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
  • D06N7/0089—Underlays
• • A—HUMAN NECESSITIES
  • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
  • A47G—HOUSEHOLD OR TABLE EQUIPMENT
  • A47G27/00—Floor fabrics; Fastenings therefor
  • A47G27/04—Carpet fasteners; Carpet-expanding devices ; Laying carpeting; Tools therefor
  • A47G27/0437—Laying carpeting, e.g. wall-to-wall carpeting
  • A47G27/0468—Underlays; Undercarpets
• • 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
  • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
  • B32B27/065—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
• • 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
  • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
• • 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
  • B32B27/28—Layered products comprising a layer of synthetic resin comprising synthetic resins not wholly covered by any one of the sub-groups B32B27/30 - B32B27/42
  • B32B27/285—Layered products comprising a layer of synthetic resin comprising synthetic resins not wholly covered by any one of the sub-groups B32B27/30 - B32B27/42 comprising polyethers
• • 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
  • B32B27/34—Layered products comprising a layer of synthetic resin comprising polyamides
• • 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
  • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
• • 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
• • 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
  • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
  • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
• • 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
  • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
  • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
  • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
• • 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
  • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
  • B32B7/04—Interconnection of layers
  • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
• • 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
  • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
  • B32B2262/02—Synthetic macromolecular fibres
  • B32B2262/0276—Polyester fibres
• • 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
  • B32B2266/00—Composition of foam
  • B32B2266/02—Organic
  • B32B2266/0214—Materials belonging to B32B27/00
  • B32B2266/025—Polyolefin
• • 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
  • B32B2266/00—Composition of foam
  • B32B2266/02—Organic
  • B32B2266/0214—Materials belonging to B32B27/00
  • B32B2266/0278—Polyurethane
• • 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
  • B32B2307/00—Properties of the layers or laminate
  • B32B2307/70—Other properties
  • B32B2307/724—Permeability to gases, adsorption
• • 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
  • B32B2307/00—Properties of the layers or laminate
  • B32B2307/70—Other properties
  • B32B2307/726—Permeability to liquids, absorption
  • B32B2307/7265—Non-permeable
• • 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
  • B32B2471/00—Floor coverings
  • B32B2471/02—Carpets
• • 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
  • Y10T428/249921—Web or sheet containing structurally defined element or component
  • Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
  • Y10T428/249982—With component specified as adhesive or bonding agent
  • Y10T428/249985—Composition of adhesive or bonding component specified
• • 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
  • Y10T428/249921—Web or sheet containing structurally defined element or component
  • Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
  • Y10T428/249987—With nonvoid component of specified composition
  • Y10T428/249991—Synthetic resin or natural rubbers

Definitions

• Water resistant carpet underlays provide a way to clean spills on carpet more thoroughly by helping to contain the spill above the padding or floor. If a spill is not removed from under the carpet, the spill will allow the growth of mold, mildew, and bacteria. Not only may the padding and wood flooring deteriorate as a result, but such conditions are conducive to the formation of odors and allergens. Spills on fitted or wall-to-wall carpeting are particularly insidious since detection and prevention of the seepage into the padding following a spill is typically impractical with large or fitted carpets. A spill on broadloom carpeting often puddles on the padding or flooring where it can not be removed by cleaning. This spill then accelerates the growth of mold, mildew and odors.
• the carpet underlay is simultaneously impermeable to liquid deposited onto the underlay from above the barrier film, and permeable to moisture vapor at a moisture vapor transmission rate of at least 14.6 grams per square meter per twenty- four hours (14.6 g/m 2 /24 hours), the underlay being sufficiently durable to maintain liquid impermeability under a pressure of at least eight pounds per square inch (0.56 kg/m 2 ) as measured by a Modified Mullen Bursting Strength Test, whereby the carpet underlay does not absorb liquid deposited onto the underlay from above the upper surface of the barrier film and allows moisture from below the lower surface of the cushion to pass through the underlay.
• the foamed cushion comprises foamed polyurethane or polyurethane urea that comprises polytrimethylene ether) blocks as a soft segment.
• the polyurethane or polyurethane-urea is preferably prepared from a reaction mixture comprising: (a) polytrimethylene ether glycol having a hydroxyl functionality greater than 2, preferably greater than 2 and less than about 4; and (b) diisocyanate.
• the reaction mixture may further comprise vegetable oil polyol preferably in an amount of from about 10 to about 90 weight % of the total amount of polyols.
• the reaction mixture may also further comprise polyisocyanate, a blowing agent and a chain extender.
• the barrier film has a thickness in the range from about 0.5 to about 1.5 mils.
• the carpet underlay can further comprise a layer of polymeric adhesive material bonding the barrier film to the upper surface of the cushion.
• the polymeric adhesive is a hot melt adhesive comprising copolymer that comprises polytrimethylene ether segments and segments selected from the group consisting of poly- ester, polyamide, polyurethane and polyurethane-urea.
• the present invention comprises a carpet underlay comprising a foamed carpet cushion, and at least one barrier film affixed to one side of the foamed cushion.
• the film is impermeable to liquids and permeable to moisture vapor and comprises copolymer that comprises polytrimethylene ether soft segments and hard segments se- lected from the group consisting of polyester, polyamide, polyurethane and polyure- thane-urea.
• Important attributes of the underlay or impermeable barrier for carpets provided by the present invention are (1 ) the ability to keep the underlying carpet cushion and floor dry under a wide range of spills and cleaning techniques, and (2) the ability to prevent the retention of trapped moisture under the barrier by allowing it to evaporate promptly.
• breathable denotes a moisture vapor transport rate of 14.6 g/m 2 /day or more, determined by the test method B described below.
• any of the conventional natural or synthetic fibers may be employed for the carpet pile face.
• a particularly preferred fiber is poly(trimethylene terephthalate).
• Poly(trimethylene terephthalate) fibers suitable for use in carpets are available from E.I. du Pont de Nemours and Company under the trade name SORONA ® polymer fibers.
• the barrier film between the carpet backing and the foamed cushion may op- tionally be bonded to the foamed cushion with a polymeric adhesive, preferably a hot melt adhesive, which does not substantially alter the liquid impermeability or moisture vapor permeability of the underlay.
• a carpet underlay in accordance with this invention is both substantially impermeable to liquid deposited onto the pad from above the carpet (as from wetting caused by a liquid spill or animal wetting), and simultaneously permeable to moisture vapor transmitted through pad ("breathable") from below (such as, for example, from moisture vapor from ordinary residential activity penetrating through the flooring below).
• “Impermeable to liquid” means that a liquid deposited onto the pad from above the barrier film does not enter nto the cushion or pass through the pad.
• Substantially imper- meable as used herein, means at least 90% impermeable, preferably at least 95% impermeable, and even more preferably at least 98% impermeable.
• Permeable to moisture vapor means that moisture vapor is transmissible through the pad at a moisture vapor transmission rate of at least 14.6 grams per square meter per twenty-four hours (14.6 g/m 2 /24 hours). In this way, the pad is compatible with a floor surface that meets the recommended moisture vapor transmis.
• films suitable for use in the underlay are described in U.S. Patent Application Publication No. 2005/0282966.
• Particularly preferred films as disclosed in U.S. Patent Application Publication No. 2005/0282966 are based on copolymers comprising polyester hard segments prepared by reaction of 1 ,3-trimethylene glycol and terephthalic acid, esters of terephthalic acid, acid halides of terephthalic acid or acid anhydrides of terephthalic acid.
• Copolymers comprising polytrimethylene ether soft segments and hard segments comprising polyurethane and/or polyurethane-ureas that are suitable for prepar- ing the barrier films are described in US6852823 and US6946539.
• the film can be a cast film, an oriented film or a biaxially oriented film.
• thickness of the film is not a critical dimension so long as the film has the required liquid impermeability and moisture vapor permeability, preferred thickness is in the range of from about 0.5 to about 1.5 mils (0.0127 to 0.0381 cm).
• the barrier film should be sufficiently strong and resilient to resist rupture and to deform and recover repeatedly over its lifetime without adversely affecting its impermeability to liquids.
• Use of an appropriate barrier film results in the finished pad that exhibits the requisite ranges of liquid impermeability, moisture vapor permeability and durability.
• the barrier film may be used as a free film and placed in contact with the carpet cushion; it may be laminated to the carpet cushion; or, it may bonded to the carpet cushion with a layer of adhesive, preferably a hot melt adhesive as discussed below.
• the strength of the barrier film may be enhanced by use of a reinforcing struc- ture disposed within the body of the film.
• the reinforcing structures may take the form of discrete threads or fibrils or a mesh structure that are formed within the body of the film during its manufacture.
• the cushion is formed of a compressible resilient foamed material.
• the thick- ness of the cushion is selected to be consistent with considerations of cost, comfort and aesthetics for a given installation.
• the thickness dimension of the cushion lies in the range from 0.125 to 2 inches (0.3175 to 5 centimeters).
• Suitable compressible and recoverable natural or synthetic foamed material may be used for the cushion.
• Suitable synthetic, non-cellulosic materials useful as the cushion include polyurethane or rubber continuous foams.
• Preferred materials for the cushion are polyurethane foams, and particularly preferred materials for the cushion are polyurethane or polyurethane-urea foams prepared from ingredients comprising poly- trimethylene ether glycol or polyol and diisocyanate.
• Polyurethane foam is produced by mixing diisocyanate, polyol, and water to create two simultaneous reactions: a gelling or polymerization reaction and a blowing or gas-producing reaction.
• the gelling reaction occurs when the isocyanate reacts with the polyol to form urethane chains.
• the blowing reaction occurs when the isocyanate reacts with the water to form carbon dioxide gas. Blowing can also be accomplished by the addition of organic blowing agents instead of or in addition to the use of water.
• the urethane chains make up the structure of the foam, while the carbon dioxide gas creates porosity within the foam by expanding the polyurethane polymer.
• Numerous additives may be mixed with the isocyanate, polyol, and water to control the rate and duration of the gelling and blowing reactions, while also providing a mechanism for urethane chain cross-linking and chain extension.
• the re- suiting polyurethane foam bun may be processed into various polyurethane foam products such as carpet underlay pads.
• polyurethane foams are prepared from reaction mixtures comprising polytrimethylene ether glycol and diisocyanate. Additional diols may be included as chain extenders. Polyurethanes of this type are discussed in US6852823.
• Polytrimethylene ether glycol used in the manufacture of the foams is can be prepared by any process known to those skilled in the art. For example, it can be pre- pared by dehydration of 1 ,3-propanediol or by ring opening polymerization of oxetane. Preferred methods for making polytrimethylene ether glycol by acid catalyzed polycon- densation of 1 ,3-propanediol are described in US6720459 and US6977291. For the purpose of the present invention the 1 ,3-propane diol used for making polytrimethylene ether glycol may contain small amount of polyols, e.g.
• An alternative method of achieving an average hydroxyl functionality greater than 2 is to include in the reaction mixture for preparing the polyurethane foam a polyol or mixture of polyols in addition to polytrimethylene ether glycol.
• Any conventional iso- cyanate reactive polyol may be utilized. Typical examples are glycerine, pentaerythri- tol, trimethylol propane and vegetable oil polyols. Vegetable oil polyols are preferred.
• Polyurethane foams containing vegetable oil polyols are disclosed in US6852823. Polyols, when used will generally be used in an amount of from about 10 to about 90 weight % of the total amount of polyols and diols.
• Typical diisocyanate for use in preparing the foams include, but are not re- stricted to toluene diisocyanate (TDI), diisocyanatodiphenyl methane (MDI), or blends thereof.
• TDI toluene diisocyanate
• MDI diisocyanatodiphenyl methane
• TDI toluene diisocyanate
• 80/20 TDI which is a blend comprising 80 percent of the 2, 4 isomer of TDI and 20 percent of the 2,6 isomer of TDI.
• the hot melt adhesives comprise copolymer that contains poly- trimethylene ether soft segments and hard segments selected from the group consisting of polyester, polyamide, polyurethane and polyurethane-urea.
• Copolymers useful as adhesives are those copolymers useful in the barrier film, disclosed hereinabove.
• the underlay is sufficiently durable to maintain liquid impermeability under a pressure of at least eight pounds per square inch (0.56 kg per square meter) as measured by the Modified Mullen Bursting Strength Test, to be described. Durability may alternatively be expressed in terms of the ability of the pad to maintain liquid impermeability (as indicated by a stain/stain cleaning test) after a Vetterman Drum Wear Test/Staining/Stain Cleaning Test of at least ten thousand cycles (10,000 cycles), as will also be described herein. As a result the underlay does not absorb liquid deposited onto the pad from above the barrier film and allows moisture from below the lower surface of the cushion to pass through. The underlay is thus rendered less sub- ject to odors related to moisture and bacterial growth.
• the carpet underlays may be used in conjunction with any type of conventional carpets, in particular with those containing tufted face yarns. Any of the common natural or synthetic face yarns may be utilized.
• a particularly preferred fiber is poly(trimethylene terephthalate). Poly(trimethylene terephthalate) fibers suitable for use in carpets are available, for example, from E.I. du Pont de Nemours and Company under the trade name SORONA ® polymer fibers.
• Carpet systems comprising poly(trimethylene terephthalate) face yarns and a carpet underlay as disclosed herein have a substantial advantage over other commonly used systems in that they are based in part on 1 ,3-propanediol, which is available biochemically from a renewable source ("biologically-derived" 1 ,3-propanediol).
• Other systems known in the art are based totally on non-renewable petroleum derived raw materials.
• the biologically-derived 1 ,3-propanediol such as produced by the processes described and referenced above, contains carbon from the atmospheric carbon dioxide incorporated by plants, which compose the feedstock for the production of the 1 ,3- propanediol.
• the materials based on biologically-derived 1 ,3-propanediol contain a substantial level of renewable carbon instead of fossil fuel-based or petroleum-based carbon.
• Materials based on biologically-derived 1 ,3-propanediol therefore, have less impact on the environment because the 1 ,3-propanediol used does not deplete diminishing fossil fuels and, upon degradation, releases carbon back to the atmosphere for use by plants once again.
• the compositions disclosed herein for use in making the underlays can be characterized as more natural and having less environmental impact than similar compositions comprising petroleum based diols.
• the described method is a modification of ASTM E-96 (14.1 ) except that twenty-four hour exposure is employed rather than attempting to measure a time rate to achieve steady state so that the results of this test method will be more directly comparable to the moisture vapor transmission standards of the Carpet and Rug Institute.
• the paper towels used are single-fold paper towels available from Kimberly- Clark, Dallas Tex. Since the test requires no visible wetness of the towel, the choice of paper towel is not critical and other thin absorbent media, such as Whatman No.1 Filter paper may be substituted.
• a colored aqueous solution may be used to aid visual detection.
• 100 ml of water, at a room temperature of 24 +/-3°C is slowly poured onto the carpet sample through a cylinder of about 8 cm diameter and from a height of about 1 meter to create a circular puddle. The cylinder is removed and the sample is left undisturbed for 20 minutes. For the 0 psi (0 kPa, i.e. spill only test) the carpet and underlay are removed.
• the underlay is judged a failure to provide sufficient water impermeability to a water spill. If the paper towel between the padding and carpet was dry (desig- nated “dry” in the results), the underlay is judged acceptable and provided sufficient water impermeability to a water spill. Alternatively, the water is “blotted” from the carpet pile with dry paper towels at a given pressure. After ten “blottings” with the given pressure, the carpet and underlay are removed. If any water spot is visible on the towel, then the underlay is judged a failure (or "wet") and did not provide sufficient water impermeability for a water spill followed by blotting at the given pressure.
• Blotting pressures of 0, 3, 8, 16, and 33 psi (0, 21 , 55, 110, and 227 kPa) are utilized.
• a blotting pressure of 33 psi or 228 kPa exceeds the pressure exerted by a typical homeowner standing on a paper towel to accelerate the blotting of a spill.
• the blotting pressures are created by placing weights on a circular disc as follows:
• Modified Mullen Bursting Strength Test (“Modified Mullen Test”): The durability of the underlay to maintain liquid impermeability is measured using a test that is a modification of the Diaphragm Bursting Strength Test Method (ASTM D-3786-87) using a Modified Mullen Model HA tester available from B. F. Perkins, Inc., Chicopee, Mass., or equivalent.
• the testing apparatus comprises a pressure cylinder open on one end to the atmosphere and connected to a water reservoir and hydraulic gage. The other end of the pressure cylinder has a piston, which can be advanced by a motor drive to compress any water in the chamber.
• a valve is provided on the water reservoir as a convenience in filling the chamber and also to prevent reverse flow of the water back into the reservoir.
• a sample is mounted in a test ring that is clamped securely at the mouth of the pressure cylinder with the upper side of the underlay (which would in use contact the bottom of the carpet) presented to the pressure cylinder. Water pressure is then applied to the sample and the value of the pressure at which water is observed to break through the sample is noted.
• a low value under six to 6-8 psi (approximately 0.4-0.6 kg/cm 2 ) indicates that the pad is not likely to maintain liquid impermeability under normal household spot cleaning by hand.
• a 16 pound steel ball having 14 rubber buffers is placed on the top of the carpet and is allowed to roll randomly inside the rotating drum.
• a circular brush within the drum is in light contact with the carpet pile surface and picks up loose fuzz of or fibers, which are continuously removed by suction.
• Stain Cleaning Test After 10,000 cycles in the Vetterman drum test appara- tus the carpet pad sample is stained 24 hours using the "Staining Test” procedure followed by the “Stain Cleaning Test (With Hand Pressure)” procedure.
• the excess cleaning solution is blotted with an absorbent white paper towel.
• Approximately 10 ml of water is then poured onto the stained area of the surface of the test pad through a 1-1/2" diameter cylinder from the height of about 3 cm.
• the cylinder is removed and the water is blotted using white absorbent paper towel with 3 clockwise and 3 counter-clockwise hand circular motions with an estimated pressure of about 6-8 psi (approximately 0.4-0.6 kg/cm 2 ) to simulate normal household spot cleaning by hand.
• the applied pressure can be measured by placing a scale underneath the sample to determine the total applied pressure (in pounds) and dividing by the area of contact with the cleaning surface (in square inches).
• the sample underlay is lifted and the white absorbent paper is examined for visual red staining.
• test sample of the pad If a considerable amount of the staining solution has passed through the test sample of the pad a severe stain will be visible on the white absorbent towel or blotter paper ("STAIN", i.e., fails the test).
• the sample pad will be termed as “substantially impervious” (“NO STAIN”, i.e., passes the test) if none or a very slight amount of staining solution has passed through the test sample of the pad, leaving none or a few visible drops of stain on the white absorbent towel or blotter paper.

Landscapes

• Engineering & Computer Science (AREA)
• Textile Engineering (AREA)
• Laminated Bodies (AREA)
• Carpets (AREA)
• Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
• Synthetic Leather, Interior Materials Or Flexible Sheet Materials (AREA)

Priority Applications (7)

Applications Claiming Priority (2)

Publications (1)

Family

ID=40185078

Family Applications (1)

Country Status (11)

Families Citing this family (4)

Citations (1)

Family Cites Families (8)

• 2007
  • 2007-11-08 US US11/937,371 patent/US20090123688A1/en not_active Abandoned
• 2008
  • 2008-11-07 WO PCT/US2008/082746 patent/WO2009061997A1/en not_active Ceased
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