Classifications

• • 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
  • C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
  • C08G18/30—Low-molecular-weight compounds
  • C08G18/36—Hydroxylated esters of higher fatty acids
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B27/00—Layered products comprising a layer of synthetic resin
  • B32B27/40—Layered products comprising a layer of synthetic resin comprising polyurethanes
• • 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
  • C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
  • C08G18/40—High-molecular-weight compounds
  • C08G18/42—Polycondensates having carboxylic or carbonic ester groups in the main chain
• • 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
  • C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
  • C08G18/40—High-molecular-weight compounds
  • C08G18/42—Polycondensates having carboxylic or carbonic ester groups in the main chain
  • C08G18/4288—Polycondensates having carboxylic or carbonic ester groups in the main chain modified by higher fatty oils or their acids or by resin acids
• • 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
  • C08G18/82—Post-polymerisation treatment
• • 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
• • 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
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/23907—Pile or nap type surface or component
  • Y10T428/23914—Interlaminar
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/23907—Pile or nap type surface or component
  • Y10T428/23979—Particular backing structure or composition
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/23907—Pile or nap type surface or component
  • Y10T428/23993—Composition of pile or adhesive
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/31504—Composite [nonstructural laminate]
  • Y10T428/31551—Of polyamidoester [polyurethane, polyisocyanate, polycarbamate, etc.]

Definitions

• the invention relates to tufted or woven carpet having a polynrethane backing, and to methods of making such carpet.
• Tufted carpets are manufactured by tufting fiber bundles through a primary backing and securing them to the primary backing with a precoat.
• the tufted carpets may also have additional layers such as a laminate layer, a secondary backing layer and a foam layer.
• Woven carpets are often manufactured similarly, except that the fiber bundles are woven through the primary backing.
• the precoat anchors the fiber bundles to the primary backing, providing fiber lock properties like good pilling and fuzzing resistance, good tuftbind and good edge ravel.
• the precoat is usually called upon to contribute to other desirable attributes of the carpet such as dimensional stability, flame retardancy, antimicrobial/antifungal activity and liquid barrier functionality.
• the tufted or woven carpet is often laminated to a so-called "secondary backing", which provides characteristics such as improved dimensional stability and/or acts as a release backing that allows the carpet to be easily removed from a glue-down installation.
• a laminate layer is commonly used to adhere this secondary backing to the carpet.
• Polyurethanes can be used as the precoat and/or the laminate layer.
• Polyurethane precoat systems are described, for example, in U.S. Pat. No. 4,296,159 to Jenkines et al. and U. S. Patent No. 4,696,849 to Mobley et al. Polyurethane precoat systems of this type are useful as the laminate layer, too.
• the polyurethanes described in these patents are formed from a polyisocyanate and a polyol compound.
• the polyol compounds that are most widely used in polyurethane applications, including carpet precoats, are polyether or polyester polyols that are derived mainly from petroleum- based feedstocks.
• Most vegetable oils are mixtures of fatty acid triglycerides that do not have isocyanate-reactive functionality. It is therefore necessary to modify the triglycerides to introduce the needed functional groups. This is commonly accomplished by performing a transesterification reaction between a polyol compound and either the triglyceride itself or a fatty acid or fatty acid ester obtained from the triglyceride. This reaction creates compounds having one or two fatty acid ester groups and one or more free hydroxyl groups. In order to increase the hydroxyl functionality, the triglycerides or corresponding fatty acids can be "blown" or reacted with moist air to couple them.
• the conventional polyols mostly have their hydroxyl groups located at the chain ends. Vegetable oil-based polyols as described above usually have closely spaced hydroxyl groups and a free hydrocarbon tail that is not isocyanate-reactive at one end. This leads to profound differences in the chain structure of the polyurethane. Still another problem is that the vegetable oil-based polyols are mixtures of molecules that have significant variations in their structures. This leads to still further differences in the structure of the ensuing polyurethane, compared to polyurethanes made using conventional polyols. The variations can lead to unpredictability in the properties of the polyurethane.
• fatty acids contained in vegetable oils vary in terms of chain length, number and position of unsaturated sites and/or functional groups (such as hydroxyl groups), among the different types of vegetable oils and even within lots of a single type of oil. This variability introduces still more unpredictability in the performance of these polyols. 63876AWO
• this invention is a carpet having a substantially noncellular polyurethane carpet backing, wherein the polyurethane is the reaction product of a polyisocyanate component and a polyol component containing a mixture of isocyanate- reactive materials of which one or more optionally alkoxylated hydroxymethyl- containing polyester polyols constitutes from 25 to 90% by weight.
• this invention is a carpet comprising (I) a primary backing,
• polyurethane is the reaction product of a polyisocyanate component and a polyol component containing a mixture of isocyanate-reactive materials of which one or more optionally alkoxylated hydroxymethyl-containing polyester polyols constitutes from 25 to 90% by weight.
• This invention is a method comprising Q) applying a polyurethane-forming composition to the underside of a carpet having a primary backing and a yarn tufted or woven through the primary backing to form a yarn bundle on the underside of the carpet and QI) curing the polyurethane-forming composition to form a polyurethane coating that adheres the yarn bundle to the primary backing, wherein the polyurethane-forming composition includes a polyisocyanate component and a polyol component containing a 63876AWO
• This invention is also a carpet comprising a primary backing and a secondary backing adhered directly or indirectly to the primary backing with a polyurethane laminate layer, wherein the polyurethane laminate layer is the reaction product of a polyisocyanate component and a polyol component containing a mixture of isocyanate- reactive materials of which one or more optionally alkoxylated hydroxymethyl- containing polyester polyols constitutes 25 to 90% by weight.
• This invention is also a method for adhering a secondary backing to a carpet, comprising applying a polyurethane-forming composition to the secondary backing or to the carpet, joining the carpet to the secondary backing such that the polyurethane- forming composition is intermediate to the secondary backing and the carpet, and curing the polyurethane-forming composition, wherein the polyurethane-forming composition includes a polyisocyanate component and a polyol component containing a mixture of isocyanate-reactive materials of which one or more optionally alkoxylated fatty acid amide polyols constitute from 25 to 90% by weight.
• carpet meeting necessary standards of performance for commercial applications can be prepared in accordance with the invention, using a significant proportion of a polyol derived from renewable resources such as vegetable oil or animal fat.
• the carpet includes a primary backing that defines multiple openings through which a facing fiber is tufted or woven to produce a carpet face.
• the primary backing is generally in the form of a woven or nonwoven scrim, and can be made of any convenient material, such as, for example, jute, polypropylene, nylon, a polyester, a polyacrylate, cotton, wool, or other material.
• the facing fiber also can be of any convenient material, such as wool, cotton, nylon, a polyester, an acrylic fiber, polypropylene, polyethylene, a blend of any two or more of these, or the like.
• the primary backing and the facing fiber should be stable under the conditions at which the polyurethane precoat is applied and cured, so the carpet does not degrade or become distorted.
• the facing fiber is typically in the form of fiber bundles that are tufted or woven through the primary backing to produce a carpet face and an opposing underside.
• a polyurethane-forming composition is applied to the underside of the carpet to wet out the fiber bundles and adhere them to the primary backing. This is conveniently done by creating a puddle of the polyurethane-forming composition on the underside of 63876AWO
• the carpet and mechanically spreading the composition over the back surface It is often convenient to froth the composition before applying it, as frothing makes it easier to control coating weight. It is preferred to use a doctor blade or similar apparatus to spread the polyurethane-forming composition, as this method mechanically pushes the polyurethane-forming composition into and between the fiber bundles and into contact with the primary backing, thereby improving the bond between the fibers and primary backing.
• the polyurethane-forming composition is allowed to cure to form a polyurethane polymer. This curing can occur at room temperature ( ⁇ 22°C), but it is generally desirable to apply heat to accelerate the cure.
• a suitable curing temperature is from 100 to 200 0 C, such as from 110 to 150 0 C. It is desired that the curing temperature be such that the formulation cures to a taek-free state in 4 minutes or less, preferably 2.5 minutes or less and more preferably in 2 minutes or less.
• the spreading and curing process generally will remove gasses entrapped in the polyurethane-forming composition if the composition is frothed prior to application, except if the composition contains a surfactant or other foam stabilizer. It is usually preferred that the precoat be non-cellular.
• the carpet is preferably stretched no more than 2% in either the weft (cross machine) or warp (machine) direction, and more preferably no more than 0.75%, during the precoating process.
• the carpet may be heated slightly prior to applying the polyurethane-forming composition.
• the carpet is preferably dry, as residual moisture can react with the polyisocyanate component of the polyurethane- forming composition to generate a gas. Gas generation leads to forming a cellular structure in the precoat or at the interface of the precoat and the carpet, which is generally undesirable.
• the polyurethane-forming composition includes a polyisocyanate component and a polyol component.
• the polyisocyanate component includes at least one organic polyisocyanate, which may be an aromatic, cycloaliphatic, or aliphatic isocyanate.
• suitable polyisocyanates include m-phenylene diisocyanate, tolylene-2-4- diisocyanate, tolylene-2-6-diisocyanate, hexamethylene- 1,6-d ⁇ socyanate, tetramethylene- 1,4-diisocyanate, cyclohexane- 1,4-diisocyanate, hexahydrotolylene diisocyanate, naphthylene- 1,5-diisocyanate, methoxyphenyl-2,4-diisocyanate, diphenylmethane-4,4'-diisocyanate, 4,4'-biphenylene diisocyanate, 3,3'-dimethoxy-4,4'- 63876AWO
• biphenyl diisocyanate 3,3'-dimetliyl-4-4'-biphenyl d ⁇ socyanate, 3,3'-dimethyldiphenyl methane-4,4'-diisocyanate, 4,4',4"-triphenyl methane triisocyanate, a polymethylene polyphenylisocyanate (PMDI), tolylene-2,4,6-triisocyanate and 4,4'- dimethyldiphenybnethane-2,2',5,5'-tetraisocyanate.
• PMDI polymethylene polyphenylisocyanate
• tolylene-2,4,6-triisocyanate 4,4'- dimethyldiphenybnethane-2,2',5,5'-tetraisocyanate.
• the polyisocyanate is diphenylmethane-4,4'-diisocyanate, diphenylmethane-2,4'-diisocyanate, PMDI, tolylene- 2-4-d ⁇ socyanate, tolylene-2-6-diisocyanate or mixtures thereof.
• Diphenylmethane-4,4'- diisocyanate, diphenylmethane-2,4'-diisocyanate and mixtures thereof are generically referred to as MDI, and all can be used.
• Tolylene-2,4-diisocyanate, tolylene-2,6- diisocyanate and mixtures thereof are generically referred to as TDI, and all can be used.
• Prepolymers made by reacting a stoichiometric excess of any of the foregoing polyisocyanates with an isocyanate-reactive compound such as those described below can be used as well.
• the polyol component includes a mixture of isocyanate-reactive compounds.
• 25 to 90%, such as from 25 to 75%, from 30 to 60% or from 30 to 50%, of the total weight isocyanate-reactive compounds is one or more hydroxymethyl-containing polyester polyols.
• the hydroxymethyl-containing polyester polyol(s) have an average of at least 1.8, preferably at least 2.0 hydroxyl, primary and secondary amine groups combined per molecule. Hydroxyl groups are preferred.
• the hydroxymethyl group-containing polyester polyol may have an average of up to 3 hydroxyl, primary and secondary amine groups combined per molecule, but preferably no more than about 2.5 such groups and even more preferably no more than about 2.25 such groups.
• the hydroxymethyl- containing polyester polyol has an equivalent weight of at least 400, such as at least about 600, at least about 650, at least about 700, or at least about 725, to about 15,000, such as to about 6000, to about 3500, up to about 1700, up to about 1300, or to about 1000. Equivalent weight is equal to the number average molecular weight of the molecule divided by the combined number of hydroxyl, primary amine and secondary amine groups.
• hydroxymethyl-containing polyester polyols of this type are described in detail in WO 04/096882 and WO 04/096883.
• the hydroxymethyl-containing polyester polyol is conveniently prepared by reacting a hydroxymethyl-group containing fatty acid having from 12 to 26 carbon atoms, or an ester of such a hydroxymethylated fatty acid, with a 63876AWO
• polyol, hydroxylan ⁇ ine or polyamine initiator compound having an average of at least 2.0 hydroxyl, primary amine and/or secondary amine groups/molecule.
• Proportions of starting materials and reaction conditions are selected such that the resulting hydroxymethyl-containing polyester polyol contains an average of at least 1.3 repeating units derived from the hydroxmethyl-group containing fatty acid or ester thereof for each hydroxyl, primary amine and secondary amine group in the initiator compound, and the hydroxymethyl-containing polyester polyol has an equivalent weight of at least 400 up to about 15,000.
• R is the residue of an initiator compound having z hydroxyl and/or primary or secondary amine groups, where z is at least two; each X is independently — O — , — NH — or — NR' — in which R' is an inertly substituted alkyl, aryl, cycloalkyl, or aralkyl group, p is a number from 1 to z representing the average number of [X — Z] groups per hydroxymethyl-containing polyester polyol molecule, Z is a linear or branched chain containing one or more A groups, provided that the average number of A groups per molecule is > 1.3 times z, and each A is independently selected from the group consisting of Al, A2, A3, A4 and A5, provided that at least some A groups are Al, A2 or A3.
• Al is:
• B is H or a covalent bond to a carbonyl carbon atom of another A group; m is number greater than 3, n is greater than or equal to zero and m + n is from 8 to 22, especially from 11 to 19.
• A2 is:
• v is a number greater than 3
• r and s are each numbers greater than or equal to zero with v + r + s being from 6 to 20, especially 10 to 18.
• A3 is:
• R' is a linear or branched alkyl group that is substituted with at least one cyclic ether group and optionally one or more hydroxyl groups or other ether groups.
• the cyclic ether group may be saturated or unsaturated and may contain other inert substitution.
• the hydroxyl groups may be on the alkyl chain or on the cyclic ether group, or both.
• the alkyl group may include a second terminal -C(O) - or -C(O)O- group through which it may bond to another initiator molecule.
• A5 groups in general are lactols, lactones, saturated or unsaturated cyclic ethers or dimers that are formed as impurities during the manufacture of the hydroxyhnethyl-group containing fatty acid or ester.
• A5 groups may contain from 12 to 50 carbon atoms.
• n is preferably from 2 to 8, more preferably from 2 to 6, even more preferably from 2 to 5 and especially from about 3 to 5.
• Each X is preferably — O — .
• the total average number of A groups per hydroxymethylated polyester polyol molecule is preferably at least 1.5 times the value of z, such from about 1.5 to about 10 times the value of z, about 2 to about 10 times the value of z or from about 2 to about 5 times the value of z. 63876AWO
• A is preferably Al, a mixture of Al and A2, a mixture of Al and A4, a mixture of Al, A2 and A4, a mixture of Al, A2 and A3, or a mixture of Al, A2, A3 and A4, in each case optionally containing a quantity of A5.
• Mixtures of Al and A2 preferably contain Al and A2 groups in a mole ratio of 10:90 to 95:5, particularly from 60:40 to 90:10.
• Mixtures of Al and A4 preferably contain Al and A4 groups in a mole ratio of 99.9:0.1 to 70:30, especially in a ratio of from 99.9:0.1 to 85:15.
• Mixtures of Al, A2 and A4 preferably contain from about 10 to 95 mole percent Al groups, 5 to 90 percent A2 groups and up to about 30 percent A4 groups. More preferred mixtures of Al, A2 and A4 contain about 25-70 mole-% Al groups, 15-40% A2 groups and up to 30% A4 groups.
• Mixtures of Al, A2 and A3 preferably contain from about 30-80 mole-% Al, from 10-60% A2 and from 0.1 to 10% A3 groups.
• Mixtures of Al, A2, A3 and A4 groups preferably contain from 20 to 50 mole percent Al, 1 to about 65 percent A2, from 0.1 to about 10 percent A3 and up to 30 percent A4 groups.
• polyester polyols of the invention contain a mixture of about 20-50% Al groups, 20-50% A2 groups, 0.5 to 4% A3 groups and 15-30% A4 groups.
• A5 groups advantageously constitute from 0-7%, especially from 0-5%, of all A groups.
• Preferred mixtures of A groups conveniently contain an average of about 0.8 to about 1.5 -CH2OH and.or -CH2OB groups/A group, such as from about 0.9 to about 1.3 -CH2OH and.or -CH2OB groups/A group or from about 0.95 to about 1.2 -CH2OH and/or -CH2OB groups/A group.
• Such proportions of A groups (1) allow the initiator functionality to mainly determine the functionality the polyester polyol and (2) tend to form less densely branched polyester polyols.
• “Inertly substituted” groups are groups that do not react with an isocyanate group and which do not otherwise engage in side reactions during the preparation of the hydroxymethyl-group containing polyester polyol.
• inert substituents include aryl, eycloalkyl, silyl, halogen (especially fluorine, chlorine or bromine), nitro, ether, ester, and the like.
• the hydroxymethyl-containing polyester polyol generally contains some unreacted initiator compound, and may contain unreacted hydroxymethylated fatty acids (or esters). Initiator compounds often react only monofunctionally or difunctionally with the fatty acids (or esters), and resulting polyester polyol often contains free hydroxyl or amino groups bonded directly to the residue of the initiator compound. 63876AWO
• the hydroxymethyl-containing polyester polyol may be alkoxylated, if desired, to introduce polyether chains onto one or more of the hydroxymethyl groups.
• the hydroxymethyl-containing polyester polyol may also be aminated through reaction with ammonia or a primary amine, followed by hydrogenation, to replace the hydroxy! groups 5 with primary or secondary amine groups.
• Primary or secondary amine groups can also be introduced by capping the polyester polyol with a diisocyanate, and then converting the terminal isocyanate groups so introduced to amino groups through reaction with water.
• the polyol component includes other isocyanate-reactive materials in addition to 10 the hydroxymethyl-containing polyester polyol. These other materials may constitute from 10% up to 80% of the total weight of all isocyanate-reactive materials (including the hydroxymethylated polyester polyol materials described above). These other isocyanate-reactive materials include those having an average of from 2 to 6, especially from 2 to 3 isocyanate-reactive groups per molecule.
• the isocyanate-reactive groups are 15 preferably primary or secondary hydroxyl groups, but may be amino groups or other isocyanate-reactive groups.
• the additional isocyanate-reactive materials preferably include at least one high equivalent weight polyol having a hydroxyl equivalent weight of at least 400, especially from about 500 to about 1500 and preferably from 800 to 1200.
• This polyol preferably 20 has a nominal functionality of 2 to 3 and an actual functionality in the range of 1.8 to 3.0.
• the "nominal" functionality is the number of functional groups expected to be present on the polyol based on the composition of the starting materials. The actual functionality is sometimes somewhat lower, especially with polyether polyols which tend to contain some terminal unsaturation that reduces average functionality somewhat.
• the additional high equivalent weight polyol may be a polyether polyol, such as a polymer of ethylene oxide, propylene oxide, tetrahydrofuran or butylene oxide, or a j mixture of two or more of these.
• Particularly suitable polyether polyols include polymers
• These polyols are conveniently prepared by adding the corresponding alkylene oxide to an initiator material such as a low molecular weight i compound containing two or more hydroxyl and/or primary or secondary amine groups.
• Polyester polyols such as polycaprolatone and butanediol/adipate polyesters can also be used as an additional high equivalent weight polyol.
• the additional high equivalent weight polyol will in general constitute from about 10 to about 80% of the total weight of the isocyanate-reactive materials. Preferably, it will constitute about 30-65% by weight, and especially from about 40-65% by weight of the isocyanate-reactive materials.
• a chain extender is also preferably present in the polyol composition.
• a chain extender is a material other than the hydroxymethyl- containing polyester polyol and the additional high equivalent weight polyols discussed above, having two isocyanate-reactive groups/molecule and an equivalent weight per isocyanate-reactive group of from about 30 to 150. Chain extenders having two hydroxyl groups are preferred.
• chain extenders examples include ethylene glycol, diethylene glycol, triethylene glycol, propylene glycol, dipropylene glycol, tripropylene glycol, 1,4-dimethylolcyclohexane, diethyltoluene diamine, 1,4-butane diol, 1,6-hexane diol, 1,3-propane diol, amine-terminated polyethers such as Jeffamine D-400 (from
• Amine chain extenders can be blocked, encapsulated, or otherwise rendered less reactive. Chain extenders advantageously constitute up to about 20%, especially up to about 15% of the combined weight of all isocyanate-reactive materials.
• a crosslinker is a compound having three or more isocyanate reactive groups and an equivalent weight per isocyanate-reactive group of 150 or less.
• the isocyanate-reactive groups may be hydroxyl, primary amine or secondary amine groups.
• the reactive ingredients i.e., the polyisocyanates and isocyanate- reactive compounds
• the reactive ingredients are selected so that collectively they have an average of about 1.8 to about 2.5, especially from about 1.8 to about 2.3, reactive groups per molecule.
• the somewhat low average functionality produces a polyurethane that is at most only lightly crosslinked, which promotes dimensional stability in the carpet, as evidenced by low edge curl values. 63876AWO
• a particularly preferred average actual functionality for the isocyanate- reactive components is from 1.97 to 2.03.
• a particularly preferred isocyanate index is from 85 to about 125.
• the polyurethane-forming composition preferably contains a filler, which reduces overall cost and may improve flame resistance and other physical properties.
• the filler advantageously constitutes from about 20 to about 80 percent, such from 30 to 70, 50 to 65 or 55 to 60 percent, of the total weight of the polyurethane-forming composition.
• Suitable fillers include talc, mica, montmorillonite, marble, milled glass granite, milled glass, calcium carbonate, aluminum trihydrate, carbon, aramid, silica, silica-alumina, zirconia, talc, bentonite, antimony trioxide, kaolin, coal based fly ash and boron nitride.
• the polyurethane-forming composition also preferably contains one or more catalysts, which promote the reaction of the polyisocyanate with the isocyanate-reactive materials.
• Suitable catalysts include tertiary amines, organometallic compounds, or mixtures thereof.
• An amine-blocked tin (TV) catalyst such as those described in U. S. Patent No. 5,491,174, can be used.
• An amount of catalyst is advantageously employed such that a relatively rapid cure to a tack-free state can be obtained, while providing enough open time that the polyurethane composition can be dispensed and spread over the carpet back before curing.
• an organometallic catalyst is employed, such a cure can be obtained using from about 0.01 to about 0.5 parts per 100 parts of the polyurethane- forming composition, by weight.
• a tertiary amine catalyst is employed, the catalyst preferably provides a suitable cure using from about 0.01 to about 3 parts of tertiary amine catalyst per 100 parts of the polyurethane-forming composition, by weight.
• An amine type catalyst and an organometallic catalyst can be employed in combination.
• additives may be used, including fire retardants, pigments, antistatic agents, reinforcing fibers, antioxidants, preservatives, acid scavengers, and the like. It is usually preferred not to include a blowing agent.
• Components are preferably dried to remove residual water.
• the polyurethane-forming composition preferably contains less than 0.1% by weight water, so as to avoid a gas-generating reaction with the 63876AWO
• polyisocyanate In order to provide a non-cellular coating, it is preferred to eliminate or minimize the presence of surfactants and foam stabilizers. The elimination of these materials permits the formulation to be frothed in order to control coating weight, while then allowing the entrapped gases to escape before the formulation is cured.
• the polyurethane composition is conveniently formed into a blended polyol component, which includes all isocyanate-reactive materials, and a polyisocyanate component.
• the filler is typically blended into the polyol component. Catalysts may be added to either the polyol or polyisocyanate component (preferably the polyol component) or added as one or more separate streams.
• the amount of polyisocyanate used is conveniently sufficient to provide an isocyanate index, i.e. 100 times the ratio of NCO groups to isocyanate-reactive groups in the reaction mixture of from about 95 to about 140, preferably about 85 to 125, and especially from about 100 to 115.
• a convenient coating weight is from about 20 to about 45 ounces/square yard (0.68-1.53 kg/m 2 ), and in particular from about 25-35 ounces per square yard (0.85-1.19 kg/m 2 ).
• the precoated carpet advantageously exhibits a tuftbind, measured according to ASTM D 1335, of at least 10 Ib (44.5N), more preferably at least 13 Ib (58N) and even more preferably at least 15 Ib (67N).
• the tuftbind is advantageously at least 0.40 lb/ounce/square yard (5.38 ⁇ r 2 ), preferably at least 0.48 (6.46 ⁇ r 2 ) and more preferably at least about 0.52 lb/ounce/square yard (7 nr 2 ), with coating weights in the 25-35 ounce/square yard (0.85- 1.19 kg/m 2 ) range.
• Wet tuftbind values are advantageously at least 5.5 Ib (24N), more preferably at least 8.8 Ib (39N) and even more preferably at least 11 Ib (49N).
• wet tuftbinds Normalized to coating weight (for coating weights in the 25-35 ounces/square yard (0.85- 1.19 kg/m 2 ) range), wet tuftbinds of at least 0.26 lb/ounce/square yard (3.5 nr 2 ), such as at least 0.35 (4.71 ⁇ r 2 ) or at least 0.40 lb/ounce/square yard (5.38 ⁇ r 2 ) are desirable.
• Wet tuftbind is measured according to ASTM D 1335 after soaking the carpet sample in room temperature tap water for 20 minutes.
• the precoated carpet desirably has an edge curl of no greater than 2.54 cm, preferably no greater than 1.8 cm, more preferably no greater than 1.3 cm and even more preferably no greater than 0.8 cm, in each of the machine and cross machine direction.
• the precoated carpet also advantageously exhibits excellent pilling and fuzzing resistance and high edge ravel (such as greater than >78N, especially greater than 98N or greater than 108N on the test described below).
• the coated carpet preferably exhibits 63876AWO
• the precoated carpet also advantageously exhibits good flame retardancy, antimicrobial/antifungal activity, low 24-hour total volatile organic components (TVOC), good liquid barrier functionality as measured by the British spill passage test (United Kingdom Health Care Specifications Method E), and excellent castor chair resistance to backing delamination and zippering (measured according to the Feingerate Baumberg Roller Chair Testing Device, ASTM D6962).
• the carpet of the invention may contain components in addition to those described above. Examples of these include a secondary backing, an attached foam cushion, a non- woven secondary fabric, a release layer, one or more moisture barrier layers, and the like.
• the precoat formulation described herein may be used to adhere any of these additional components to the carpet structure.
• a secondary backing may be laid into the precoat layer prior to the curing step. Subsequent curing of the precoat layer will then bond the secondary backing to the carpet. It is possible to apply the precoat to the secondary backing first, and then bring the tufted or carpet into contact with the precoated secondary backing, followed by a curing step. However, this latter method often does not permit good penetration of the precoat into and around the fiber bundles, and tuftbind and other properties sometimes suffer as a result.
• the precoat formulation of the invention is coated on the back of the carpet, spread so it penetrates through and between the tufted or woven fiber bundles, and cured. If it is then desired to use this polyurethane formulation as a lamination layer for attaching a secondary backing or other component, an additional layer of the formulation is then applied (atop the precoat layer or onto the other component), the carpet and secondary backing or other component are brought together, and the polyurethane is cured.
• the carpet backings of the invention have particular applicability in the residential and commercial carpet industry as well as in carpeting for recreational use, such as boats, cars, patios, synthetic tuft, etc.
• a preferred practice is to use the precoat formulations of this invention as scrape-down unitary coatings for artificial or synthetic tuft for football fields, soccer fields and the like.
• HMPP A Hydroxymethyl containing polyester polyol A
• HMPP A Hydroxymethyl containing polyester polyol A
• Soy Oil Polyol A is a 130-OH-number functional blown soy oil polyol transesterified with a blend of sucrose and glycerin, sold as SoyOylTM GC5N by Urethane Soy Systems Corporation.
• Polyether Polyol A is a 2000 molecular weight, nominally difunctional poly(propylene oxide). It is available commercially as Voranol® 9120A polyol from Dow Chemical.
• Polyether Polyol B is a 2000 molecular weight, nominally difunctional poly(propylene oxide) end-capped with 12 percent ethylene oxide, available commercially as Voranol® 9287A polyol from Dow Chemical.
• Calcium carbonate A is a quarried calcium carbonate ground such that 70 weight percent passes through a 325 mesh screen. It is available commercially as Georgia Marble D70 from Georgia Marble Company.
• Polyisocyanate A is a 50/50 blend of a 2.3 functional, 32%-NCO polymeric MDI and an MDI prepolymer (181 LE.). 2,4'-MDI constitutes 14% of the total weight of the polymeric MDI.
• the MDI prepolymer is made from dipropylene glycol, tripropylene glycol and a pure MDI containing 2.6 weight percent of the 2,4'-isomer.
• Catalyst A is a blend of 10% of a dibutyltin diisooctylmercaptoacetate delayed action catalyst, commercially available as FomrezTM UL6 from OSI Specialties, in Polyether Polyol B
• Catalyst B is a blend of 20% dibutyltin dilaurate (DabcoTM T12, from Air Products and Chemicals, Inc.) in Polyether Polyol B.
• a polyol blend is prepared from the following components: 63876AWO
• the polyols, chain extenders and filler are blended using a 2.54 cm diameter Cowels blade at about 49°C.
• the compounded polyol blend is then cooled to 25°C.
• the compounded polyol blend of Example 1 has a Brookfield viscosity (#6 spindle, 20 rpm) of 23,800 cps.
• the viscosity of Comparative Sample A is
• the precoated carpet is allowed to condition for one day under ASTM D 1335 conditions, and is tested for coating weight, hand, tuftbind, wet tuftbind, edge ravel and edge curl.
• Tuftbind is measured according to ASTM D 1335.
• Wet tuftbind is measured according to ASTM D 1335, after first immersing the sample in room temperature tap water for 20 minutes.
• Edge curl is measured by first submerging three 2" X 6" (5 cm X 15 cm) carpet samples in room temperature water for 30 seconds. Excess water is shaken off the samples and they are placed face up on a flat surface. A panel is applied over the 63876AWO
• Hand punch is measured by a test that simulates the action of pushing the carpet into a corner during installation.
• a 9" X 12" (21.6 cm X 30.5 cm) sample of the carpet is conditioned at 50% relative humidity and 25°C for two hours.
• the carpet is placed face up over a hollow cylinder with a 5.5" (14 cm) internal diameter.
• An Instron 4465 tensile tester is equipped with a IkN compression/extension load cell and a compression foot having a 2.25" (5.7 cm) outside diameter.
• the compression foot is then forced 0.65 inch (1.65 cm) into the carpet at a rate of 12 inches/minute (30 cm/minute).
• the force at 0.5 inch (1.27 cm) deflection is reported.
• the test is repeated three more times, with the carpet being reversed each time.
• "Hand" is the average of the four measurements.
• Edge ravel is measured on samples conditioned at ⁇ 21°C and ⁇ 50% humidity for 24 hours. Tuft rows are pulled from the sample until two complete rows are pulled out. About 1-/4 to 2 inches (4-5 cm) of a third row is pulled out, leaving the resulting partially pulled row otherwise attached to the carpet.
• the sample is placed in the lower jaw of an Instron 4465 tensile tester equipped with 100 Ib (45 kg) tension cell, and the free end of the partially pulled tuft row is placed in the upper jaw. The jaws are then pulled apart at the rate of 10 inches (25.4 cm)/minute. The force is measured on three duplicate sample and the average reported as edge ravel. Results are as given in Table 2.
• the precoat made in accordance with the invention exhibits significantly greater tuftbind and edge ravel values, compared to the precoat containing the blown soy oil 63876AWO
• Edge curl values are a little higher for Example 1, but are acceptable commercially. Reduction of the functionality of the hydroxymethyl-containing polyester polyol to closer to 2.0 is expected to reduce the amount of edge curl that is seen.
• Precoat Example 2 and Comparative Sample B are prepared and tested in the same general manner as described for Example 1, using formulations as described in Table 3. In this case, the formulations are adjusted so each polymer contains about 19% of polyols made from renewable resources, and each contains about 56% filler. Test results are as described in Table 4.
• Example 2 exhibits significantly superior hand and tuft binds, compared to Comparative Sample B. Edge curl value is higher, but acceptable and expected to decrease with the use of a lower functionality hydroxymethyl-containing polyester polyol.

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