Extruded carpet backing with resin and elastomer components
First Claim
1. A composition of matter useful in the preparation of a thermoplastic acoustical and thermal barrier for carpet backing having improved flexibility as measured with the Tinius Olsen stiffness test, such composition being extrudable and comprising from 10 up to about 25 weight percent of a thermoplastic resin component comprising a copolymer of ethylene and an unsaturated ester of a lower carboxylic acid, from about 4 to about 15 weight percent of an olefinic elastomer component, and from about 60 to about 85 weight percent of a filler component.
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Accused Products
Abstract
Highly flexible compositions of matter useful in the preparation of carpet backing are disclosed comprising thermoplastic resin compositions including copolymers of ethylene and unsaturated esters of lower carboxylic acids, such as vinyl esters and/or lower alkyl acrylates, in admixture with olefinic elastomers and substantial amounts of filler. The preferred thermoplastic resins employed include the copolymers of ethylene and vinyl acetate, and the preferred olefinic elastomers disclosed are ethylene copolymer elastomers, such as copolymers of ethylene and propylene, as well as terpolymers of ethylene, propylene and a diene, and the compositions preferably include a stearate or stearic acid and a hydrocarbon oil component. Carpet constructions are also disclosed comprising a plurality of carpet fibers and a thermoplastic barrier coating comprising the above combination of a thermoplastic resin, an olefinic elastomer and a substantial portion of filler material. Preferably a thermoplastic adhesive pre-coat layer is employed to bind the fibers together, and this is employed with a tufted carpet to adhere the carpet tufts to a woven or non-woven carpet scrim. These carpet constructions are preferably utilized in automotive carpeting applications. Methods for preparing said carpet constructions are also disclosed, comprising preparing the above thermoplastic barrier coating, applying (preferably by extrusion) an adhesive precoat to the surface of the carpet fibers so as to bind the fibers securely together, and applying the barrier coating so as to provide a strong and highly flexible carpet construction.
62 Citations
63 Claims
- 1. A composition of matter useful in the preparation of a thermoplastic acoustical and thermal barrier for carpet backing having improved flexibility as measured with the Tinius Olsen stiffness test, such composition being extrudable and comprising from 10 up to about 25 weight percent of a thermoplastic resin component comprising a copolymer of ethylene and an unsaturated ester of a lower carboxylic acid, from about 4 to about 15 weight percent of an olefinic elastomer component, and from about 60 to about 85 weight percent of a filler component.
- 19. A composition of matter useful in the preparation of a thermoplastic acoustical and thermal barrier for carpet backing having improved flexibility as measured with the Tinius Olsen stiffness test, such composition being extrudable and comprising from about 4 to about 15 weight percent of an olefinic elastomer component, from about 60 to about 85 weight percent of a filler component, and a thermoplastic resin component comprising a copolymer of ethylene and an unsaturated ester of a lower carboxylic acid.
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27. A thermoplastic composition useful as a backing material for carpeting, said thermoplastic composition consisting of by weight:
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(a) About 10-25 percent of an ethylene containing polymer which is an ethylene/monounsaturated ester copolymer having a melt index of about 2.5 to 50 (b) About 4-15 percent of a non-vulcanized elastomer having a Mooney viscosity of about 25-80, which is a polyisobutylene, butyl rubber, a copolymer of ethylene and propylene or a terpolymer of ethylene, propylene and a minor amount of a diene monomer or mixtures thereof, and the diene is selected from the class consisting of 1,4-hexadiene, dicyclopenatdiene, methylenenorbornene, ethylenenorbornene, tetrahydroindene, 5-methylene-2-norbornene, 5-ethylidene norbornene, and 4-7-8-9-tetrahydroindene, (c) About 60-85 percent of an inert mineral filler, and (d) About 1-15 percent of a plasticizer for the ethylene containing polymer comprising a hydrocarbon oil. - View Dependent Claims (28, 29, 30, 31, 32)
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- 33. A carpet construction comprising a plurality of carpet fibers, and an extrudable thermoplastic acoustical and thermal barrier comprising from 10 up to about 25 weight percent of a thermoplastic resin component comprising a copolymer of ethylene and an unsaturated ester of a lower carboxylic acid, from about 4 to about 15 weight percent of an olefinic elastomer component, and from about 60 to about 85 weight percent of a filler component.
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48. A tufted automotive carpet comprising a base fabric stitched with erect loops of yarn to form tufts on the top side of the base fabric and a thermoplastic backing composition on the bottom side of said base fabric, said composition comprising by weight:
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(a) About 10-25 percent of an ethylene containing polymer comprising an ethylene/mono-unsaturated ester copolymer, (b) About 4-15 percent of a non-vulcanized elastomeric resin, (c) About 60-85 percent of an inert mineral filler, and (d) About 2-10 percent of a plasticizer. - View Dependent Claims (50, 51)
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49. A tufted automotive carpet comprising a base fabric stitched with erect loops of yarn to form tufts on the top side of the base fabric and a thermoplastic backing composition on the bottom side of said base fabric, said composition comprising by weight:
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(a) About 10-25 percent of an ethylene containing polymer comprising an ethylene/mono-unsaturated ester copolymer, (b) About 4-10 percent of a non-vulcanized elastomeric resin, (c) About 60-85 percent of an inert mineral filler, and (d) About 2-10 percent of a plasticizer.
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- 52. A method for producing a carpet construction comprising providing a plurality of carpet fibers, preparing a thermoplastic barrier comprising from 10 up to about 25 weight percent of a thermoplastic resin component comprising a copolymer of ethylene and an unsaturated ester of a lower carboxylic acid, from about 4 to about 15 weight percent of an olefinic elastomer component, and from about 60 to about 85 weight percent of a filler component, and extruding said thermoplastic barrier for application onto said carpet fibers so as to securely bind said carpet fibers together and to provide an acoustical and thermal barrier therefore.
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62. In a process for preparing a molded automotive carpet comprising forming a tufted structure of a base fabric stitched with closely spaced tufts of yarn, applying a thermoplastic composition to the bottom side of the tufted structure and molding the resulting product to the desired contour, the improvement of using a thermoplastic composition comprising by weight:
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(a) About 10-25 percent of an ethylene containing polymer comprising an ethylene/mono-unsaturated ester copolymer, (b) About 4-15 percent of a non-vulcanized elastomeric resin, (c) About 60-85 percent of an inert mineral filler, and (d) About 2-10 percent of a plasticizer.
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63. In a process for preparing a molded automotive carpet comprising forming a tufted structure of a base fabric stitched with closely spaced tufts of yarn, applying a thermoplastic composition to the bottom side of the tufted structure and molding the resulting product to the desired contour, the improvement of using a thermoplastic composition comprising by weight:
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(a) About 10-25 percent of an ethylene containing polymer comprising an ethylene/mono-unsaturated ester copolymer, (b) About 4-10 percent of a non-vulcanized elastomeric resin, (c) About 60-85 percent of an inert mineral filler, and (d) About 2-10 percent of a plasticizer.
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Specification