Adhesive backing compositions and methods related thereto
Patent Information
- Application Number
- EP2023913652
- Authority / Receiving Office
- EP · EP
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2023-07-19
- Filing Date
- 2023-12-27
- Publication Date
- 2025-11-05
AI Technical Summary
The recycling of carpets containing bitumen is difficult, and bitumen is not environmentally friendly, necessitating an alternative adhesive backing composition that mimics bitumen's properties for carpet production.
An adhesive backing composition comprising a combination of polypropylene elastomer components, aliphatic tackifier resin, and filler components, with specific weight percentages and ethylene-derived units, which provides a suitable viscosity for carpet lamination processes and is more environmentally friendly than bitumen.
The adhesive backing composition enables efficient carpet production by replicating the lamination process of bitumen while being environmentally more friendly and facilitating easier recycling.
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Figure 1.1
Abstract
Description
ADHESIVE BACKING COMPOSITIONS AND METHODS RELATED THERETOCROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 63 / 477,240, filed December 27, 2022, and U.S. Provisional Application No. 63 / 514,403, filed July 19, 2023, each of which are hereby incorporated by reference in their entirety.FIELD OF THE INVENTION
[0002] The disclosure herein relates to an adhesive backing composition suitable for use in carpets and methods of using the same.BACKGROUND
[0003] Bitumen can be used in the production of carpets as an adhesive composition. In production, hot bitumen having a certain viscosity can be deposited onto a secondary backing layer. A conveyor belt carries the secondary backings layer with the deposited bitumen under a doctor blade, which allows for an even application of the bitumen to the secondary backing layer. Immediately after passing under the doctor blade, an additional layer of the final carpet structure can be pressed into the hot bitumen using one or two lamination rollers depending on processing need.
[0004] However, it can be difficult to recycle carpets containing bitumen. In addition, bitumen is not considered particularly environmentally friendly. Thus, there is a need for alternative adhesive backing compositions that behave similarly to bitumen in the process described above. Such adhesive backing compositions and related methods are disclosed herein.SUMMARY
[0005] Disclosed herein is an adhesive backing composition, comprising: a) from about 4 to about 20 weight percent of a first polypropylene elastomer component comprising from greater than 10 to 15 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 20 to about 40 weight percent of a second polypropylene elastomer component comprising from greater than 4 to 8 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 4 to about 10 weight percent of an aliphatic tackifier resin; and d) from about 30 to about 60 weight percent of filler component, wherein the adhesive backing composition has aviscosity of 10,000 - 100,000 mPa s as measured by ASTM D3236-15 at 150 °C.
[0006] Also disclosed herein is an adhesive backing composition, comprising: a) from about 5 to about 12 weight percent of a first polypropylene elastomer component comprising from greater than 10 to 15 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 30 to about 40 weight percent of a second polypropylene elastomer component comprising from greater than 4 to 8 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 4 to about 10 weight percent of an aliphatic tackifier resin; and d) from about 30 to about 60 weight percent of filler component, wherein the adhesive backing composition has a viscosity of 25,000 - 100,000 mPa s as measured by ASTM D3236-15.
[0007] Also disclosed herein is an adhesive backing composition, comprising: a) from about 2 to about 15 weight percent of a first polypropylene elastomer component comprising from greater than 10 to 15 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 10 to about 30 weight percent of a second polypropylene elastomer component comprising from greater than 4 to 8 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 3 to about 8 weight percent of an aliphatic tackifier resin; d) from about 40 to about 70 weight percent of filler component; and e) from about greater than 0 to about 5 weight percent of a mixture of at least one metal salt of a fatty acid and at least one amide, wherein the adhesive backing composition has a viscosity of 10,000 - 100,000 mPa s as measured by ASTM D3236-15 at 150 °C.
[0008] Also disclosed herein is an adhesive backing composition, comprising: a) from about 4 to about 9 weight percent of a first polypropylene elastomer component comprising from greater than 10 to 15 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 20 to about 30 weight percent of a second polypropylene elastomer component comprising from greater than 4 to 8 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 3 to about 8 weight percent of an aliphatic tackifier resin; d) from about 40 to about 70 weight percent of filler component; and e) from about greater than 0 to about 5 weight percent of a mixture of at least one metal salt of a fatty acid and at least one amide, wherein the adhesive backing composition has a viscosity of 25,000 - 100,000 mPa s as measured by ASTM D3236-15.
[0009] Also disclosed is a carpet, comprising a) a primary backing layer having a face side and a back side; b) a plurality of fibers attached to the primary backing layer and extending from both the face side and the back side of the primary backing layer; and c) a cured adhesive backing composition formed from an adhesive backing composition, i.e. adhesive backing composition A or adhesive backing composition B, disclosed herein; and d) an secondary backing layer attached to the back side of the primary backing layer, via the cured adhesive backing composition.
[0010] Also disclosed is a method for making a carpet comprising the steps of: a) dispensing an adhesive backing composition discloses herein on a secondary backing layer; b) passing the secondary backing layer with the dispensed adhesive backing composition under a blade to produce an even layer of the dispensed adhesive backing composition; and c) contacting the even layer of the dispensed adhesive backing composition with a back side of a primary backing layer having a plurality of fibers attached to the primary backing layer and extending from both a face side and the back side of the primary backing layer side.
[0011] Additional aspects of the invention will be set forth, in part, in the detailed description, figures, and claims which follow, and in part will be derived from the detailed description, or can be learned by practice of the invention. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention as disclosed.BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate several embodiments of the disclosed apparatus, system, and method and together with the description, serve to explain the principles of the disclosed apparatus, system, and method.
[0013] FIG. 1 is a schematic of spindle SC4-27.DETAILED DESCRIPTION
[0014] The present invention can be understood more readily by reference to the following detailed description, examples, drawings, and claims, and their previous and following description. However, before the present articles, systems, and / or methods are disclosed and described, it is to be understood that this invention is not limited to the specific or exemplaryaspects of articles, systems, and / or methods disclosed unless otherwise specified, as such can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting.
[0015] The following description of the invention is provided as an enabling teaching of the invention in its best, currently known embodiment. To this end, those skilled in the relevant art will recognize and appreciate that many changes can be made to the various aspects of the invention described herein, while still obtaining the beneficial results of the present invention. It will also be apparent that some of the desired benefits of the present invention can be obtained by selecting some of the features of the present invention without utilizing other features. Accordingly, those of ordinary skill in the pertinent art will recognize that many modifications and adaptations to the present invention are possible and may even be desirable in certain circumstances and are a part of the present invention. Thus, the following description is again provided as illustrative of the principles of the present invention and not in limitation thereof.A. Definitions
[0016] In this specification and in the claims that follow, reference will be made to a number of terms, which shall be defined to have the following meanings:
[0017] Throughout the description and claims of this specification the word “comprise” and other forms of the word, such as “comprising” and “comprises,” means including but not limited to, and is not intended to exclude, for example, other additives, components, integers, or steps. Furthermore, it is to be understood that the terms comprise, comprising and comprises as they related to various aspects, elements and features of the disclosed invention also include the more limited aspects of “consisting essentially of’ and “consisting of.”
[0018] As used herein, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to an “adhesive backing” includes aspects having two or more such adhesive backings unless the context clearly indicates otherwise.
[0019] Ranges can be expressed herein as from “about” one particular value, and / or to “about” another particular value. When such a range is expressed, another aspect includes from the one particular value and / or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another aspect. It should be further understood that the endpoints of eachof the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.
[0020] As used herein, the terms “optional” or “optionally” mean that the subsequently described event or circumstance may or may not occur, and that the description includes instances where said event or circumstance occurs and instances where it does not.
[0021] References in the specification and concluding claims to parts by weight of a particular element or component in a composition or article, denotes the weight relationship between the element or component and any other elements or components in the composition or article for which a part by weight is expressed. Thus, in a composition or a selected portion of a composition containing 2 parts by weight of component X and 5 parts by weight component Y, X and Y are present at a weight ratio of 2:5, and are present in such ratio regardless of whether additional components are contained in the composition.
[0022] A weight percent of a component, unless specifically stated to the contrary, is based on the total weight of the formulation or composition in which the component is included.
[0023] As used herein, and unless the context clearly indicates otherwise, the term “carpet” is used to generically include broadloom carpet, carpet tiles, area rugs, and artificial grass (or turf). To that end, the term “broadloom carpet” refers to a broadloom textile flooring product manufactured for and intended to be used in roll form. The term “carpet tile” refers to a modular floor covering, conventionally manufactured in 18” x 18,” 24” x 24” or 36” x 36” squares, but other sizes and shapes are also within the scope of the present invention. Any of these exemplary carpets can be woven, non-woven, tufted, or needle-punched.
[0024] As used herein, “carpet” includes, for example, broadloom carpet, carpet tiles and portions of a carpet.
[0025] As used herein, “primary backing” layer, "second" layer, and “middle” layer are merely identifiers used for convenience, and shall not be construed as limitation on individual layers, their relative positions, or the laminated structure, unless otherwise specified.
[0026] The viscosity of the adhesive backing composition was measured according to ASTM D3236-15 at 150 °C unless otherwise noted in the specification at an alternate temperature. The ASTM D3236-15 test can be performed at 2 rpm or 4 rpm using a SC4-27 spindle from Brookfield. The dimensions of the SC4-27 spindle can be seen in FIG. 1.B. Adhesive Backing Composition
[0027] Disclosed herein are adhesive backing compositions that can be used to replace molten bitumen in a process where a conveyor belt carries a secondary backings material with the deposited bitumen under a doctor blade, which allows for an even application of the bitumen to the secondary backings. The disclosed adhesive backing compositions have a viscosity suitable for such a process at a temperature that does not damage the secondary backing. Furthermore, the disclosed adhesive backing compositions comprises polyolefin, which has an increasing market demand in view of being more environmentally friendly, as compared to alternative materials.
[0028] Disclosed herein is an adhesive backing composition, comprising: a) from about 4 to about 20 weight percent of a first polypropylene elastomer component comprising from greater than 10 to 15 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 20 to about 40 weight percent of a second polypropylene elastomer component comprising from greater than 4 to 8 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 4 to about 10 weight percent of an aliphatic tackifier resin; and d) from about 30 to about 60 weight percent of filler component, wherein the adhesive backing composition has a viscosity of 10,000 - 100,000 mPa s as measured by ASTM D3236-15 at 150 °C. This adhesive backing composition is encompassed in adhesive backing composition A described herein.
[0029] Disclosed herein is an adhesive backing composition, comprising: a) from about 5 to about 12 weight percent of a first polypropylene elastomer component comprising from greater than 10 to 15 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 30 to about 40 weight percent of a second polypropylene elastomer component comprising from greater than 4 to 8 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 4 to about 10 weight percent of an aliphatic tackifier resin; and d) from about 30 to about 60 weight percent of filler component, wherein the adhesive backing composition has a viscosity of 25,000 - 100,000 mPa s as measured by ASTM D3236-15. This adhesive backing composition is encompassed in adhesive backing composition A described herein.
[0030] Also disclosed herein is an adhesive backing composition, comprising: a) from about 2 to about 15 weight percent of a first polypropylene elastomer component comprising from greater than 10 to 15 weight percent ethylene derived units based upon the weight of the firstpolypropylene elastomer component; b) from about 10 to about 30 weight percent of a second polypropylene elastomer component comprising from greater than 4 to 8 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 3 to about 8 weight percent of an aliphatic tackifier resin; d) from about 40 to about 70 weight percent of filler component; and e) from about greater than 0 to about 5 weight percent of a mixture of at least one metal salt of a fatty acid and at least one amide, wherein the adhesive backing composition has a viscosity of 10,000 - 100,000 mPa s as measured by ASTM D3236-15 at 150 °C. This adhesive backing composition is encompassed in adhesive backing composition B described herein.
[0031] Also disclosed herein is an adhesive backing composition, comprising: a) from about 4 to about 9 weight percent of a first polypropylene elastomer component comprising from greater than 10 to 15 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 20 to about 30 weight percent of a second polypropylene elastomer component comprising from greater than 4 to 8 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 3 to about 8 weight percent of an aliphatic tackifier resin; d) from about 40 to about 70 weight percent of filler component; and e) from about greater than 0 to about 5 weight percent of a mixture of at least one metal salt of a fatty acid and at least one amide, wherein the adhesive backing composition has a viscosity of 25,000 - 100,000 mPa s as measured by ASTM D3236-15. This adhesive backing composition is encompassed in adhesive backing composition B described herein.
[0032] In one aspect, the adhesive backing compositions disclosed herein, such as adhesive backing composition A and adhesive backing composition A, do not comprise a vinyl compound. For example, in one aspect, adhesive backing composition A does not comprise a vinyl compound. In another example, in one aspect, adhesive backing composition B does not comprise a vinyl compound.
[0033] In one aspect, the adhesive backing compositions disclosed herein, such as adhesive backing composition A and adhesive backing composition A, do not comprise bitumen. For example, in one aspect, adhesive backing composition A does not comprise bitumen. In another example, in one aspect, adhesive backing composition B does not comprise bitumen.1. Adhesive Backing Composition A
[0034] As described, adhesive backing composition A, comprises: a) from about 4 to about20 weight percent of a first polypropylene elastomer component comprising from greater than 10 to 15 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 20 to about 40 weight percent of a second polypropylene elastomer component comprising from greater than 4 to 8 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 4 to about 10 weight percent of an aliphatic tackifier resin; and d) from about 30 to about 60 weight percent of filler component, wherein the adhesive backing composition has a viscosity of 10,000- 100,000 mPa s as measured by ASTM D3236-15 at 150 °C.
[0035] As described, adhesive backing composition A, comprises: a) from about 5 to about 12 weight percent of a first polypropylene elastomer component comprising from greater than 10 to 15 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 30 to about 40 weight percent of a second polypropylene elastomer component comprising from greater than 4 to 8 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 4 to about 10 weight percent of an aliphatic tackifier resin; and d) from about 30 to about 60 weight percent of filler component, wherein the adhesive backing composition has a viscosity of 25,000- 100,000 mPa s as measured by ASTM D3236-15.
[0036] In one aspect, adhesive backing composition A does not comprise a mixture of at least one metal salt of a fatty acid and at least one amide.
[0037] In one aspect, adhesive backing composition A, consists of: a) from about 4 to about 20 weight percent of a first polypropylene elastomer component comprising from greater than 10 to 15 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 20 to about 40 weight percent of a second polypropylene elastomer component comprising from greater than 4 to 8 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 4 to about 10 weight percent of an aliphatic tackifier resin; and d) from about 30 to about 60 weight percent of filler component, wherein the adhesive backing composition has a viscosity of 10,000- 100,000 mPa- s as measured by ASTM D3236-15 at 150 °C.
[0038] In one aspect, adhesive backing composition A, consists of: a) from about 5 to about 12 weight percent of a first polypropylene elastomer component comprising from greater than 10 to 15 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 30 to about 40 weight percent of a second polypropyleneelastomer component comprising from greater than 4 to 8 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 4 to about 10 weight percent of an aliphatic tackifier resin; and d) from about 30 to about 60 weight percent of filler component, wherein the adhesive backing composition has a viscosity of 25,000 - 100,000 mPa s as measured by ASTM D3236-15.
[0039] In one aspect, adhesive backing composition A, consists of: a) from about 12 to about 20 weight percent of a first polypropylene elastomer component comprising from greater than 10 to 15 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 20 to about 30 weight percent of a second polypropylene elastomer component comprising from greater than 4 to 8 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 4 to about 10 weight percent of an aliphatic tackifier resin; and d) from about 30 to about 60 weight percent of filler component, wherein the adhesive backing composition has a viscosity of 10,000 - 100,000 mPa s as measured by ASTM D3236-15 at 150 °C.
[0040] For example, adhesive backing composition A can comprise from about 4 to about 20 weight percent of the first polypropylene elastomer component. For example, adhesive backing composition A can comprise from about 12 to about 20 percent of the first polypropylene elastomer component. For example, adhesive backing composition A can comprise from about 12 to about 18 percent of the first polypropylene elastomer component. For example, adhesive backing composition A can comprise from about 15 to about 20 percent of the first polypropylene elastomer component. For example, adhesive backing composition A can comprise from about 4 to about 12 weight percent of the first polypropylene elastomer component. For example, adhesive backing composition A can comprise from about 5 to about 10 weight percent of the first polypropylene elastomer component. For example, adhesive backing composition A can comprise from about 6 to about 10 weight percent of the first polypropylene elastomer component. In another example, adhesive backing composition A can comprise from about 10 to about 20 weight percent of the first polypropylene elastomer component. In another example, adhesive backing composition A can comprise from about 7 to about 9 weight percent of the first polypropylene elastomer component. In yet another example, adhesive backing composition A can comprise from about 8 weight percent of the first polypropylene elastomer component.
[0041] For example, adhesive backing composition A can comprise from about 20 to about40 weight percent of the second polypropylene elastomer component. For example, adhesive backing composition A can comprise from about 32 to about 40 weight percent of the second polypropylene elastomer component. In another example, adhesive backing composition A can comprise from about 34 to about 40 weight percent of the second polypropylene elastomer component. In another example, adhesive backing composition A can comprise from about 20 to about 30 weight percent of the second polypropylene elastomer component. In another example, adhesive backing composition A can comprise from about 22 to about 30 weight percent of the second polypropylene elastomer component. In yet another example, adhesive backing composition A can comprise from about 32 to about 38 weight percent of the second polypropylene elastomer component. In yet another example, adhesive backing composition A can comprise from about 23 to about 35 weight percent of the second polypropylene elastomer component. In yet another example, adhesive backing composition A can comprise from about 33 to about 37 weight percent of the second polypropylene elastomer component. In yet another example, adhesive backing composition A can comprise from about 35 weight percent of the second polypropylene elastomer component.
[0042] For example, adhesive backing composition A can comprise from about 5 to about 10 weight percent of an aliphatic tackifier resin. In another example, adhesive backing composition A can comprise from about 5 to about 9 weight percent of an aliphatic tackifier resin. In yet another example, adhesive backing composition A can comprise from about 6 to about 8 weight percent of an aliphatic tackifier resin. In yet another example, adhesive backing composition A can comprise about 7 weight percent of an aliphatic tackifier resin.
[0043] For example, adhesive backing composition A can comprise from about 35 to about 60 weight percent of filler component. In another example, adhesive backing composition A can comprise from about 40 to about 60 weight percent of filler component. In yet another example, adhesive backing composition A can comprise from about 45 to about 60 weight percent of filler component. In yet another example, adhesive backing composition A can comprise from about 45 to about 55 weight percent of filler component. In yet another example, adhesive backing composition A can comprise about 50 weight percent of filler component.
[0044] For example, adhesive backing composition A can have a viscosity of 15,000 - 90,000 mPa s as measured by ASTM D3236-15 at 150 °C. In another example, adhesive backing composition A can have a viscosity of 20,000 - 80,000 mPa s as measured by ASTM D3236-15 at 150 °C. In another example, adhesive backing composition A can have a viscosityof 30,000 - 70,000 mPa s as measured by ASTM D3236-15 at 150 °C. In another example, adhesive backing composition A can have a viscosity of 30,000 - 50,000 mPa- s as measured by ASTM D3236-15 at 150 °C. In yet another example, adhesive backing composition A can have a viscosity of 30,000 - 60,000 mPa s as measured by ASTM D3236-15 at 150 °C. In yet another example, adhesive backing composition A can have a viscosity of 40,000 - 80,000 mPa s as measured by ASTM D3236-15 at 150 °C.
[0045] As described, adhesive backing composition A, comprises: a) from about 14 to about 18 weight percent of a first polypropylene elastomer component comprising from greater than 10 to 15 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 22 to about 28 weight percent of a second polypropylene elastomer component comprising from greater than 4 to 8 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 5 to about 9 weight percent of an aliphatic tackifier resin; and d) from about 45 to about 55 weight percent of filler component, wherein the adhesive backing composition has a viscosity of 10,000 - 100,000 mPa s as measured by ASTM D3236-15 at 150 °C.
[0046] For example, adhesive backing composition A, can comprise: a) from about 6 to about 10 weight percent of a first polypropylene elastomer component comprising from greater than 10 to 15 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 30 to about 37 weight percent of a second polypropylene elastomer component comprising from greater than 4 to 8 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 5 to about 9 weight percent of an aliphatic tackifier resin; and d) from about 45 to about 55 weight percent of filler component, wherein the adhesive backing composition has a viscosity of 25,000 - 100,000 mPa s as measured by ASTM D3236-15.
[0047] As described, adhesive backing composition A, comprises: a) from about 14 to about 18 weight percent of a first polypropylene elastomer component comprising from greater than 10 to 15 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 22 to about 28 weight percent of a second polypropylene elastomer component comprising from greater than 4 to 8 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 5 to about 9 weight percent of an aliphatic tackifier resin; and d) from about 45 to about 55 weight percent of filler component, wherein the adhesive backing composition has a viscosity of 10,000- 100,000 mPa s as measured by ASTM D3236-15 at 150 °C.
[0048] In another example, adhesive backing composition A, can comprise: a) from about 6 to about 10 weight percent of a first polypropylene elastomer component comprising from greater than 10 to 15 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 30 to about 37 weight percent of a second polypropylene elastomer component comprising from greater than 4 to 8 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 5 to about 9 weight percent of an aliphatic tackifier resin; and d) from about 45 to about 55 weight percent of filler component, wherein the adhesive backing composition has a viscosity of 30,000 - 50,000 mPa s as measured by ASTM D3236-15.
[0049] In another example, adhesive backing composition A, can comprise: a) from about 13 to about 18 weight percent of a first polypropylene elastomer component comprising from greater than 10 to 15 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 22 to about 28 weight percent of a second polypropylene elastomer component comprising from greater than 4 to 8 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 5 to about 9 weight percent of an aliphatic tackifier resin; and d) from about 45 to about 55 weight percent of filler component, wherein the adhesive backing composition has a viscosity of 30,000 - 50,000 mPa s as measured by ASTM D3236-15 at 150 °C.
[0050] In yet another example, adhesive backing composition A, can comprise: a) from about 6 to about 10 weight percent of a first polypropylene elastomer component comprising about 13 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 30 to about 37 weight percent of a second polypropylene elastomer component comprising about 6 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 5 to about 9 weight percent of an aliphatic tackifier resin; and d) from about 45 to about 55 weight percent of filler component, wherein the adhesive backing composition has a viscosity of 25,000 - 100,000 mPa s as measured by ASTM D3236-15.
[0051] In yet another example, adhesive backing composition A, can comprise: a) from about 13 to about 18 weight percent of a first polypropylene elastomer component comprising about 12 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 22 to about 28 weight percent of a second polypropyleneelastomer component comprising about 6 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 5 to about 9 weight percent of an aliphatic tackifier resin; and d) from about 45 to about 55 weight percent of filler component, wherein the adhesive backing composition has a viscosity of 10,000 - 100,000 mPa s as measured by ASTM D3236-15 at 150 °C.
[0052] In yet another example, adhesive backing composition A, can comprise: a) from about 6 to about 10 weight percent of a first polypropylene elastomer component comprising about 13 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 30 to about 37 weight percent of a second polypropylene elastomer component comprising about 6 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 5 to about 9 weight percent of an aliphatic tackifier resin; and d) from about 45 to about 55 weight percent of filler component, wherein the adhesive backing composition has a viscosity of 30,000 - 50,000 mPa s as measured by ASTM D3236-15.
[0053] In yet another example, adhesive backing composition A, can comprise: a) from about 13 to about 18 weight percent of a first polypropylene elastomer component comprising about 12 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 22 to about 28 weight percent of a second polypropylene elastomer component comprising about 6 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 5 to about 9 weight percent of an aliphatic tackifier resin; and d) from about 45 to about 55 weight percent of filler component, wherein the adhesive backing composition has a viscosity of 30,000 - 50,000 mPa s as measured by ASTM D3236-15 at 150 °C.
[0054] In yet another example, adhesive backing composition A, can consist of: a) from about 6 to about 10 weight percent of a first polypropylene elastomer component comprising about 13 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 30 to about 37 weight percent of a second polypropylene elastomer component comprising about 6 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 5 to about 9 weight percent of an aliphatic tackifier resin; and d) from about 45 to about 55 weight percent of filler component, wherein the adhesive backing composition has a viscosity of 25,000 - 100,000 mPa s as measured by ASTM D3236-15.
[0055] In yet another example, adhesive backing composition A, can consist of: a) from about 13 to about 18 weight percent of a first polypropylene elastomer component comprising about 12 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 22 to about 28 weight percent of a second polypropylene elastomer component comprising about 6 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 5 to about 9 weight percent of an aliphatic tackifier resin; and d) from about 45 to about 55 weight percent of filler component, wherein the adhesive backing composition has a viscosity of 10,000 - 100,000 mPa s as measured by ASTM D3236-15 at 150 °C.
[0056] In yet another example, adhesive backing composition A, can consist of: a) from about 6 to about 10 weight percent of a first polypropylene elastomer component comprising about 13 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 30 to about 37 weight percent of a second polypropylene elastomer component comprising about 6 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 5 to about 9 weight percent of an aliphatic tackifier resin; and d) from about 45 to about 55 weight percent of filler component, wherein the adhesive backing composition has a viscosity of 30,000 - 50,000 mPa s as measured by ASTM D3236-15.
[0057] In yet another example, adhesive backing composition A, can consist of: a) from about 13 to about 18 weight percent of a first polypropylene elastomer component comprising about 12 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 22 to about 28 weight percent of a second polypropylene elastomer component comprising about 6 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 5 to about 9 weight percent of an aliphatic tackifier resin; and d) from about 45 to about 55 weight percent of filler component, wherein the adhesive backing composition has a viscosity of 30,000 - 50,000 mPa s as measured by ASTM D3236-15 at 150 °C.
[0058] In yet another example, adhesive backing composition A, can comprise: a) about 8 weight percent of a first polypropylene elastomer component comprising about 13 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) about 35 weight percent of a second polypropylene elastomer component comprising about 6 weight percent ethylene derived units based upon the weight of the secondpolypropylene elastomer component; c) about 7 weight percent of an aliphatic tackifier resin; and d) about 50 weight percent of filler component, wherein the adhesive backing composition has a viscosity of 25,000 - 100,000 mPa s as measured by ASTM D3236-15.
[0059] In yet another example, adhesive backing composition A, can comprise: a) about 8 weight percent of a first polypropylene elastomer component comprising about 13 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) about 35 weight percent of a second polypropylene elastomer component comprising about 6 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) about 7 weight percent of an aliphatic tackifier resin; and d) about 50 weight percent of filler component, wherein the adhesive backing composition has a viscosity of 30,000 - 50,000 mPa s as measured by ASTM D3236-15.2. Adhesive Backing Composition B
[0060] A difference between adhesive backing composition A and adhesive backing composition B is that component “a mixture of at least one metal salt of a fatty acid and at least one amide” is required in adhesive backing composition B. One function of the a mixture of at least one metal salt of a fatty acid and at least one amide is to allow for a higher percentage of filler to be present in adhesive backing composition B compared to adhesive backing composition A while retaining the desired flow and adhesive properties. An increase of filler is desired in the in adhesive backing composition because this lowers the cost of the adhesive backing composition.
[0061] As described, adhesive backing composition B, comprises: a) from about 2 to about 15 weight percent of a first polypropylene elastomer component comprising from greater than 10 to 15 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 10 to about 30 weight percent of a second polypropylene elastomer component comprising from greater than 4 to 8 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 3 to about 8 weight percent of an aliphatic tackifier resin; d) from about 40 to about 70 weight percent of filler component; and e) from about greater than 0 to about 5 weight percent of a mixture of at least one metal salt of a fatty acid and at least one amide, wherein the adhesive backing composition has a viscosity of 10,000 - 100,000 mPa s as measured by ASTM D3236- 15 at 150 °C.
[0062] As described, adhesive backing composition B, comprises: a) from about 4 to about 9 weight percent of a first polypropylene elastomer component comprising from greater than 10 to 15 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 20 to about 30 weight percent of a second polypropylene elastomer component comprising from greater than 4 to 8 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 3 to about 8 weight percent of an aliphatic tackifier resin; d) from about 40 to about 70 weight percent of filler component; and e) from about greater than 0 to about 5 weight percent of a mixture of at least one metal salt of a fatty acid and at least one amide, wherein the adhesive backing composition has a viscosity of 25,000 - 100,000 mPa s as measured by ASTM D3236- 15.
[0063] In one aspect, adhesive backing composition B, consists of: a) from about 2 to about 15 weight percent of a first polypropylene elastomer component comprising from greater than 10 to 15 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 10 to about 30 weight percent of a second polypropylene elastomer component comprising from greater than 4 to 8 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 3 to about 8 weight percent of an aliphatic tackifier resin; d) from about 40 to about 70 weight percent of filler component; and e) from about greater than 0 to about 5 weight percent of a mixture of at least one metal salt of a fatty acid and at least one amide, wherein the adhesive backing composition has a viscosity of 10,000 - 100,000 mPa s as measured by ASTM D3236- 15 at 150 °C.
[0064] In one aspect, adhesive backing composition B, consists of: a) from about 4 to about 9 weight percent of a first polypropylene elastomer component comprising from greater than 10 to 15 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 20 to about 30 weight percent of a second polypropylene elastomer component comprising from greater than 4 to 8 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 3 to about 8 weight percent of an aliphatic tackifier resin; d) from about 40 to about 70 weight percent of filler component; and e) from about greater than 0 to about 5 weight percent of a mixture of at least one metal salt of a fatty acid and at least one amide, wherein the adhesive backing composition has a viscosity of 25,000 - 100,000 mPa s as measured by ASTM D3236-
[0065] For example, adhesive backing composition B can comprise from about 3 to about 14 weight percent of the first polypropylene elastomer component. For example, adhesive backing composition B can comprise from about 10 to about 14 weight percent of the first polypropylene elastomer component. For example, adhesive backing composition B can comprise from about 11 to about 15 weight percent of the first polypropylene elastomer component. For example, adhesive backing composition B can comprise from about 4 to about 7 weight percent of the first polypropylene elastomer component. For example, adhesive backing composition B can comprise from about 4 to about 9 weight percent of the first polypropylene elastomer component. In another example, adhesive backing composition B can comprise from about 12 to about 14 weight percent of the first polypropylene elastomer component. In another example, adhesive backing composition B can comprise from about 4 to about 6 weight percent of the first polypropylene elastomer component. In another example, adhesive backing composition B can comprise from about 5 to about 7 weight percent of the first polypropylene elastomer component. In another example, adhesive backing composition B can comprise from about 11 to about 13 weight percent of the first polypropylene elastomer component. In another example, adhesive backing composition B can comprise from about 5 to about 8 weight percent of the first polypropylene elastomer component. In yet another example, adhesive backing composition B can comprise from about 6 weight percent of the first polypropylene elastomer component. In yet another example, adhesive backing composition B can comprise from about 4% weight percent of the first polypropylene elastomer component.
[0066] For example, adhesive backing composition B can comprise from about 10 to about 28 weight percent of the second polypropylene elastomer component. For example, adhesive backing composition B can comprise from about 22 to about 30 weight percent of the second polypropylene elastomer component. For example, adhesive backing composition B can comprise from about 10 to about 18 weight percent of the second polypropylene elastomer component. In another example, adhesive backing composition B can comprise from about 24 to about 30 weight percent of the second polypropylene elastomer component. In another example, adhesive backing composition B can comprise from about 12 to about 18 weight percent of the second polypropylene elastomer component. In yet another example, adhesive backing composition B can comprise from about 20 to about 29 weight percent of the second polypropylene elastomer component. In yet another example, adhesive backing composition B can comprise from about 13 to about 19 weight percent of the second polypropylene elastomer component. In yet another example, adhesive backing composition B can comprise from about 23 to about 28 weight percent of the second polypropylene elastomer component. In yet anotherexample, adhesive backing composition B can comprise from about 13 to about 17 weight percent of the second polypropylene elastomer component. In yet another example, adhesive backing composition B can comprise from about 24 to about 27 weight percent of the second polypropylene elastomer component. In yet another example, adhesive backing composition B can comprise from about 14 to about 16 weight percent of the second polypropylene elastomer component. In yet another example, adhesive backing composition B can comprise from about 25 weight percent of the second polypropylene elastomer component. In yet another example, adhesive backing composition B can comprise from about 26% weight percent of the second polypropylene elastomer component.
[0067] For example, adhesive backing composition B can comprise from about 4 to about 8 weight percent of an aliphatic tackifier resin. In another example, adhesive backing composition B can comprise from about 4 to about 7 weight percent of an aliphatic tackifier resin. In yet another example, adhesive backing composition B can comprise from about 4 to about 6 weight percent of an aliphatic tackifier resin. In yet another example, adhesive backing composition B can comprise about 5 weight percent of an aliphatic tackifier resin.
[0068] For example, adhesive backing composition B can comprise from about 45 to about 70 weight percent of filler component. In another example, adhesive backing composition B can comprise from about 50 to about 70 weight percent of filler component. In yet another example, adhesive backing composition B can comprise from about 55 to about 70 weight percent of filler component. In yet another example, adhesive backing composition B can comprise from about 60 to about 70 weight percent of filler component. In yet another example, adhesive backing composition B can comprise about 63 weight percent of filler component.
[0069] For example, adhesive backing composition B can comprise from more than 0 to about 4 weight percent of the mixture of at least one metal salt of a fatty acid and at least one amide. In another example, adhesive backing composition B can comprise from more than 0 to about 3 weight percent of the mixture of at least one metal salt of a fatty acid and at least one amide. In yet another example, adhesive backing composition B can comprise from more than 0 to about 2 weight percent of the mixture of at least one metal salt of a fatty acid and at least one amide. In yet another example, adhesive backing composition B can comprise from more than 0 to about 1 weight percent of the mixture of at least one metal salt of a fatty acid and at least one amide. In yet another example, adhesive backing composition B can comprise from more than 0.5 to about 1.5 weight percent of the mixture of at least one metal salt of a fatty acid and at leastone amide. For example, adhesive backing composition B can comprise from about 0.25 to about 2 weight percent of the mixture of at least one metal salt of a fatty acid and at least one amide. In yet another example, adhesive backing composition B can comprise about 1 weight percent of the mixture of at least one metal salt of a fatty acid and at least one amide. In yet another example, adhesive backing composition B can comprise about 0.5 weight percent of the mixture of at least one metal salt of a fatty acid and at least one amide.
[0070] For example, adhesive backing composition B can have a viscosity of 15,000 - 90,000 mPa s as measured by ASTM D3236-15 at 150 °C. In another example, adhesive backing composition B can have a viscosity of 20,000 - 80,000 mPa s as measured by ASTM D3236-15 at 150 °C. In another example, adhesive backing composition B can have a viscosity of 30,000 - 70,000 mPa s as measured by ASTM D3236-15 at 150 °C. In another example, adhesive backing composition B can have a viscosity of 30,000 - 50,000 mPa- s as measured by ASTM D3236-15 at 150 °C. In yet another example, adhesive backing composition B can have a viscosity of 30,000 - 60,000 mPa s as measured by ASTM D3236-15. In yet another example, adhesive backing composition B can have a viscosity of 40,000 - 80,000 mPa s as measured by ASTM D3236-15 at 150 °C. In yet another example, adhesive backing composition B can have a viscosity of 70,000 - 90,000 mPa s as measured by ASTM D3236-15 at 150 °C. In yet another example, adhesive backing composition B can have a viscosity of 70,000 - 100,000 mPa- s as measured by ASTM D3236-15 at 150 °C. In yet another example, adhesive backing composition B can have a viscosity of 60,000 - 90,000 mPa s as measured by ASTM D3236-15 at 150 °C.
[0071] In one aspect, adhesive backing composition B, comprises: a) from about 2 to about 13 weight percent of a first polypropylene elastomer component comprising from greater than 10 to 15 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 12 to about 27 weight percent of a second polypropylene elastomer component comprising from greater than 4 to 8 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 4 to about 7 weight percent of an aliphatic tackifier resin; d) from about 60 to about 70 weight percent of filler component; and e) from about greater than 0 to about 2 weight percent of a mixture of at least one metal salt of a fatty acid and at least one amide, wherein the adhesive backing composition has a viscosity of 10,000 - 100,000 mPa s as measured by ASTM D3236- 15 at 150 °C.
[0072] In one aspect, adhesive backing composition B, comprises: a) from about 5 to about 8 weight percent of a first polypropylene elastomer component comprising from greater than 10 to 15 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 23 to about 27 weight percent of a second polypropylene elastomer component comprising from greater than 4 to 8 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 4 to about 7 weight percent of an aliphatic tackifier resin; d) from about 60 to about 70 weight percent of filler component; and e) from about greater than 0 to about 2 weight percent of a mixture of at least one metal salt of a fatty acid and at least one amide, wherein the adhesive backing composition has a viscosity of 25,000 - 100,000 mPa s as measured by ASTM D3236- 15.
[0073] In one aspect, adhesive backing composition B, comprises: a) from about 10 to about14 weight percent of a first polypropylene elastomer component comprising from greater than 10 to 15 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 12 to about 18 weight percent of a second polypropylene elastomer component comprising from greater than 4 to 8 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 4 to about 7 weight percent of an aliphatic tackifier resin; d) from about 60 to about 70 weight percent of filler component; and e) from about greater than 0 to about 2 weight percent of a mixture of at least one metal salt of a fatty acid and at least one amide, wherein the adhesive backing composition has a viscosity of 10,000 - 100,000 mPa s as measured by ASTM D3236-15 at 150 °C.
[0074] In one aspect, adhesive backing composition B, comprises: a) from about 5 to about 8 weight percent of a first polypropylene elastomer component comprising from greater than 10 to 15 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 23 to about 27 weight percent of a second polypropylene elastomer component comprising from greater than 4 to 8 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 4 to about 7 weight percent of an aliphatic tackifier resin; d) from about 60 to about 70 weight percent of filler component; and e) from about greater than 0 to about 2 weight percent of a mixture of at least one metal salt of a fatty acid and at least one amide, wherein the adhesive backing composition has a viscosity of 30,000 - 50,000 mPa- s as measured by ASTM D3236- 15.
[0075] In one aspect, adhesive backing composition B, comprises: a) from about 10 to about 14 weight percent of a first polypropylene elastomer component comprising from greater than 10 to 15 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 12 to about 18 weight percent of a second polypropylene elastomer component comprising from greater than 4 to 8 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 4 to about 7 weight percent of an aliphatic tackifier resin; d) from about 60 to about 70 weight percent of filler component; and e) from about greater than 0 to about 2 weight percent of a mixture of at least one metal salt of a fatty acid and at least one amide, wherein the adhesive backing composition has a viscosity of 30,000 - 50,000 mPa s as measured by ASTM D3236-15 at 150 °C.
[0076] In one aspect, adhesive backing composition B, comprises: a) from about 5 to about 8 weight percent of a first polypropylene elastomer component comprising from about 13 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 23 to about 27 weight percent of a second polypropylene elastomer component comprising from about 6 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 4 to about 7 weight percent of an aliphatic tackifier resin; d) from about 60 to about 70 weight percent of filler component; and e) from about greater than 0 to about 2 weight percent of a mixture of at least one metal salt of a fatty acid and at least one amide, wherein the adhesive backing composition has a viscosity of 25,000 - 100,000 mPa s as measured by ASTM D3236-15.
[0077] In one aspect, adhesive backing composition B, comprises: a) from about 10 to about 14 weight percent of a first polypropylene elastomer component comprising from about 12 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 12 to about 18 weight percent of a second polypropylene elastomer component comprising from about 6 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 4 to about 7 weight percent of an aliphatic tackifier resin; d) from about 60 to about 70 weight percent of filler component; and e) from about greater than 0 to about 2 weight percent of a mixture of at least one metal salt of a fatty acid and at least one amide, wherein the adhesive backing composition has a viscosity of 10,000 - 100,000 mPa s as measured by ASTM D3236-15 at 150 °C.
[0078] In one aspect, adhesive backing composition B, comprises: a) from about 5 to about 8 weight percent of a first polypropylene elastomer component comprising from about 13 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 23 to about 27 weight percent of a second polypropylene elastomer component comprising from about 6 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 4 to about 7 weight percent of an aliphatic tackifier resin; d) from about 60 to about 70 weight percent of filler component; and e) from about greater than 0 to about 2 weight percent of a mixture of at least one metal salt of a fatty acid and at least one amide, wherein the adhesive backing composition has a viscosity of 30,000 - 50,000 mPa s as measured by ASTM D3236-15.
[0079] In one aspect, adhesive backing composition B, comprises: a) from about 10 to about 14 weight percent of a first polypropylene elastomer component comprising from about 12 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 12 to about 18 weight percent of a second polypropylene elastomer component comprising from about 6 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 4 to about 7 weight percent of an aliphatic tackifier resin; d) from about 60 to about 70 weight percent of filler component; and e) from about greater than 0 to about 2 weight percent of a mixture of at least one metal salt of a fatty acid and at least one amide, wherein the adhesive backing composition has a viscosity of 30,000 - 50,000 mPa s as measured by ASTM D3236-15 at 150 °C.
[0080] In one aspect, adhesive backing composition B, consists of: a) from about 5 to about 8 weight percent of a first polypropylene elastomer component comprising from about 13 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 23 to about 27 weight percent of a second polypropylene elastomer component comprising from about 6 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 4 to about 7 weight percent of an aliphatic tackifier resin; d) from about 60 to about 70 weight percent of filler component; and e) from about greater than 0 to about 2 weight percent of a mixture of at least one metal salt of a fatty acid and at least one amide, wherein the adhesive backing composition has a viscosity of 25,000 - 100,000 mPa s as measured by ASTM D3236-15.
[0081] In one aspect, adhesive backing composition B, consists of: a) from about 10 to about 14 weight percent of a first polypropylene elastomer component comprising from about 12weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 12 to about 18 weight percent of a second polypropylene elastomer component comprising from about 6 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 4 to about 7 weight percent of an aliphatic tackifier resin; d) from about 60 to about 70 weight percent of filler component; and e) from about greater than 0 to about 2 weight percent of a mixture of at least one metal salt of a fatty acid and at least one amide, wherein the adhesive backing composition has a viscosity of 10,000 - 100,000 mPa s as measured by ASTM D3236-15 at 150 °C.
[0082] In one aspect, adhesive backing composition B, consists of: a) from about 5 to about 8 weight percent of a first polypropylene elastomer component comprising from about 13 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 23 to about 27 weight percent of a second polypropylene elastomer component comprising from about 6 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 4 to about 7 weight percent of an aliphatic tackifier resin; d) from about 60 to about 70 weight percent of filler component; and e) from about greater than 0 to about 2 weight percent of a mixture of at least one metal salt of a fatty acid and at least one amide, wherein the adhesive backing composition has a viscosity of 30,000 - 50,000 mPa s as measured by ASTM D3236-15.
[0083] In one aspect, adhesive backing composition B, consists of: a) from about 3 to about 6 weight percent of a first polypropylene elastomer component comprising from about 13 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 24 to about 28 weight percent of a second polypropylene elastomer component comprising from about 6 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 4 to about 7 weight percent of an aliphatic tackifier resin; d) from about 60 to about 70 weight percent of filler component; and e) from about greater than 0 to about 2 weight percent of a mixture of at least one metal salt of a fatty acid and at least one amide, wherein the adhesive backing composition has a viscosity of 30,000 - 50,000 mPa s as measured by ASTM D3236-15 at 150 °C.
[0084] In one aspect, adhesive backing composition B, consists of: a) from about 10 to about 14 weight percent of a first polypropylene elastomer component comprising from about 12 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 12 to about 18 weight percent of a second polypropylene elastomercomponent comprising from about 6 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 4 to about 7 weight percent of an aliphatic tackifier resin; d) from about 60 to about 70 weight percent of filler component; and e) from about greater than 0 to about 2 weight percent of a mixture of at least one metal salt of a fatty acid and at least one amide, wherein the adhesive backing composition has a viscosity of 30,000 - 50,000 mPa s as measured by ASTM D3236-15 at 150 °C.
[0085] In one aspect, adhesive backing composition B, comprises: a) about 6 weight percent of a first polypropylene elastomer component comprising from about 13 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) about 25 weight percent of a second polypropylene elastomer component comprising from about 6 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) about 5 weight percent of an aliphatic tackifier resin; d) about 63 weight percent of filler component; and e) about 0.5 weight percent of a mixture of at least one metal salt of a fatty acid and at least one amide, wherein the adhesive backing composition has a viscosity of 25,000 - 100,000 mPa s as measured by ASTM D3236-15.
[0086] In one aspect, adhesive backing composition B, comprises: a) about 4 weight percent of a first polypropylene elastomer component comprising from about 13 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) about 26 weight percent of a second polypropylene elastomer component comprising from about 6 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) about 5 weight percent of an aliphatic tackifier resin; d) about 63 weight percent of filler component; and e) about 1.0 weight percent of a mixture of at least one metal salt of a fatty acid and at least one amide, wherein the adhesive backing composition has a viscosity of 25,000 - 100,000 mPa s as measured by ASTM D3236-15 at 150 °C. i. First and Second Polypropylene Elastomer Components
[0087] As described, the adhesive backing compositions A and B disclosed herein contain a first polypropylene elastomer component comprising from greater than 10 to 15 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component and a second polypropylene elastomer component comprising from greater than 4 to 8 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component.
[0088] In one aspect, the first polypropylene elastomer component comprises from 11 to 14 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component. In another aspect, the first polypropylene elastomer component comprises from 12 to 14 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component. In yet another aspect, the first polypropylene elastomer component comprises about 13 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component. A commercial example of the first polypropylene elastomer component is VISTAMAXX™ 6502, which is manufactured by ExxonMobil Chemical Company.
[0089] In one aspect, the first polypropylene elastomer component comprises from 10 to 14 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component. In another aspect, the first polypropylene elastomer component comprises from 11 to 13 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component. In yet another aspect, the first polypropylene elastomer component comprises about 12 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component. A commercial example of the first polypropylene elastomer component is VISTAMAXX™ 6902, which is manufactured by ExxonMobil Chemical Company.
[0090] In one aspect, second polypropylene elastomer component comprises from than 5 to 7 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component. In one aspect, second polypropylene elastomer component comprises about 6 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component. A commercial example of the second polypropylene elastomer component is VISTAMAXX™ 8880, which is manufactured by ExxonMobil Chemical Company.
[0091] As such, the adhesive backing compositions A and B disclosed herein can comprise VISTAMAXX™ 6502 and VISTAMAXX™ 8880.
[0092] As such, the adhesive backing compositions A and B disclosed herein can comprise VISTAMAXX™ 6902 and VISTAMAXX™ 8880.
[0093] In some aspects, the first polypropylene elastomer is a copolymer of propylene and ethylene derived units, and wherein the ethylene derived units of the first polypropyleneelastomer are present in an amount of about 10 to 15 weight percent based upon the weight of the first polypropylene elastomer; and wherein the first polypropylene elastomer has a melt index (MI) according to ASTM D1238 of from about 15 to about 50 g / lOmin; and the second polypropylene elastomer is a copolymer of propylene and ethylene derived units, and wherein the ethylene derived units of the second propylene elastomer are present in an amount of about 4 to 8 weight percent based upon the weight of the second polypropylene elastomer; and wherein the second polypropylene elastomer has a viscosity of from about lOOOcP to 1400cP at 190°C.
[0094] In some aspects, the first polypropylene elastomer is a copolymer of propylene and ethylene derived units, and wherein the ethylene derived units of the first polypropylene elastomer are present in an amount of about 10 to 15 weight percent based upon the weight of the first polypropylene elastomer; and wherein the first polypropylene elastomer has a melt index (MI) according to ASTM D1238 of from about 15 to about 25 g / lOmin; and the second polypropylene elastomer is a copolymer of propylene and ethylene derived units, and wherein the ethylene derived units of the second propylene elastomer are present in an amount of about 4 to 8 weight percent based upon the weight of the second polypropylene elastomer; and wherein the second polypropylene elastomer has a viscosity of from about lOOOcP to 1400cP at 190°C.
[0095] In some aspects, the first polypropylene elastomer is a copolymer of propylene and ethylene derived units, and wherein the ethylene derived units of the first polypropylene elastomer are present in an amount of about 10 to 15 weight percent based upon the weight of the first polypropylene elastomer; and wherein the first polypropylene elastomer has a melt index (MI) according to ASTM D1238 of from about 35 to about 50 g / lOmin; and the second polypropylene elastomer is a copolymer of propylene and ethylene derived units, and wherein the ethylene derived units of the second propylene elastomer are present in an amount of about 4 to 8 weight percent based upon the weight of the second polypropylene elastomer; and wherein the second polypropylene elastomer has a viscosity of from about lOOOcP to 1400cP at 190°C.
[0096] In some aspects, the first and / or second polypropylene elastomer component can be a copolymer of propylene-derived units and units derived from ethylene. The polypropylene elastomer component can contain at least about 60 wt % propylene-derived units based on the weight of the polypropylene elastomer component. The polypropylene elastomer component can have limited crystallinity due to adjacent isotactic propylene units and a melting point as described herein. The crystallinity and the melting point of the polypropylene elastomer component can be reduced compared to highly isotactic polypropylene by the introduction oferrors in the insertion of propylene. The polypropylene elastomer component is generally devoid of any substantial intermolecular heterogeneity in tacticity and comonomer composition, and also is generally devoid of any substantial heterogeneity in intramolecular composition distribution.
[0097] In one aspects, the first and / or second polypropylene elastomer components comprise ethylene-derived units or consists essentially of units derived from propylene and ethylene, i.e., the polypropylene elastomer component does not contain any other comonomer in an amount other than that typically present as impurities in the ethylene and / or propylene feedstreams used during polymerization, or in an amount that would materially affect the heat of fusion, melting point, crystallinity, or MI of the polypropylene elastomer component, or any other comonomer intentionally added to the polymerization process.
[0098] In another aspect, the first and / or second polypropylene elastomer component can comprise one or more additional comonomer. For example, a polypropylene elastomer component having more than one comonomer includes, but is not limited to, propyleneethyl ene-octene, propylene-ethylene-hexene, and propylene-ethylene-butene polymers.
[0099] In some aspects, the first and / or second polypropylene elastomer component can further comprise a diene. The optional diene can be any hydrocarbon structure having at least two unsaturated bonds wherein at least one of the unsaturated bonds is readily incorporated into a polymer. For example, the optional diene can be selected from straight chain acyclic olefins, such as 1,4-hexadiene and 1,6-octadiene; branched chain acyclic olefins, such as 5-methyl-l,4- hexadiene, 3,7-dimethyl-l,6-octadiene, and 3,7-dimethyl-l,7-octadiene; single ring alicyclic olefins, such as 1,4-cyclohexadiene, 1,5-cyclooctadiene, and 1,7-cyclododecadiene; multi-ring alicyclic fused and bridged ring olefins, such as tetrahydroindene, norbornadiene, methyltetrahydroindene, dicyclopentadiene, bicyclo-(2.2.1)-hepta-2,5-diene, norbornadiene, alkenyl norbomenes, alkylidene norbomenes, e.g., ethylidiene norbornene (“ENB”), cycloalkenyl norbomenes, and cycloalkyliene norbornenes (such as 5-methylene-2 -norbornene, 5-ethylidene- 2-norbomene, 5-propenyl-2-norbornene, 5-isopropylidene-2-norbomene, 5-(4-cyclopentenyl)-2- norbomene, 5-cyclohexylidene-2-norbomene, 5-vinyl-2-norbomene); and cycloalkenylsubstituted alkenes, such as vinyl cyclohexene, allyl cyclohexene, vinyl cyclooctene, 4-vinyl cyclohexene, allyl cyclodecene, vinyl cyclododecene, and tetracyclo (A-l l,12)-5,8-dodecene. The amount of diene-derived units present in the first and / or second polypropylene elastomer component can range from an upper limit of about 15%, about 10%, about 7%, about 5%, about4.5%, about 3%, about 2.5%, or about 1.5%, to a lower limit of about 0%, about 0.1%, about 0.2%, about 0.3%, about 0.5%, or about 1%, based on the total weight of the propylene elastomer component. In some aspects, the first and / or second polypropylene elastomer component does not contain any diene-derived units.
[0100] In some aspects, the first and / or second polypropylene elastomer components can have a weight average molecular weight (Mw) of about 5,000 to about 5,000,000 g / mole, about 10,000 to about 1,000,000 g / mole, about 20,000 to about 750,000 g / mole, about 30,000 to about 400,000 g / mole.
[0101] In some aspects, the first and / or second propylene elastomer components can have a number average molecular weight (Mn) of about 2,500 to about 250,000 g / mole, about 10,000 to about 250,000 g / mole, or about 25,000 to about 200,000 g / mole.
[0102] In some aspects, the first and / or second polypropylene elastomer component can have a z-average molecular weight (Mz) of about 10,000 to about 7,000,000 g / mole, about 80,000 to about 700,000 g / mole, or about 100,000 to about 500,000 g / mole.
[0103] In some aspects, the first and / or second polypropylene elastomer component can have a molecular weight distribution (“MWD”) of about 1.5 to about 20, or about 1.5 to about 15, preferably about 1.5 to about 5, and more preferably about 1.8 to about 3, and most preferably about 1.8 to about 2.5.
[0104] Suitable first and / or second propylene elastomers components are available commercially under the trade names VISTAMAXX™ (ExxonMobil Chemical Company, Tex., USA), VERSIFY™ (The Dow Chemical Company, Mich., USA), certain grades of TAFMER™ XM or NOTIO™ (Mitsui Company, Japan), and certain grades of SOFTEL™ (Basell Polyolefins of the Netherlands). ii. Aliphatic tackifier resin
[0105] In some aspects, the aliphatic tackifier resin is an aromatic modified aliphatic tackifier resin. For example, an aliphatic tackifier resin can be those commercially available under the trade name ESCOREZ™, which is produced by ExxonMobil Chemical Company. For example, the aliphatic tackifier resin can be ESCOREZ™ 1315. In another example the aliphatic tackifier resin can be ESCOREZ™ 5637.
[0106] The term "tackifier" is used herein to refer to an agent that allows the polymer of the composition to be more adhesive by improving wetting during the application. The aliphatic tackifier resin may be produced from petroleum-derived hydrocarbons and monomers of feedstock including tall oil and other polyterpene or resin sources. The aliphatic tackifier resin is added to give tack to the adhesive and also to modify viscosity. Tack is required in most adhesive formulations to allow for proper joining of materials prior to the adhesive backing compositions solidifying.
[0107] The resins described above may be produced by methods generally known in the art for the production of hydrocarbon resins. See for example, the Kirk-Othmer Encyclopedia of Chemical Technology, 4th ed., Vol. 13, pp. 717-744. A preferred method for production of the resins described above is by thermally or catalytically polymerizing petroleum fractions. These polymerizations may be batch, semi-batch or continuous. Petroleum fractions containing aliphatic Cs to Ce linear, branched, alicyclic monoolefins, diolefins, alicyclic Cio diolefins can be polymerized. The aliphatic olefins can comprise one or more natural or synthetic terpenes, preferably one or more of alpha-pinene, beta-pinene, delta-3 carene, dipentene, limonene or isoprene dimers. Cs-Cio aromatic olefinic streams containing styrene, vinyl toluenes, indene, methyl-indenes can also be polymerized as such or in mixture with the aliphatic streams.
[0108] Thermal polymerization is usually carried out at a temperature between 160 °C and 320 °C, e.g., at about 250 °C., for a period of 0.5 to 9 hours, typically 1.5 to 4 hours.
[0109] The polymeric resin so produced is dissolved in an inert, de-aromatized or non-de- aromatized hydrocarbon solvent such as Exxsol™ or Varsol™ or base White spirit in proportions varying from 10% to 60% and preferably in the region of 30% by weight polymer. Hydrogenation is then conducted in a fixed-bed, continuous reactor with the feed flow being either an upflow or downflow liquid phase or trickle bed operation.
[0110] Hydrogenation treating conditions generally include reactions ranging in temperature of from about 100 °C to about 350 °C, preferably ranging from about 150 °C to about 300 °C, more preferably ranging from about 160 °C to about 270 °C. The hydrogen pressure within the reactor should not exceed more than 2000 psi, preferably no more than 1500 psi, and most preferably no more than 1000 psi. The hydrogenation pressure is, however, a function of the hydrogen purity and the overall reaction pressure should be higher if the hydrogen contains impurities to give the desired hydrogen pressure. Typically the optimal pressure used is between about 750 psi and 1500 psi, preferably between about 800 psi and about 1000 psi. The hydrogento feed volume ratio to the reactor under standard conditions (25 °C, 1 atm pressure) typically can range from about 20 to about 200. Further description of exemplary methods for preparing the tackifiers described herein may be found in U.S. Pat. No. 6,433,104, which is incorporated by reference herein. iii. Filler Component
[0111] The adhesive backing compositions A and B also comprise a filler component. The filler component can be any suitable filler, including, for example, calcium carbonate, aluminum oxide trihydrate (alumina), barium sulfate, flyash, recycled calcium carbonate, aluminum trihydrate, talc, nano-clay, barium sulfate, barite, barite glass fiber, glass powder, glass cullet, metal powder, alumina, hydrated alumina, clay, magnesium carbonate, calcium sulfate, silica, glass, fumed silica, carbon black, graphite, cement dust, feldspar, nepheline, magnesium oxide, zinc oxide, aluminum silicate, calcium silicate, titanium dioxide, titanates, glass microspheres, chalk, calcium oxide, and any combination thereof, or mixtures thereof. The filler components can be virgin filler, waste material, or even reclaimed filler components. For example, the filler component can comprise calcium carbonate. In another example, the filler component consist of calcium carbonate.
[0112] The filler component can be a plurality of particles having a mean particle size. The particle size distribution (PSD) is herein presented by a D-value, such as a D50 value. The D50, the median, is defined as the particle diameter where half of the population of the plurality of particles has a size smaller than this value.
[0113] In one aspect, the filler component can have a mean particle size of D50 from about 5 pm to about 500 pm. For example, the filler component can have a mean particle size of D50 from about 5 pm to about 250 pm. In another example, the filler component can have a mean particle size of D50 from about 5 pm to about 100 pm. In yet another example, the filler component can have a mean particle size of D50 from about 5 pm to about 50 pm. In yet another example, the filler component can have a mean particle size of D50 from about 5 pm to about 40 pm. In yet another example, the filler component can have a mean particle size of D50 from about 10 pm to about 40 pm. In yet another example, the filler component can have a mean particle size of D50 from about 15 pm to about 30 pm. In yet another example, the filler component can have a mean particle size of D50 from about 30 pm to about 500 pm. In yet another example, the filler component can have a mean particle size of D50 from about 30 pm to about 250 pm. In yet another example, the filler component can have a mean particle size ofD50 from about 30 m to about 100 pm. In yet another example, the filler component can have a mean particle size of D50 from about 30 pm to about 75 pm. In yet another example, the filler component can have a mean particle size of D50 from about 50 pm to about 500 pm. In yet another example, the filler component can have a mean particle size of D50 from about 50 pm to about 250 pm. In yet another example, the filler component can have a mean particle size of D50 from about 50 pm to about 100 pm. In yet another example, the filler component can have a mean particle size of D50 from about 50 pm to about 75 pm. In yet another example, the filler component can have a mean particle size of D50 from about 75 pm to about 500 pm. In yet another example, the filler component can have a mean particle size of D50 from about 75 pm to about 250 pm. In yet another example, the filler component can have a mean particle size of D50 from about 75 pm to about 150 pm. In yet another example, the filler component can have a mean particle size of D50 from about 75 pm to about 100 pm. In yet another example, the filler component can have a mean particle size of D50 from about 100 pm to about 500 pm. In yet another example, the filler component can have a mean particle size of D50 from about 100 pm to about 250 pm. In yet another example, the filler component can have a mean particle size of D50 from about 100 pm to about 150 pm. In yet another example, the filler component can have a mean particle size of D50 from about 250 pm to about 500 pm. iv. Mixture of at least One Metal Salt of a Fatty Acid and at least one Amide
[0114] The adhesive backing composition B also comprises a mixture of at least one metal salt of a fatty acid and at least one amide. The fatty acids generally comprise from 16 to 18 carbon atoms. Representative examples include stearic acid, oleic acid, palmitic acid and mixtures thereof. In a preferred embodiment the fatty acid comprises stearic acid. Fatty acid mixtures may additionally comprise 9,12-linoleic acid, 9,11-linoleic acid (conjugated linoleic acid), pinolenic acid, palmitoleic acid, magaric acid, octadecadienoic acid, octadecatri enoic acid, and the like. Fatty acid mixtures may contain minor amounts of rosin acids. Illustrative rosin acids include, but are not limited to, those generally found in tall oil fatty acid mixtures, and may comprise abietic acid, dihydroabietic acid, palustric / levopimaric acid, pimaric acids, tetrahydroabietic acid, isopimaric acid, neoabietic acid, and the like. Suitable metal salts include, but are not limited to, those comprising aluminum, magnesium, calcium, and zinc, and mixtures thereof. In some embodiments suitable amides comprise those derived from C8-C18 carboxylic acids and hydroxy- substituted amines. The ratio of fatty acid metal salt to amide component in the mixture is that which is effective to obtain a reduction in plate-out in compositions of the invention. Mixtures of at least one metal salt of a fatty acid and at least one amide may beprepared by mixing the individual components. Commercial mixtures suitable for use in compositions of the present invention comprise those available from Struktol Company of America (Stow, Ohio), including, but are not limited to, STRUKTOL™ TR 251, STRUKTOL™ TR 255, STRUKTOL™ TR 071, and STRUKTOL™ TR 016.
[0115] In one aspect, the mixture of at least one metal salt of a fatty acid and at least one amide is STRUKTOL™ TR 251.C. Carpet
[0116] Also disclosed herein is a carpet comprising the adhesive backing composition, i.e. adhesive backing composition A or adhesive backing composition B, disclosed herein.
[0117] Disclosed is a carpet, comprising a) a primary backing layer having a face side and a back side; b) a plurality of fibers attached to the primary backing layer and extending from both the face side and the back side of the primary backing layer; and c) a cured adhesive backing composition formed from an adhesive backing composition, i.e. adhesive backing composition A or adhesive backing composition B, disclosed herein; and d) an secondary backing layer attached to the back side of the primary backing layer, via the cured adhesive backing composition.
[0118] In one aspect, the cured adhesive backing composition can have a thickness from 1 mil to 100 mils. For example, the cured adhesive backing composition can have a thickness from 1 mil to 75 mils. In another example, the cured adhesive backing composition can have a thickness from 1 mil to 50 mils. In yet another example, the cured adhesive backing composition can have a thickness from 1 mil to 25 mils. In yet another example, the cured adhesive backing composition can have a thickness from 1 mil to 15 mils. In yet another example, the cured adhesive backing composition can have a thickness from 10 mils to 100 mils. In yet another example, the cured adhesive backing composition can have a thickness from 20 mils to 100 mils.
[0119] In one aspect, the cured adhesive backing composition can have an add-on weight range of 500 gsm to 3000 gsm. For example, the cured adhesive backing composition can have an add-on weight range of 500 gsm to 2000 gsm. In another example, the cured adhesive backing composition can have an add-on weight range of 500 gsm to 1500 gsm. In yet another example, the cured adhesive backing composition can have an add-on weight range of 500 gsm to 1000 gsm. In yet another example, the cured adhesive backing composition can have an addon weight range of 500 gsm to 800 gsm. In yet another example, the cured adhesive backingcomposition can have an add-on weight range of 1000 gsm to 2000 gsm. In yet another example, the cured adhesive backing composition can have an add-on weight range of 1250 gsm to 1500 gsm.
[0120] In one aspect, the carpet further comprises a reinforcement layer between the cured adhesive backing composition and the secondary backing layer. For example, the carpet further can comprise a precoat composition between the cured adhesive backing composition and the primary backing layer. In another example, the carpet can further comprise a second reinforcement layer between the cured adhesive backing composition and the precoat composition.
[0121] In some aspects, the carpet is a carpet tile. The carpet tiles can be any size or shape. In some aspects, the carpet is a broadloom carpet.1. Primary backing layer
[0122] In some aspects, the primary backing layer can comprise a number of different materials including, but not limited to, polypropylene and polyester. In some aspects, the primary backing layer can comprise a thermoplastic polyolefin. In other aspects, the primary backing layer can be a nonwoven layer comprising bicomponent filaments. For example, the primary backing layer can comprise bicomponent continuous filaments having a polyethylene terephthalate core and a polyamide or polypropylene skin / sheath.
[0123] In some aspects, the plurality of fibers attached to the primary backing layer can comprise various materials including, but not limited to, polypropylene, nylon, wool, cotton, acrylic, polyester and polyethylene terephthalate (PET).
[0124] In some aspects, the primary backing layer can comprise a thermoplastic polyolefin. In some aspects, the thermoplastic polyolefin can be the same as the thermoplastic polyolefin present in the adhesive backing layer. Depending on the type and amount of the thermoplastic polyolefin, the final structure comprising the thermoplastic olefin can have thermoplastic, elastomeric, or thermoplastic elastomeric properties.2. Precoat layer
[0125] In some aspects, the disclosed precoat layers are present between the back surface of the primary backing layer and the adhesive layer. In these aspects, the precoat layer can at leastpartially encapsulate the plurality of fibers of the greige good. In some aspects, the precoat layer can comprise latex. In other aspects, the precoat layer can comprise SBR latex. In further aspects, the precoat layer can comprise VAE latex. In still further aspects, the precoat layer can comprise EVA latex. Optionally, in other exemplary aspects, the precoat layer can comprise an acrylic material.
[0126] Disclosed are precoat layers comprising materials including, but not limited to, latex, urethane, and vinyl systems, with latex systems being most popular. Styrene butadiene rubbers (SBR) and vinyl acetate ethylene (VAE) are the most common polymers used for latex adhesive backing materials. Thus, in some aspects, the precoat layer can comprise SBR latex. In further aspects, the precoat layer can comprise VAE latex. In still further aspects, the precoat layer can comprise EVA latex. Optionally, in other exemplary aspects, the precoat layer can comprise an acrylic material. In some aspects, the latex backing system is heavily filled with an inorganic filler such as calcium carbonate or aluminum trihydrate and includes other ingredients such as antioxidants, antimicrobials, flame retardants, smoke suppressants, wetting agents, and froth aids.
[0127] In some aspects, the precoat layer comprises an aqueous precoat material. In some exemplary aspects, the aqueous precoat material can, for example, be added as a dispersion or as an emulsion. A precoat emulsion can be made from various polyolefin materials such as, for example and without limitation, ethylene acrylic acid (EAA), ethylene vinyl acetate (EVA), polypropylene or polyethylene (e.g., low density polyethylene (LDPE), linear low density polyethylene (LLDPE) or substantially linear ethylene polymer, or mixtures thereof). In some aspects, the precoat layer can comprise latex. It is further contemplated that the precoat material in the precoat layer can be selected from a group comprising, without limitation, an EVA hotmelt, a vinyl acetate ethylene (VAE) emulsion, carboxylated styrene-butadiene (XSB) latex copolymer, a styrene- butadiene resin (SBR) latex, a BDMMA latex, an acrylic latex, an acrylic copolymer, a styrene copolymer, butadiene acrylate copolymer, a polyolefin hotmelt, polyurethane, polyolefin dispersions and / or emulsions, and any combination thereof.
[0128] In some aspects, the precoat layer can further comprise one or more flame retardant components. Exemplary flame retardants that can be incorporated into the precoat layer include, without limitation, organo-phosphorous flame retardants, red phosphorous magnesium hydroxide, magnesium dihydroxide, hexabromocyclododecane, bromine containing flame retardants, brominated aromatic flame retardants, melamine cyanurate, melamine polyphosphate,melamine borate, methylol and its derivatives, silicon dioxide, calcium carbonate, resourcinol bis-(diphenyl phosphate), brominated latex base, antimony trioxide, strontium borate, strontium phosphate, monomeric N-alkoxy hindered amine (NOR HAS), triazine and its derivatives, high aspect ratio talc, phosphated esters, organically modified nanoclays and nanotubes, non- organically modified nanoclays and nanotubes, ammonium polyphosphate, polyphosphoric acid, ammonium salt, triaryl phosphates, isopropylated triphenyl phosphate, phosphate esters, magnesium hydroxide, zinc borate, bentonite (alkaline activated nanoclay and nanotubes), organoclays, aluminum trihydrate (ATH), azodi carbonamide, diazenedicarboxamide, azodicarbonic acid diamide (ADC), triaryl phosphates, isopropylated triphenyl phosphate, triazine derivatives, alkaline activated organoclay and aluminum oxide. Any desired amount of flame retardant can be used in the precoat layer and the selection of such amount will depend on a required carpet application. Such amounts can be readily determined through no more than routine experimentation.
[0129] In some aspects, the precoat layer can further contain other ingredients. For example, a surfactant can be included. Suitable surfactants can include, for example and without limitation, nonionic, anionic, cationic and fluorosurfactants. In one aspect, the surfactant is present in an amount between about 0.01 and about 5 weight percent based on the total weight of the emulsion or dispersion. In another aspect, the surfactant is anionic. In a further aspect, the surfactant is cationic. In a yet further aspect, the surfactant is nonionic. In a still further aspect, the surfactant is a fluorosurfactant.
[0130] In another aspect, the precoat layer can further comprise a thickener, a defoaming agent, and / or a dispersion enhancer. In this aspect, the thickener helps to provide a suitable viscosity to the dispersion. For example, the thickener can exemplarily comprise sodium and ammonium salts of polyacrylic acids and best present in an amount between about 0.1 and about 5 weight percent based on the total weight of the dispersion. The defoaming agent can, without limitation, be a non-silicone defoaming agent and is present in an amount between about 0.01 and about 5.0 weight percent based on the total weight of the dispersion. An exemplified dispersion enhancer can be a fumed silica that acts as a compatibilizer for the dispersion. In some aspects, the fumed silica is present at between about 0.1 and about 0.2 weight percent based on the total weight of the dispersion.
[0131] In still another aspect, the precoat layer can comprise one or more fillers. Exemplary and non-limiting fillers that can be incorporated into the precoat layer can include calciumcarbonate, fly-ash, recycled calcium carbonate, aluminum trihydrate, talc, nano-clay, barium sulfate, barite, barite glass fiber, glass powder, glass cullet, metal powder, alumina, hydrated alumina, clay, magnesium carbonate, calcium sulfate, silica, glass, fumed silica, carbon black, graphite, cement dust, feldspar, nepheline, magnesium oxide, zinc oxide, aluminum silicate, calcium silicate, titanium dioxide, titanates, glass microspheres, chalk, calcium oxide, and any combination thereof. In some aspects, the filler can comprise both calcium carbonate and alumina trihydrate. Calcium carbonate and alumina trihydrate can be present in any relative ratio suitable for a specific carpet application, for example and without limitation, calcium carbonate and alumina trihydrate can be present in a ratio of from about 100:25 to about 100:75 parts of calcium carbonate to alumina trihydrate. Any of the fillers described as being present in the adhesive backing composition can also be present in the precoat layer.3. Adhesive backing layer
[0132] The cured adhesive backing composition is formed from an adhesive backing composition disclosed herein. In some aspects, the cured adhesive backing composition and the precoat layer can be combined into a single layer, thus elements of both the precoat layer and the cured adhesive backing composition can be present.
[0133] In some aspects, the cured adhesive backing composition can be attached to the back side of the primary backing layer and lock in the plurality of fibers extending from the back side of the primary backing layer. In such aspects, the adhesive backing layer can comprise a propylene elastomer component as described herein. In some aspects, a precoat layer, as described herein, can be present between the adhesive backing layer and the back side of the primary backing layer.4. Secondary Backing Layer
[0134] The disclosed carpets comprise a secondary backing layer on the back side of the cured adhesive backing composition opposite to the primary backing layer.
[0135] The carpet comprises a secondary backing layer having a first surface and a second surface, wherein the first surface of the secondary backing is adhered to the back surface of the primary backing component by the adhesive backing compositions. In one aspect the secondary backing layer can comprise a woven material. In another aspect, the secondary backing layer can comprise a tape-tape yarn, or a tape-spun yam. In certain aspects, the secondary backing layer can be a tape-tape yarn woven material. In one aspect, the secondary backing layer cancomprise a polyolefin. In a yet further aspect, the polyolefin can comprise polypropylene. In certain exemplary aspects, the material for the secondary backing layer can be a conventional material, for example and without limitation, the woven polypropylene fabric sold by Propex. Such secondary backing layers can comprise a material that is a leno weave with polypropylene tape running in one direction and polypropylene spun yarn running in the other. In other aspects, the secondary backing layer used is a woven polypropylene fabric with monofilaments running in both directions. A suitable example of such a material is manufactured by Shaw Industries, Inc. under the designation Style S8880.
[0136] In further aspects, the secondary backing layer can be a material known as fiber lock weave or "FLW." FLW is a fabric which includes fibers needle punched into it. Sometimes FLW is used as a primary backing component on a carpet with a low pile weight.
[0137] In some aspects, the secondary backing layer can be a woven needle punched polypropylene fabric such as SoftBac® manufactured by Shaw Industries, Inc. In this exemplary aspect, this material has been enhanced by having about 1.5 ounce / sq. yard of polypropylene fibers or polyethylene terephthalate fibers needle punched onto one side of it and has a total basis weight of about 3.5 ounce / sq. yard. This needle punched fabric can be laminated so as to have the polypropylene fibers embedded within the adhesive backing layer. In still further aspects other materials can be used for the secondary backing, for example, and without limitation, if an integral pad is desired, a polyurethane foam or other cushion material can be laminated to the back side of the carpet. Such backings can be used for broadloom carpet.
[0138] In yet other aspects, the secondary backing layer can comprise a non-woven material. In certain aspects, the secondary backing layer can comprise a spunbond non-woven material. The spunbond backing can be produced by depositing extruded, spun filaments onto a collecting belt in a uniform random manner followed by bonding the fibers. The fibers are separated during the web laying process by air jets or electrostatic charges. The collecting surface is usually perforated to prevent the air stream from deflecting and carrying the fibers in an uncontrolled manner. Bonding imparts strength and integrity to the web by applying heated rolls or hot needles to partially melt the polymer and fuse the fibers together. Since molecular orientation increases the melting point, fibers that are not highly drawn can be used as thermal binding fibers. In some aspect, the spun-bond secondary backing component can comprise a bicomponent filament of a sheath-core type. In some aspects, the polymeric core component canhave a higher melting point than the polymeric sheath component. In some aspects, the polymeric core component can comprise polyester, aliphatic polyamides, polyphenylene oxide and / or co-polymers or blends thereof. In yet other aspects, the polyester can comprise polyethylene terephthalate, polybutylene terephthalate, or polyparaphenylene terephthalamide. In yet other aspects, the polymeric core comprises polyethylene terephthalate. In further aspects, the sheath polymer can comprise a polyamide, polyethylene, or polyester. In yet further aspects, the sheath polymer comprises nylon. In still further aspects, the sheath-core primary backing component comprises a polyester as a core component and nylon as a sheath component. The exemplary sheath-core secondary backing component can be commercially available from Bonar. In yet other aspects, a polyester non-woven secondary backing can be commercially available from Freudenberg.
[0139] In some aspects, the secondary backing layer can comprise a thermoplastic polyolefin. In certain aspects, the secondary backing material comprises substantially linear ethylene polymers and homogeneously branched linear ethylene polymers (i.e., homogeneously branched ethylene polymers). Homogeneously branched ethylene polymers (including substantially linear ethylene polymers in particular) have low solidification temperatures, good adhesion to polypropylene, and low modulus relative to conventional ethylene polymers such as low density polyethylene (LDPE), heterogeneously branched linear low density polyethylene (LLDPE), high density polyethylene (HDPE), and heterogeneously branched ultra low density polyethylene (ULDPE).
[0140] In some aspects, the secondary backing layer comprises one or more propylene elastomer components. In other aspects, the second layer comprises at least one thermoplastic polyolefin described herein. It is preferred that the second layer is made from a thermoplastic polyolefin to facilitate recycling, which can be the same as or different from the propylene elastomer component in the adhesive backing layer.5. Reinforcement layer
[0141] In some aspects, the carpet further comprises an optional reinforcement layer. The layer of reinforcing material has been found to enhance the dimensional stability of the carpet composition. To that end, the optional reinforcing layer can be positioned between any two layers of the carpet composition. For example, the reinforcement layer can be positioned between the cured adhesive backing composition and the secondary backing layer. In another example, the carpet further comprises a second reinforcement layer between the cured adhesivebacking composition and the precoat composition.
[0142] Suitable reinforcing materials include dimensionally and thermally stable fabrics such as non-woven or fiberglass scrims, such as wet-laid fiberglass scrims, as well as woven and non-woven thermoplastic fabrics (e.g. polypropylene, nylon and polyester). In some aspects, the reinforcement layer is a polypropylene non-woven fabric sold by Reemay as "Typar" with a basis weight of 3.5 OSY (124 cm3 / m2). Alternatively, in other aspects, a reinforcement layer is a fiberglass scrim sold by ELK Corp, as "Ultra-Mat:" with a basis weight of 1.4 OSY (49.5 cm3 / m2).D. Methods of Making
[0143] Also disclosed are methods for making the disclosed carpets.
[0144] Disclosed is a method for making a carpet comprising the steps of: a) dispensing an adhesive backing composition discloses herein on a secondary backing layer; b) passing the secondary backing layer with the dispensed adhesive backing composition under a blade to produce an even layer of the dispensed adhesive backing composition; and c) contacting the even layer of the dispensed adhesive backing composition with a back side of a primary backing layer having a plurality of fibers attached to the primary backing layer and extending from both a face side and the back side of the primary backing layer side.
[0145] In one aspect, the method further comprises after step c) curing the adhesive backing composition.
[0146] The plurality of fibers can be inserted into the primary backing by any conventional tufting or needle-punching apparatus and any stitch patterns can be used. Tufted yam loops may be left uncut to produce a loop pile; cut to make cut pile; or cut, partially cut and uncut to make a face texture known as tip sheared.Examples
[0147] In this Example, three exemplary adhesive backing compositions, one adhesive backing composition related to adhesive backing composition A and two to adhesive backing composition B, disclosed herein were prepared, as shown in Table 1.TABLE 1
[0148] The non-limiting Exemplary Adhesive Backing Composition A has a viscosity of 56,500 mPa.s at 2 rpm and a viscosity of 48,250 mPa.s at 4 rpm as measured by ASTM D3236- 15 at 150° C using a SC4-27 spindle. The non-limiting First Exemplary Adhesive Backing Composition B has a viscosity of 75,500 mPa.s at 2 rpm and a viscosity of 60,500 mPa.s at 4 rpm as measured by ASTM D3236-15 at 150° C using a SC4-27 spindle. The non-limiting Second Exemplary Adhesive Backing Composition B has a viscosity of 80,000 mPa.s at 2 rpm and a viscosity of 65,000 mPa.s at 4 rpm as measured by ASTM D3236-15 at 150° C using a SC4-27 spindle. The viscosities of the formulations are desirable.ASPECTS
[0149] In view of the described products, systems, and methods and variations thereof,herein below are described certain more particularly described aspects of the invention. These particularly recited aspects should not however be interpreted to have any limiting effect on any different claims containing different or more general teachings described herein, or that the “particular” aspects are somehow limited in some way other than the inherent meanings of the language literally used therein.
[0150] Aspect 1 : An adhesive backing composition, comprising: a) from about 5 to about 12 weight percent of a first polypropylene elastomer component comprising from greater than 10 to 15 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 30 to about 40 weight percent of a second polypropylene elastomer component comprising from greater than 4 to 8 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 4 to about 10 weight percent of an aliphatic tackifier resin; and d) from about 30 to about 60 weight percent of filler component, wherein the adhesive backing composition has a viscosity of 25,000 - 100,000 mPa s as measured by ASTM D3236-15.
[0151] Aspect 2: The adhesive backing composition of aspect 1, wherein: i) the first polypropylene elastomer has a melt index (MI) according to ASTM DI 238 of from about 15 to about 25 g / lOmin; and ii) the second polypropylene elastomer has a viscosity of from about lOOOcP to 1400cP at 190°C.
[0152] Aspect 3: The adhesive backing composition of aspects 1 or 2, wherein the adhesive backing composition comprises from about 6 to about 10 weight percent of the first polypropylene elastomer component.
[0153] Aspect 4: The adhesive backing composition of any one of aspects 1-3, wherein the adhesive backing composition comprises from about 33 to about 37 weight percent of the second polypropylene elastomer component.
[0154] Aspect 5: The adhesive backing composition of any one of aspects 1-4, wherein the adhesive backing composition comprises from about 5 to about 9 weight percent of an aliphatic tackifier resin.
[0155] Aspect 6: The adhesive backing composition of any one of aspects 1-5, wherein the adhesive backing composition comprises from about 45 to about 55 weight percent of filler component.
[0156] Aspect 7: The adhesive backing composition of any one of aspects 1-6, wherein the first polypropylene elastomer component comprises about 13 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component.
[0157] Aspect 8: The adhesive backing composition of any one of aspects 1-7, wherein the second polypropylene elastomer component comprises about 6 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component.
[0158] Aspect 9: The adhesive backing composition of any one of aspects 1-8, wherein the adhesive backing composition has a viscosity of 30,000 - 50,000 mPa s as measured by ASTM D3236-15.
[0159] Aspect 10: The adhesive backing composition of any one of aspects 1-9, wherein the adhesive backing composition comprises: a) from about 6 to about 10 weight percent of a first polypropylene elastomer component comprising from greater than 10 to 15 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 33 to about 37 weight percent of a second polypropylene elastomer component comprising from greater than 4 to 8 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 5 to about 9 weight percent of an aliphatic tackifier resin; and d) from about 45 to about 55 weight percent of filler component, wherein the adhesive backing composition has a viscosity of 25,000 - 100,000 mPa s as measured by ASTM D3236-15.
[0160] Aspect 11 : The adhesive backing composition of any one of aspects 1-10, whereinthe adhesive backing composition comprises: a) from about 6 to about 10 weight percent of a first polypropylene elastomer component comprising from about 13 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 33 to about 47 weight percent of a second polypropylene elastomer component comprising from about 6 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 5 to about 9 weight percent of an aliphatic tackifier resin; and d) from about 45 to about 55 weight percent of filler component, wherein the adhesive backing composition has a viscosity of 25,000 - 100,000 mPa s as measured by ASTM D3236-15.
[0161] Aspect 12: An adhesive backing composition, comprising: a) from about 4 to about 9 weight percent of a first polypropylene elastomer component comprising from greater than 10 to 15 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 20 to about 30 weight percent of a second polypropylene elastomer component comprising from greater than 4 to 8 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 3 to about 8 weight percent of an aliphatic tackifier resin; d) from about 40 to about 70 weight percent of filler component; and e) from about greater than 0 to about 5 weight percent of a mixture of at least one metal salt of a fatty acid and at least one amide, wherein the adhesive backing composition has a viscosity of 25,000 - 100,000 mPa s as measured by ASTM D3236-15.
[0162] Aspect 13: The adhesive backing composition of aspect 12, wherein: i) the first polypropylene elastomer has a melt index (MI) according to ASTM DI 238 of from about 15 to about 25 g / lOmin; andii) the second polypropylene elastomer has a viscosity of from about lOOOcP to 1400cP at 190°C.
[0163] Aspect 14: The adhesive backing composition of aspects 12 or 13, wherein the adhesive backing composition comprises from about 5 to about 8 weight percent of the first polypropylene elastomer component.
[0164] Aspect 15: The adhesive backing composition of any one of aspects 12-14, wherein the adhesive backing composition comprises from about 23 to about 27 weight percent of the second polypropylene elastomer component.
[0165] Aspect 16: The adhesive backing composition of any one of aspects 12-15, wherein the adhesive backing composition comprises from 4 to about 7 weight percent of an aliphatic tackifier resin.
[0166] Aspect 17: The adhesive backing composition of any one of aspects 12-16, wherein the adhesive backing composition comprises from about 60 to about 70 weight percent of filler component.
[0167] Aspect 18: The adhesive backing composition of any one of aspects 12-17, wherein the adhesive backing composition comprises from more than 0 to about 2 weight percent of the mixture of at least one metal salt of a fatty acid and at least one amide.
[0168] Aspect 19: The adhesive backing composition of any one of aspects 12-18, wherein the first polypropylene elastomer component comprises about 13 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component.
[0169] Aspect 20: The adhesive backing composition of any one of aspects 12-19, wherein the second polypropylene elastomer component comprises about 6 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component.
[0170] Aspect 21 : The adhesive backing composition of any one of aspects 12-20, wherein the adhesive backing composition has a viscosity of 30,000 - 50,000 mPa s as measured by ASTM D3236-15.
[0171] Aspect 22: The adhesive backing composition of any one of aspects 12-21, wherein the adhesive backing composition comprises:a) from about 5 to about 8 weight percent of a first polypropylene elastomer component comprising from greater than 10 to 15 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 23 to about 27 weight percent of a second polypropylene elastomer component comprising from greater than 4 to 8 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 4 to about 7 weight percent of an aliphatic tackifier resin; d) from about 60 to about 70 weight percent of filler component; and e) from about greater than 0 to about 2 weight percent of a mixture of at least one metal salt of a fatty acid and at least one amide, wherein the adhesive backing composition has a viscosity of 25,000 - 100,000 mPa s as measured by ASTM D3236-15.
[0172] Aspect 23: The adhesive backing composition of any one of aspects 12-22, wherein the adhesive backing composition comprises: a) from about 5 to about 8 weight percent of a first polypropylene elastomer component comprising from about 13 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 23 to about 27 weight percent of a second polypropylene elastomer component comprising from about 6 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 4 to about 7 weight percent of an aliphatic tackifier resin; d) from about 60 to about 70 weight percent of filler component; and e) from about greater than 0 to about 2 weight percent of a mixture of at least one metal salt of a fatty acid and at least one amide, wherein the adhesive backing composition has a viscosity of 25,000 - 100,000 mPa s as measured by ASTM D3236-15.
[0173] Aspect 24: A carpet, comprisinga) a primary backing layer having a face side and a back side; b) a plurality of fibers attached to the primary backing layer and extending from both the face side and the back side of the primary backing layer; c) a cured adhesive backing composition formed from the adhesive backing composition of any one of aspects 1-23 of the back side of the primary backing layer; and d) an secondary backing layer attached to the back side of the primary backing layer, via the cured adhesive backing composition.
[0174] Aspect 25: The carpet of aspect 24, wherein the cured adhesive backing composition has a thickness from 1 mil to 100 mils.
[0175] Aspect 26: The carpet of aspects 24 or 25, wherein the carpet further comprises a reinforcement layer between the cured adhesive backing composition and the secondary backing layer.
[0176] Aspect 27: The carpet of aspect 26, wherein the carpet further comprises a precoat composition between the cured adhesive backing composition and the primary backing layer.
[0177] Aspect 28: The carpet of aspect 27, wherein the carpet further comprises a second reinforcement layer between the cured adhesive backing composition and the precoat composition.
[0178] Aspect 29: The carpet of any one of aspects 24-28, wherein the carpet is a carpet tile.
[0179] Aspect 30: The carpet of any one of aspects 24-28, wherein the carpet is a broadloom carpet.
[0180] Aspect 31 : A method of making a carpet comprising the steps of: a) dispensing the adhesive backing composition of any one of aspects 1-23 on a secondary backing layer; b) passing the secondary backing layer with the dispensed adhesive backing composition under a blade to produce an even layer of the dispensed adhesive backing composition; andc) contacting the even layer of the dispensed adhesive backing composition with a back side of a primary backing layer having a plurality of fibers attached to the primary backing layer and extending from both a face side and the back side of the primary backing layer side.
[0181] Aspect 32: The method of aspect 31, after step c) further comprising the step of curing the adhesive backing composition.
[0182] Aspect 33: An adhesive backing composition, comprising: a) from about 4 to about 20 weight percent of a first polypropylene elastomer component comprising from greater than 10 to 15 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 20 to about 40 weight percent of a second polypropylene elastomer component comprising from greater than 4 to 8 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 4 to about 10 weight percent of an aliphatic tackifier resin; and d) from about 30 to about 60 weight percent of filler component, wherein the adhesive backing composition has a viscosity of 10,000 - 100,000 mPa s as measured by ASTM D3236-15 at 150 °C.
[0183] Aspect 34: The adhesive backing composition of aspect 33, wherein: a) from about 12 to about 20 weight percent of a first polypropylene elastomer component comprising from greater than 10 to 15 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 20 to about 30 weight percent of a second polypropylene elastomer component comprising from greater than 4 to 8 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component
[0184] Aspect 35: The adhesive backing composition of aspect 33 or 34, wherein: i) the first polypropylene elastomer has a melt index (MI) according to ASTM D1238 of from about 15 to about 50g / 10min; andii) the second polypropylene elastomer has a viscosity of from about lOOOcP to 1400cP at 190°C.
[0185] Aspect 36: The adhesive backing composition of aspects 33 - 35, wherein the adhesive backing composition comprises from about 12 to about 18 weight percent of the first polypropylene elastomer component.
[0186] Aspect 37: The adhesive backing composition of any one of aspects 33-36, wherein the adhesive backing composition comprises from about 22 to about 28 weight percent of the second polypropylene elastomer component.
[0187] Aspect 38: The adhesive backing composition of any one of aspects 33-37, wherein the adhesive backing composition comprises from about 5 to about 9 weight percent of an aliphatic tackifier resin.
[0188] Aspect 39: The adhesive backing composition of any one of aspects 33-38, wherein the adhesive backing composition comprises from about 45 to about 55 weight percent of filler component.
[0189] Aspect 40: The adhesive backing composition of any one of aspects 33-39, wherein the first polypropylene elastomer component comprises about 12 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component.
[0190] Aspect 41 : The adhesive backing composition of any one of aspects 33-40, wherein the second polypropylene elastomer component comprises about 6 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component.
[0191] Aspect 42: The adhesive backing composition of any one of aspects 33-41, wherein the adhesive backing composition has a viscosity of 30,000 - 50,000 mPa s as measured by ASTM D3236-15 at 150 °C.
[0192] Aspect 43: The adhesive backing composition of any one of aspects 33-41, wherein the adhesive backing composition comprises: a) from about 12 to about 18 weight percent of a first polypropylene elastomer component comprising from greater than 10 to 15 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component;b) from about 22 to about 37 weight percent of a second polypropylene elastomer component comprising from greater than 4 to 8 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 5 to about 9 weight percent of an aliphatic tackifier resin; and d) from about 45 to about 55 weight percent of filler component, wherein the adhesive backing composition has a viscosity of 10,000 - 100,000 mPa s as measured by ASTM D3236-15.
[0193] Aspect 44: The adhesive backing composition of any one of aspects 33-43, wherein the adhesive backing composition comprises: a) from about 12 to about 18 weight percent of a first polypropylene elastomer component comprising from about 12 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 22 to about 28 weight percent of a second polypropylene elastomer component comprising from about 6 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 5 to about 9 weight percent of an aliphatic tackifier resin; and d) from about 45 to about 55 weight percent of filler component, wherein the adhesive backing composition has a viscosity of 10,000 - 100,000 mPa s as measured by ASTM D3236-15 at 150 °C.
[0194] Aspect 45: An adhesive backing composition, comprising: a) from about 2 to about 15 weight percent of a first polypropylene elastomer component comprising from greater than 10 to 15 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 10 to about 30 weight percent of a second polypropylene elastomer component comprising from greater than 4 to 8 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 3 to about 8 weight percent of an aliphatic tackifier resin;d) from about 40 to about 70 weight percent of filler component; and e) from about greater than 0 to about 5 weight percent of a mixture of at least one metal salt of a fatty acid and at least one amide, wherein the adhesive backing composition has a viscosity of 10,000 - 100,000 mPa s as measured by ASTM D3236-15.
[0195] Aspect 46: The adhesive backing composition of aspect 45, wherein: a) from about 9 to about 15 weight percent of a first polypropylene elastomer component comprising from greater than 10 to 15 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 10 to about 20 weight percent of a second polypropylene elastomer component comprising from greater than 4 to 8 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component;
[0196] Aspect 47: The adhesive backing composition of aspect 45 or 46, wherein: i) the first polypropylene elastomer has a melt index (MI) according to ASTM D1238 of from about 15 to about 50 g / lOmin; and ii) the second polypropylene elastomer has a viscosity of from about lOOOcP to 1400cP at 190°C.
[0197] Aspect 48: The adhesive backing composition of aspects 45-47, wherein the adhesive backing composition comprises from about 10 to about 14 weight percent of the first polypropylene elastomer component.
[0198] Aspect 49: The adhesive backing composition of any one of aspects 45-48, wherein the adhesive backing composition comprises from about 13 to about 17 weight percent of the second polypropylene elastomer component.
[0199] Aspect 50: The adhesive backing composition of any one of aspects 45-49, wherein the adhesive backing composition comprises from 4 to about 7 weight percent of an aliphatic tackifier resin.
[0200] Aspect 51 : The adhesive backing composition of any one of aspects 45-50, whereinthe adhesive backing composition comprises from about 60 to about 70 weight percent of filler component.
[0201] Aspect 52: The adhesive backing composition of any one of aspects 45-51, wherein the adhesive backing composition comprises from more than 0 to about 2 weight percent of the mixture of at least one metal salt of a fatty acid and at least one amide.
[0202] Aspect 53: The adhesive backing composition of any one of aspects 45-52, wherein the first polypropylene elastomer component comprises about 12 or 13 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component.
[0203] Aspect 54: The adhesive backing composition of any one of aspects 45-53, wherein the second polypropylene elastomer component comprises about 6 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component.
[0204] Aspect 55: The adhesive backing composition of any one of aspects 45-54, wherein the adhesive backing composition has a viscosity of 30,000 - 50,000 mPa s as measured by ASTM D3236-15 at 150 °C.
[0205] Aspect 56: The adhesive backing composition of any one of aspects 45-55, wherein the adhesive backing composition comprises: a) from about 10 to about 14 weight percent of a first polypropylene elastomer component comprising from greater than 10 to 15 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 13 to about 17 weight percent of a second polypropylene elastomer component comprising from greater than 4 to 8 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 4 to about 7 weight percent of an aliphatic tackifier resin; d) from about 60 to about 70 weight percent of filler component; and e) from about greater than 0 to about 2 weight percent of a mixture of at least one metal salt of a fatty acid and at least one amide, wherein the adhesive backing composition has a viscosity of 10,000 - 100,000 mPa s as measured by ASTM D3236-15 at 150 °C.
[0206] Aspect 57: The adhesive backing composition of any one of aspects 45-56, wherein the adhesive backing composition comprises: a) from about 10 to about 14 weight percent of a first polypropylene elastomer component comprising from about 12 or 13 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 13 to about 17 weight percent of a second polypropylene elastomer component comprising from about 6 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 4 to about 7 weight percent of an aliphatic tackifier resin; d) from about 60 to about 70 weight percent of filler component; and e) from about greater than 0 to about 2 weight percent of a mixture of at least one metal salt of a fatty acid and at least one amide, wherein the adhesive backing composition has a viscosity of 10,000 - 100,000 mPa s as measured by ASTM D3236-15 at 150 °C.
[0207] Aspect 58: A carpet, comprising a) a primary backing layer having a face side and a back side; b) a plurality of fibers attached to the primary backing layer and extending from both the face side and the back side of the primary backing layer; c) a cured adhesive backing composition formed from the adhesive backing composition of any one of aspects 33-57 of the back side of the primary backing layer; and d) an secondary backing layer attached to the back side of the primary backing layer, via the cured adhesive backing composition.
[0208] Aspect 59: The carpet of aspect 58, wherein the cured adhesive backing composition has an add-on weight range of about 500 gsm to about 3000 gsm.
[0209] Aspect 60: The carpet of aspects 58 or 59, wherein the carpet further comprises a reinforcement layer between the cured adhesive backing composition and the secondary backing
[0210] Aspect 61 : The carpet of aspect 60, wherein the carpet further comprises a precoat composition between the cured adhesive backing composition and the primary backing layer.
[0211] Aspect 62: The carpet of aspect 61, wherein the carpet further comprises a second reinforcement layer between the cured adhesive backing composition and the precoat composition.
[0212] Aspect 63: The carpet of any one of aspects 58-62, wherein the carpet is a carpet tile.
[0213] Aspect 64: The carpet of any one of aspects 58-62, wherein the carpet is a broadloom carpet.
[0214] Aspect 65: A method of making a carpet comprising the steps of: a) dispensing the adhesive backing composition of any one of aspects 33-57 on a secondary backing layer; b) passing the secondary backing layer with the dispensed adhesive backing composition under a blade to produce an even layer of the dispensed adhesive backing composition; and c) contacting the even layer of the dispensed adhesive backing composition with a back side of a primary backing layer having a plurality of fibers attached to the primary backing layer and extending from both a face side and the back side of the primary backing layer side.
[0215] Aspect 66: The method of aspect 65, after step c) further comprising the step of curing the adhesive backing composition.
Claims
CLAIMS1. An adhesive backing composition, comprising: a) from about 4 to about 20 weight percent of a first polypropylene elastomer component comprising from greater than 10 to 15 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 20 to about 40 weight percent of a second polypropylene elastomer component comprising from greater than 4 to 8 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 4 to about 10 weight percent of an aliphatic tackifier resin; and d) from about 30 to about 60 weight percent of filler component, wherein the adhesive backing composition has a viscosity of 10,000 - 100,000 mPa s as measured by ASTM D3236-15 at 150 °C.
2. The adhesive backing composition of claim 1, comprising: a) from about 5 to about 12 weight percent of a first polypropylene elastomer component comprising from greater than 10 to 15 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 30 to about 40 weight percent of a second polypropylene elastomer component comprising from greater than 4 to 8 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 4 to about 10 weight percent of an aliphatic tackifier resin; and d) from about 30 to about 60 weight percent of filler component, wherein the adhesive backing composition has a viscosity of 10,000 - 100,000 mPa s as measured by ASTM D3236-15 at 150 °C.
3. The adhesive backing composition of claim 1, comprising: a) from about 12 to about 20 weight percent of a first polypropylene elastomer component comprising from greater than 10 to 15 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 20 to about 30 weight percent of a second polypropylene elastomer component comprising from greater than 4 to 8 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 4 to about 10 weight percent of an aliphatic tackifier resin; and d) from about 30 to about 60 weight percent of filler component, wherein the adhesive backing composition has a viscosity of 10,000 - 100,000 mPa s as measured by ASTM D3236-15 at 150 °C.
4. The adhesive backing composition of claim 1, wherein: i) the first polypropylene elastomer has a melt index (MI) according to ASTM D1238 of from about 15 to about 50 g / lOmin; and ii) the second polypropylene elastomer has a viscosity of from about lOOOcP to 1400cP at 190°C.
5. The adhesive backing composition of claim 1, wherein the adhesive backing composition comprises from about 6 to about 10 weight percent of the first polypropylene elastomer component.
6. The adhesive backing composition of claim 1, wherein the adhesive backing composition comprises from about 12 to about 18 weight percent of the first polypropylene elastomer component.
7. The adhesive backing composition of claim 1, wherein the adhesive backing composition comprises from about 33 to about 37 weight percent of the second polypropylene elastomer component.
8. The adhesive backing composition of claim 1, wherein the adhesive backing composition comprises from about 22 to about 28 weight percent of the second polypropylene elastomer component.
9. The adhesive backing composition of claim 1, wherein the adhesive backing composition comprises from about 5 to about 9 weight percent of an aliphatic tackifier resin.
10. The adhesive backing composition of claim 1, wherein the adhesive backing composition comprises from about 45 to about 55 weight percent of filler component.
11. The adhesive backing composition of claim 1, wherein the first polypropylene elastomer component comprises about 13 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component.
12. The adhesive backing composition of claim 1, wherein the first polypropylene elastomer component comprises about 12 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component.
13. The adhesive backing composition of claim 1, wherein the second polypropylene elastomer component comprises about 6 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component.
14. The adhesive backing composition of claim 1, wherein the adhesive backing composition has a viscosity of 30,000 - 50,000 mPa- s as measured by ASTM D3236-15.
15. The adhesive backing composition of claim 1, wherein the adhesive backing composition comprises: a) from about 6 to about 10 weight percent of a first polypropylene elastomer component comprising from greater than 10 to 15 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 33 to about 37 weight percent of a second polypropylene elastomer component comprising from greater than 4 to 8 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 5 to about 9 weight percent of an aliphatic tackifier resin; andd) from about 45 to about 55 weight percent of filler component, wherein the adhesive backing composition has a viscosity of 10,000 - 100,000 mPa s as measured by ASTM D3236-15 at 150 °C.
16. The adhesive backing composition of claim 1, wherein the adhesive backing composition comprises: a) from about 12 to about 18 weight percent of a first polypropylene elastomer component comprising from greater than 10 to 15 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 22 to about 28 weight percent of a second polypropylene elastomer component comprising from greater than 4 to 8 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 5 to about 9 weight percent of an aliphatic tackifier resin; and d) from about 45 to about 55 weight percent of filler component, wherein the adhesive backing composition has a viscosity of 10,000 - 100,000 mPa s as measured by ASTM D3236-15 at 150 °C.
17. The adhesive backing composition of claim 1, wherein the adhesive backing composition comprises: a) from about 6 to about 10 weight percent of a first polypropylene elastomer component comprising from about 13 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 33 to about 47 weight percent of a second polypropylene elastomer component comprising from about 6 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 5 to about 9 weight percent of an aliphatic tackifier resin; and d) from about 45 to about 55 weight percent of filler component, wherein the adhesive backing composition has a viscosity of 25,000 - 100,000 mPa s as measured by ASTM D3236-15 at 150 °C.
18. The adhesive backing composition of claim 1, wherein the adhesive backing composition comprises: a) from about 12 to about 18 weight percent of a first polypropylene elastomer component comprising from about 12 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 22 to about 28 weight percent of a second polypropylene elastomer component comprising from about 6 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 5 to about 9 weight percent of an aliphatic tackifier resin; and d) from about 45 to about 55 weight percent of filler component, wherein the adhesive backing composition has a viscosity of 10,000 - 100,000 mPa s as measured by ASTM D3236-15 at 150 °C.
19. An adhesive backing composition, comprising: a) from about 2 to about 15 weight percent of a first polypropylene elastomer component comprising from greater than 10 to 15 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 10 to about 30 weight percent of a second polypropylene elastomer component comprising from greater than 4 to 8 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 3 to about 8 weight percent of an aliphatic tackifier resin; d) from about 40 to about 70 weight percent of filler component; and e) from about greater than 0 to about 5 weight percent of a mixture of at least one metal salt of a fatty acid and at least one amide, wherein the adhesive backing composition has a viscosity of 10,000 - 100,000 mPa s as measured by ASTM D3236-15 at 150 °C.
20. The adhesive backing composition of claim 19, comprising:a) from about 4 to about 9 weight percent of a first polypropylene elastomer component comprising from greater than 10 to 15 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 20 to about 30 weight percent of a second polypropylene elastomer component comprising from greater than 4 to 8 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 3 to about 8 weight percent of an aliphatic tackifier resin; d) from about 40 to about 70 weight percent of filler component; and e) from about greater than 0 to about 5 weight percent of a mixture of at least one metal salt of a fatty acid and at least one amide, wherein the adhesive backing composition has a viscosity of 10,000 - 100,000 mPa s as measured by ASTM D3236-15 at 150 °C.
21. The adhesive backing composition of claim 19, comprising: a) from about 9 to about 15 weight percent of a first polypropylene elastomer component comprising from greater than 10 to 15 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 10 to about 20 weight percent of a second polypropylene elastomer component comprising from greater than 4 to 8 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 3 to about 8 weight percent of an aliphatic tackifier resin; d) from about 40 to about 70 weight percent of filler component; and e) from about greater than 0 to about 5 weight percent of a mixture of at least one metal salt of a fatty acid and at least one amide, wherein the adhesive backing composition has a viscosity of 25,000 - 100,000 mPa s as measured by ASTM D3236-15 at 150 °C.
22. The adhesive backing composition of claim 19, wherein: i) the first polypropylene elastomer has a melt index (MI) according to ASTM D1238 of from about 15 to about 50 g / lOmin; and ii) the second polypropylene elastomer has a viscosity of from about lOOOcP to 1400cP at 190°C.
23. The adhesive backing composition of claim 19, wherein the adhesive backing composition comprises from about 5 to about 8 weight percent of the first polypropylene elastomer component.
24. The adhesive backing composition of claim 19, wherein the adhesive backing composition comprises from about 10 to about 14 weight percent of the first polypropylene elastomer component.
25. The adhesive backing composition of claim 19, wherein the adhesive backing composition comprises from about 23 to about 27 weight percent of the second polypropylene elastomer component.
26. The adhesive backing composition of claim 19, wherein the adhesive backing composition comprises from about 13 to about 17 weight percent of the second polypropylene elastomer component.
27. The adhesive backing composition of claim 19, wherein the adhesive backing composition comprises from 4 to about 7 weight percent of an aliphatic tackifier resin.
28. The adhesive backing composition of claim 19, wherein the adhesive backing composition comprises from about 60 to about 70 weight percent of filler component.
29. The adhesive backing composition of claim 19, wherein the adhesive backing composition comprises from more than 0 to about 2 weight percent of the mixture of at least one metal salt of a fatty acid and at least one amide.
30. The adhesive backing composition of claim 19, wherein the first polypropylene elastomer component comprises about 13 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component.
31. The adhesive backing composition of claim 19, wherein the first polypropylene elastomer component comprises about 12 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component.
32. The adhesive backing composition of claim 19, wherein the second polypropylene elastomer component comprises about 6 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component.
33. The adhesive backing composition of claim 19, wherein the adhesive backing composition has a viscosity of 30,000 - 50,000 mPa- s as measured by ASTM D3236- 15 at 150 °C.
34. The adhesive backing composition of claim 19, wherein the adhesive backing composition comprises: a) from about 5 to about 8 weight percent of a first polypropylene elastomer component comprising from greater than 10 to 15 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 23 to about 27 weight percent of a second polypropylene elastomer component comprising from greater than 4 to 8 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 4 to about 7 weight percent of an aliphatic tackifier resin; d) from about 60 to about 70 weight percent of filler component; and e) from about greater than 0 to about 2 weight percent of a mixture of at least one metal salt of a fatty acid and at least one amide, wherein the adhesive backing composition has a viscosity of 25,000 - 100,000 mPa s as measured by ASTM D3236-15 at 150 °C.
35. The adhesive backing composition of claim 19, wherein the adhesive backing composition comprises: a) from about 10 to about 14 weight percent of a first polypropylene elastomer component comprising from greater than 10 to 15 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component;b) from about 13 to about 17 weight percent of a second polypropylene elastomer component comprising from greater than 4 to 8 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 4 to about 7 weight percent of an aliphatic tackifier resin; d) from about 60 to about 70 weight percent of filler component; and e) from about greater than 0 to about 2 weight percent of a mixture of at least one metal salt of a fatty acid and at least one amide, wherein the adhesive backing composition has a viscosity of 10,000 - 100,000 mPa s as measured by ASTM D3236-15 at 150 °C.
36. The adhesive backing composition of claim 19, wherein the adhesive backing composition comprises: a) from about 5 to about 8 weight percent of a first polypropylene elastomer component comprising from about 13 weight percent ethylene derived units based upon the weight of the first polypropylene elastomer component; b) from about 23 to about 27 weight percent of a second polypropylene elastomer component comprising from about 6 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 4 to about 7 weight percent of an aliphatic tackifier resin; d) from about 60 to about 70 weight percent of filler component; and e) from about greater than 0 to about 2 weight percent of a mixture of at least one metal salt of a fatty acid and at least one amide, wherein the adhesive backing composition has a viscosity of 10,000 - 100,000 mPa s as measured by ASTM D3236-15 at 150 °C.
37. The adhesive backing composition of claim 19, wherein the adhesive backing composition comprises: a) from about 10 to about 14 weight percent of a first polypropylene elastomer component comprising from about 12 weight percent ethylene derived units basedupon the weight of the first polypropylene elastomer component; b) from about 13 to about 17 weight percent of a second polypropylene elastomer component comprising from about 6 weight percent ethylene derived units based upon the weight of the second polypropylene elastomer component; c) from about 4 to about 7 weight percent of an aliphatic tackifier resin; d) from about 60 to about 70 weight percent of filler component; and e) from about greater than 0 to about 2 weight percent of a mixture of at least one metal salt of a fatty acid and at least one amide, wherein the adhesive backing composition has a viscosity of 10,000 - 100,000 mPa s as measured by ASTM D3236-15 at 150 °C.
38. A carpet, comprising a) a primary backing layer having a face side and a back side; b) a plurality of fibers attached to the primary backing layer and extending from both the face side and the back side of the primary backing layer; c) a cured adhesive backing composition formed from the adhesive backing composition of any one of claims 1-37 of the back side of the primary backing layer; and d) an secondary backing layer attached to the back side of the primary backing layer, via the cured adhesive backing composition.
39. The carpet of claim 38, wherein the cured adhesive backing composition has a thickness from 1 mil to 100 mils.
40. The carpet of claim 38, wherein the cured adhesive backing composition has an addon weight range of 500 gsm to 3000 gsm.
41. The carpet of claim 38, wherein the carpet further comprises a reinforcement layer between the cured adhesive backing composition and the secondary backing layer.
42. The carpet of claim 41, wherein the carpet further comprises a precoat composition between the cured adhesive backing composition and the primary backing layer.
43. The carpet of claim 42, wherein the carpet further comprises a second reinforcement layer between the cured adhesive backing composition and the precoat composition.
44. The carpet of claim 38, wherein the carpet is a carpet tile.
45. The carpet of claim 38, wherein the carpet is a broadloom carpet.
46. A method of making a carpet comprising the steps of: a) dispensing the adhesive backing composition of any one of claims 1-37 on a secondary backing layer; b) passing the secondary backing layer with the dispensed adhesive backing composition under a blade to produce an even layer of the dispensed adhesive backing composition; and c) contacting the even layer of the dispensed adhesive backing composition with a back side of a primary backing layer having a plurality of fibers attached to the primary backing layer and extending from both a face side and the back side of the primary backing layer side.
47. The method of claim 46, after step c) further comprising the step of curing the adhesive backing composition.