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Carpet product and process for the manufacturing of a carpet product

a carpet and product technology, applied in the field of carpet products, can solve the problems of poor washability and said higher pri

Inactive Publication Date: 2016-09-01
WACKER CHEM CORP
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

The invention provides carpet products that are more resistant to delamination compared to products currently on the market.

Problems solved by technology

Styrene-based emulsions are described as prior art binders for coating compositions for carpet materials, but these are said to be more expensive and have worse washability and are not used in the invention.

Method used

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Examples

Experimental program
Comparison scheme
Effect test

examples

[0079]The following polymer dispersions were used to prepare the carpet products. Vinyl acetate-ethylene copolymer dispersion (VAE):

[0080]An aqueous dispersion of a vinyl acetate ethylene copolymer with a solids content of about 60 wt % was used. The dispersion was costabilized with a protective colloid and a non-ionic surfactant. The copolymer composition was about 85 wt % vinyl acetate and about 15 wt % ethylene, with a glass transition temperature Tg of about 2° C.

Styrene Butadiene Copolymer Dispersion (SBR):

[0081]An aqueous dispersion of a styrene butadiene copolymer with a solids content of about 55 wt % was used. The dispersion was stabilized with an anionic surfactant. The copolymer composition was about 65 wt % of styrene and about 35 wt % of butadiene, with a glass transition temperature Tg of about 11° C.

Carpet Coating Compositions:

Filler:

[0082]Filler used was calcium carbonate (CARMEUSE™ MW 101 manufactured by Carmeuse Lime and Stone, Chatsworth, Ga.).

Froth Aid:

[0083]Frot...

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Abstract

A carpet product includes in sequence a) a primary backing material having a back side and a face side, with carpet fibers extending from the face side to form a carpet pile and also passing through the primary backing material and forming loops on the back side; b) a primary coating layer on the loops, including a vinyl acetate ethylene copolymer and present at from 542 to 1085 g / m2 (16 to 32 oz. / yd2) on a dry solids basis; c) a secondary coating layer on the primary coating layer, including a styrene-butadiene copolymer; and d) a secondary backing material on the secondary coating layer and adhered thereby to the primary coating layer.

Description

CROSS REFERENCE TO RELATED APPLICATIONS[0001]This application claims priority benefit of U.S. provisional patent application No. 61 / 895,149, filed 24 Oct. 2013, the entirety of which is incorporated herein by reference.FIELD OF THE INVENTION[0002]The present invention relates to a carpet product and a process for manufacturing it.BACKGROUND OF THE INVENTION[0003]Carpets typically include a primary backing material to which carpet fibers are attached to form a carpet pile on the face side, and a primary coating layer on the back side of the primary backing material to fix the carpet fibers to the primary backing. To improve dimensional stability, a secondary backing material is often fixed to the primary backing material by means of a secondary coating layer.[0004]The primary and secondary coating layers are typically formed from aqueous polymer dispersions, for example aqueous vinyl acetate ethylene copolymer dispersions and lattices of carboxylated styrene butadiene copolymers.[000...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): D06N7/00
CPCD06N7/0073D06N7/0081D06N2203/045D06N2203/042D06N2213/065D06N2205/045D06N2205/023D06N2209/103D06N2211/066D06N2203/047
Inventor SAGL, DENNISPANGRAZI, RONALD JOSEPHMCCLURKEN, JOHN M.
Owner WACKER CHEM CORP