (fr) 1998-06-18

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PCT/US1997/020848 WO1998025984A1 (fr) 1996-12-10 1997-11-05 Preparation selon un processus de melange continu et en ligne de formulations utilisees dans la fabrication de couches de support de moquettes a base de polyurethanne reactif et comportant des matieres de charge

Country Status (4)

Country Link
AR (1) AR010680A1 (fr)
AU (1) AU5439098A (fr)
WO (1) WO1998025984A1 (fr)
ZA (1) ZA9710739B (fr)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6676754B1 (en) 2000-06-30 2004-01-13 3M Innovative Properties Company Coating apparatus and methods of applying a polymer coating
WO2004035910A1 (fr) * 2002-10-15 2004-04-29 Dow Global Technologies Inc. Procede de preparation d'un dossier de moquette au moyen de residus de moquette recycles
US7491775B2 (en) 2005-03-24 2009-02-17 Rohm And Haas Company Polymerization processes

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4171395A (en) * 1977-03-30 1979-10-16 Tillotson John G Method and apparatus for forming a layer of foam urethane on a carpet backing and product
EP0005549A2 (fr) * 1978-05-24 1979-11-28 Mobay Chemical Corporation Procédé de préparation de textiles enduits de mousse de polyuréthanes
US4515646A (en) * 1983-11-22 1985-05-07 Paul Walker Method for applying polyurethane backing
US4715912A (en) * 1977-03-30 1987-12-29 Tillotson John G Method for forming a layer of blown cellular urethane on a carpet backing
US4916183A (en) * 1987-05-06 1990-04-10 National Starch And Chemical Corporation Copolymers as thickeners and modifiers for latex systems
EP0427295A1 (fr) * 1985-05-28 1991-05-15 The Dow Chemical Company Procédé de préparation d'un substrat possédant un support en polyuréthane
US5096764A (en) * 1990-09-12 1992-03-17 Heuga Holding Bv Printable carpet tile and method

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4171395A (en) * 1977-03-30 1979-10-16 Tillotson John G Method and apparatus for forming a layer of foam urethane on a carpet backing and product
US4715912A (en) * 1977-03-30 1987-12-29 Tillotson John G Method for forming a layer of blown cellular urethane on a carpet backing
EP0005549A2 (fr) * 1978-05-24 1979-11-28 Mobay Chemical Corporation Procédé de préparation de textiles enduits de mousse de polyuréthanes
US4515646A (en) * 1983-11-22 1985-05-07 Paul Walker Method for applying polyurethane backing
EP0427295A1 (fr) * 1985-05-28 1991-05-15 The Dow Chemical Company Procédé de préparation d'un substrat possédant un support en polyuréthane
US4916183A (en) * 1987-05-06 1990-04-10 National Starch And Chemical Corporation Copolymers as thickeners and modifiers for latex systems
US5096764A (en) * 1990-09-12 1992-03-17 Heuga Holding Bv Printable carpet tile and method

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6676754B1 (en) 2000-06-30 2004-01-13 3M Innovative Properties Company Coating apparatus and methods of applying a polymer coating
US6991745B2 (en) 2000-06-30 2006-01-31 3M Innovative Properties Company Coating apparatus and methods of applying a polymer coating
WO2004035910A1 (fr) * 2002-10-15 2004-04-29 Dow Global Technologies Inc. Procede de preparation d'un dossier de moquette au moyen de residus de moquette recycles
US7491775B2 (en) 2005-03-24 2009-02-17 Rohm And Haas Company Polymerization processes

Also Published As

Publication number Publication date
AR010680A1 (es) 2000-06-28
ZA9710739B (en) 1999-05-28
AU5439098A (en) 1998-07-03

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