A high tack performance carpet latex raw material composition and method of making same

Abstract

The application provides a high-back adhesive performance carpet butadiene-styrene latex raw material composition, which comprises the following components in parts by weight: butadiene 60-70 parts, styrene 90-110 parts, acrylic acid 5-15 parts, mercaptan 15-25 parts, and urethane 3-10 parts. The high-back adhesive performance carpet butadiene-styrene latex is prepared by using the above raw material composition, comprising the following steps: butadiene, styrene, acrylic acid, mercaptan and urethane are fully mixed in a reactor, then an initiator is added to perform a free radical polymerization reaction, and after the reaction is completed, impurities are separated and removed. By adding mercaptan and urethane in the butadiene-styrene latex raw material, the adhesion and water resistance of the latex can be improved, the peeling force and tuft pull resistance of the latex can be significantly improved, the stability of the latex under extreme conditions can be effectively improved, the performance of the carpet can be improved, and the application range of the carpet can be expanded.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of styrene-butadiene latex, and particularly relates to a high-back adhesive performance styrene-butadiene latex raw material composition for carpets and a preparation method thereof. BACKGROUND

[0002] In modern home and commercial environments, carpets are widely used as important decorative materials in homes, offices, hotels and other places. Carpets not only provide comfortable foot feeling, but also have multiple functions such as sound insulation, heat preservation and decoration. Therefore, the quality and performance of the carpet directly affect the experience and satisfaction of the user. The performance of the carpet, especially the back adhesive performance, determines whether the carpet can be firmly pasted to the ground after laying, thereby affecting the service life and maintenance cost of the carpet.

[0003] Traditional carpet back adhesive mainly uses styrene-butadiene latex, which has good adhesion and durability. However, with the continuous improvement of market demand, traditional styrene-butadiene latex cannot meet the requirements of the modern carpet industry in some aspects. For example, traditional latex has certain limitations in properties such as crack resistance, peel strength and tuft pull resistance, especially in extreme environments such as high temperature and high humidity, its performance may decrease, resulting in problems such as carpet falling off or curling. Therefore, it is particularly important to develop new high-performance carpet latex.

[0004] In order to improve the performance of the carpet latex, researchers have begun to explore various modification methods. Among them, adding functional monomers and additives is a common modification method. Functional monomers can react with the main components in the styrene-butadiene latex to form a cross-linked structure, thereby improving the mechanical strength and weather resistance of the latex. In addition, suitable additives can improve the flowability, anti-aging performance and other physical and chemical properties of the latex. Therefore, how to reasonably select and proportion functional monomers and additives has become the key to improving the performance of carpet styrene-butadiene latex. SUMMARY

[0005] The technical problem to be solved by the present application is to provide a high-back adhesive performance styrene-butadiene latex raw material composition for carpets and a method for preparing a high-back adhesive performance styrene-butadiene latex for carpets using the raw material composition, so as to solve the above technical problems existing in the prior art.

[0006] The present application is implemented by using the following technical solutions:

[0007] A high-back adhesive performance styrene-butadiene latex raw material composition for carpets comprises the following components in parts by weight: butadiene 60-70 parts, styrene 90-110 parts, acrylic acid 5-15 parts, urethane 3-10 parts, and mercaptan 15-25 parts.

[0008] The urethane has the general formula: NH2COOR1, wherein R1 is a C2-C6 alkenyl group. The C2-C6 alkenyl group includes straight-chain or branched alkenyl groups, such as, but not limited to, ethenyl, 1-propenyl, 2-propenyl, 2-butenyl, 1-pentenyl, 3-methyl-1 butenyl, 3-hexenyl.

[0009] Preferably, the urethane has the general formula: NH2COOCH=CR1', wherein R1' is H or a C1-C4 alkyl group. Further preferably, the urethane is selected from the group consisting of vinyl carbamate (formula: NH2COOCH=CH2), 1-propenyl carbamate (formula: NH2COOCH=C-CH3).

[0010] The thiol has the general formula: R2SH, wherein R2 is a C2-C6 alkenyl group. The C2-C6 alkenyl group includes straight-chain or branched alkenyl groups, such as, but not limited to, ethenyl, 1-propenyl, 2-propenyl, 2-butenyl, 1-pentenyl, 3-methyl-1 butenyl, 3-hexenyl.

[0011] Preferably, the thiol is selected from the group consisting of 2-propen-1-thiol (formula: CH2=CHCH2-SH), 3-buten-1-thiol (formula: CH2=CHCH2CH2-SH), 4-penten-1-thiol (formula: CH2=CHCH2CH2CH2-SH).

[0012] Preferably, the back adhesive performance carpet with styrene butadiene latex raw material composition further comprises a functional additive selected from one or more of polyvinyl alcohol, polyurethane elastomer, antioxidant, thickening agent. Among them, polyvinyl alcohol can improve the flowability and processing performance of the latex, making the latex more convenient to apply; polyurethane elastomer has high strength, good toughness, wear resistance, oil resistance and other excellent properties, which improves the application effect of the latex; the antioxidant can improve the anti-aging performance of the latex, showing more excellent durability; the thickening agent can improve the viscosity of the latex, facilitating construction operation. The functional additive is selected according to the actual use needs, and the addition amount can be adjusted according to the actual application index of the product. The general addition amount is 1-5 parts by weight.

[0013] As a further preferred technical solution, the functional additive is polyvinyl alcohol and antioxidant.

[0014] Preferably, the polyvinyl alcohol has a molecular weight of 25-35 thousand and an alcoholysis degree of 80-90%.

[0015] Preferably, the antioxidant is an environmentally friendly antioxidant, such as, but not limited to, antioxidant 1010, antioxidant 1076, antioxidant 264, etc.

[0016] The application further provides a preparation method of the high-back adhesive performance butadiene-styrene latex for carpets, which adopts the high-back adhesive performance butadiene-styrene latex raw material composition and comprises the following steps: butadiene, styrene, acrylic acid, mercaptan and urethane are added into a reactor and mixed fully, then an initiator is added, the temperature is increased to a reaction temperature of 60-80℃, and reaction is performed for 2-4 hours; after the reaction is completed, impurities are separated and removed, and the high-back adhesive performance butadiene-styrene latex is obtained.

[0017] The inventors have found that, by adding mercaptan and urethane into the butadiene-styrene latex monomer raw material composition and obtaining modified butadiene-styrene latex through free radical polymerization, the butadiene-styrene latex unexpectedly has excellent anti-peeling, anti-pull cluster and anti-cracking performance, and good durability, and is suitable for use in harsher use scenarios, thereby improving the quality of carpet products. Based on the above finding, the inventors complete the present application.

[0018] The initiator is not particularly limited, and can be an initiator commonly used in the art, such as a peroxide initiator, an azo initiator, etc., including but not limited to ammonium persulfate, azobisisobutyronitrile or benzoyl peroxide. The amount of the initiator added is also not particularly limited, and can be obtained through conventional experiments according to the type and amount of the monomer, the reaction temperature and the specific type of the initiator, and is generally 0.1-0.5% of the total mass of the monomer.

[0019] Preferably, the functional auxiliary agent is added after the separation and impurity removal step; when the functional auxiliary agent comprises polyvinyl alcohol, the polyvinyl alcohol is added before the initiator is added, and the other functional auxiliary agents are added after the separation and impurity removal step.

[0020] The reaction temperature is preferably 65-75℃, at which the conversion rate is the highest and the by-products are the least.

[0021] Compared with the prior art, the present application has the following beneficial effects:

[0022] By adding acrylic acid and mercaptan into the butadiene-styrene latex, the present application can improve the adhesion and water resistance of the latex, and significantly improve the peeling force and pull cluster force of the latex. As a functional monomer, urethane can improve the weather resistance and heat resistance of the product, and effectively improve the stability of the latex under extreme conditions. In addition, polyvinyl alcohol can improve the flowability and processing performance of the latex, making the latex more convenient to use in the application process. DETAILED DESCRIPTION

[0023] The following description is provided to enable any person skilled in the art to practice the present application. The preferred embodiments disclosed herein are only examples of the present application and are not intended to limit the scope of the present application. Those skilled in the art will readily devise other ways to implement the present application without departing from the spirit and scope of the present application defined by the appended claims. Various aspects of the application are described in further detail below.

[0024] The instruments or raw materials in the present application are not specified by the manufacturer, and are all conventional commercial instruments or raw materials.

[0025] The detection indicators involved in the embodiments are not mentioned, and are detected by conventional detection methods in the art.

[0026] Example 1

[0027] The composition of the raw materials used is as follows: butadiene 60 parts, styrene 100 parts, acrylic acid 10 parts, 2-propylene-1-thiol 20 parts, vinyl carbamate 5 parts, polyvinyl alcohol 3 parts, and antioxidant 1 part. After mixing these raw materials in a reaction kettle, heat to 60°C and maintain stirring for 30 minutes to ensure thorough mixing. Then, add 0.1 wt% of ammonium persulfate as an initiator based on the total amount of monomers, and raise the temperature to 70°C for polymerization, for 2 hours. After post-treatment, the obtained emulsion shows good performance in the peel force and tuft pull force tests, and is suitable for practical application of carpets.

[0028] Example 2

[0029] In view of the need for low-temperature environments, the latex of this embodiment is prepared. The ratio of the raw materials used is butadiene 55 parts, styrene 95 parts, acrylic acid 12 parts, 3-butene-1-thiol 25 parts, 1-propylene carbamate 6 parts, polyvinyl alcohol 4 parts, and antioxidant 1 part. In a low-temperature environment, the reaction temperature is controlled at 50°C for mixing, followed by emulsion polymerization, and 0.1 wt% of ammonium persulfate is added as an initiator based on the total amount of monomers, and the temperature is raised to 65°C, and the reaction time is extended to 3 hours. After post-treatment and performance testing, the latex has obvious advantages in anti-cracking performance, and is particularly suitable for carpet applications in cold weather conditions.

[0030] Example 3

[0031] The amount of antioxidant is increased to improve the anti-aging performance. The specific raw material composition includes butadiene 60 parts, styrene 100 parts, acrylic acid 10 parts, 4-pentene-1-thiol 20 parts, vinyl carbamate 5 parts, polyvinyl alcohol 2 parts and antioxidant 2 parts. In the preparation process, after mixing and stirring all raw materials at 60°C for 30 minutes, emulsion polymerization is carried out, 0.1wt% of ammonium persulfate of the total amount of monomers is added as an initiator, the temperature is kept at 70°C, and the reaction is carried out for 3 hours. During post-processing, impurities are removed by cooling and centrifugation, and the test results show that the latex exhibits superior durability in the aging test, and is suitable for long-term use of carpet products.

[0032] Example 4

[0033] An environmentally friendly latex is prepared. In the formula of this example, the specific raw materials are butadiene 60 parts, styrene 95 parts, acrylic acid 10 parts, 2-propylene-1-thiol 20 parts, 1-propylene carbamate 5 parts, polyvinyl alcohol 3 parts and antioxidant 1 part. All raw materials are mixed uniformly at 60°C, 0.1wt% of ammonium persulfate of the total amount of monomers is added as an initiator, the temperature is raised to 70°C for polymerization, and the reaction time is controlled at 2 hours. During post-processing, the pH value of the product is ensured to be within the appropriate range, and strict filtration is carried out.

[0034] Example 5

[0035] A functional enhanced latex is prepared, and the raw material composition includes butadiene 65 parts, styrene 90 parts, acrylic acid 15 parts, 4-pentene-1-thiol 20 parts, 1-propylene carbamate 5 parts, polyvinyl alcohol 3 parts and functional additives 2 parts. After mixing the raw materials in proportion, they are thoroughly stirred and heated to 60°C, then 0.1wt% of ammonium persulfate of the total amount of monomers is added as an initiator for emulsion polymerization, the temperature is raised to 75°C, and the reaction time is 3 hours. During post-processing, the fluidity and stability of the product are ensured.

[0036] Comparative Examples 1-4

[0037] Compared with Example 4, Comparative Example 1 does not add carbamate and thiol, Comparative Example 2 does not add carbamate, Comparative Example 3 does not add thiol, and Comparative Example 4 reduces the amount of thiol by half, to investigate the influence of each component on the performance of the product. The specific formula of each comparative example is shown in Table 1, and the components not listed, their amounts, and the process conditions are the same as those of Example 4.

[0038] Table 1 Main formula comparison table of comparative examples

[0039] carbamate thiol Example 4 5 parts 20 parts Comparative Example 1 0 parts 0 parts Comparative Example 2 0 parts 20 parts Comparative Example 3 5 parts 0 parts Comparative Example 4 5 parts 10 parts

[0040] Application Example

[0041] The samples prepared by using the examples 1-5 and the comparative examples 1-4 respectively as the adhesive layer in the processing of the carpet, through an extrusion compound machine, the extruded middle adhesive layer is bonded with the upper carpet surface and the lower non-woven fabric layer at high temperature, cooled to room temperature through a cooling roller, so as to obtain the final carpet sample, corresponding to the numbers E1-E5, D1-D4 respectively. The extrusion processing temperature of the adhesive layer is 210℃, the cooling roller temperature is 30℃, and the line speed of the extrusion compound machine is 12m / min.

[0042] The carpet samples prepared by each example and comparative example are tested as follows:

[0043] 1. Peeling force test

[0044] GB / T 26843-2011 "Determination of Backing Peel Strength of Carpet" is used.

[0045] 2. Tuft pull force test

[0046] QB / T 1090-2019 "Determination of Tuft Pull of Carpet" is used.

[0047] The specific test results are shown in Table 2.

[0048] Table 2 Sample test data

[0049]

[0050] From the test results, it can be seen that the examples of the present application have better peeling force and tuft pull force contribution to the finished carpet compared with the comparative examples. Among them, example 4 compared with comparative example 1 which does not add urethane and thiol in the monomer composition, the peeling force of the corresponding carpet sample (E4 compared with D1) is increased by 31.8%, and the tuft pull force is increased by 25.0%, while comparative example 2 which adds thiol but does not add urethane, and comparative example 3 which adds urethane but does not add thiol, the peeling force and tuft pull force of the corresponding carpet samples (D2 and D3) have no obvious change compared with D1, which shows that there is a significant synergistic effect between urethane and thiol in the butadiene-styrene latex raw material composition of the present application.

[0051] Those skilled in the art will understand that the above examples are only examples and do not limit the present application. The purpose of the present application has been fully and effectively achieved. The function and structural principle of the present application has been shown and explained in the examples, and the embodiments of the present application can be any modification or modification without departing from the principle.

Claims

1. A high tack performance carpet latex raw material composition characterized by, The composition comprises the following components in parts by weight: butadiene 60-70 parts, styrene 90-110 parts, acrylic acid 5-15 parts, mercaptan 15-25 parts, urethane 3-10 parts; the urethane has the following general formula: NH2COOR1, wherein R1 is C2-C6 alkenyl; the mercaptan has the following general formula: R2SH, wherein R2 is C2-C6 alkenyl.

2. The high-tack adhesive property carpet styrene-butadiene latex raw material composition according to claim 1, characterized by, The C2-C6 alkenyl includes straight-chain or branched alkenyl.

3. The high-tack adhesive property carpet styrene-butadiene latex raw material composition according to claim 1, characterized by, The urethane has the following general formula: NH2COOCH=CR1', wherein R1' is H or C1-C4 alkyl.

4. The high-tack adhesive property carpet latex feedstock composition of claim 1, wherein, The urethane is selected from vinyl carbamate, 1-propylene carbamate.

5. The high-tack adhesive property carpet latex feedstock composition of claim 1, wherein, The mercaptan is selected from 2-propylene-1-mercaptan, 3-butene-1-mercaptan, 4-pentene-1-mercaptan.

6. The high-tack adhesive property carpet latex feedstock composition of claim 1, wherein, The functional auxiliary is selected from one or more of polyvinyl alcohol, polyurethane elastomer, antioxidant, thickening agent.

7. The high-tack adhesive property carpet latex feedstock composition of claim 6, wherein, The functional auxiliary is polyvinyl alcohol and antioxidant.

8. A process for the preparation of high tack performance latex for carpeting using the high tack performance latex for carpeting raw material composition according to any one of claims 1 to 7, characterized in that, The method comprises the following steps: butadiene, styrene, acrylic acid, urethane, mercaptan are added into a reactor and mixed well, then an initiator is added, the temperature is raised to a reaction temperature of 60-80℃, and the reaction is carried out for 2-4 hours; after the reaction is completed, impurities are separated and removed, and the butadiene-styrene latex with high tack performance for carpets is obtained.

9. The method of claim 8, wherein, The initiator is selected from at least one of ammonium persulfate, azobisisobutyronitrile or benzoyl peroxide.

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