Carpet backing precoats, laminate coats, and foam coats prepared from polyurethane formulations including fly ash

• US 6,555,199 B1
• Filed: 05/26/2000
• Issued: 04/29/2003
• Est. Priority Date: 08/28/1996
• Status: Expired due to Term

• Current Assignee: The Dow Chemical Company (Dow, Inc.)
• Original Assignee: The Dow Chemical Company (Dow, Inc.)
• Inventors: Jenkines, Randall C.
• Primary Examiner(s): JUSKA, CHERYL ANN
• Application Number:
  US09/579,605
• Time in Patent Office: 1,068 Days
• Field of Search: 428/95, 428/96, 428/97, 428/160, 428/304.4, 428/316.6, 428/317.1, 428/317.5, 428/317.7, 521/159, 521/106, 521/101
• US Class Current: 428/97
• CPC Class Codes: C08J 2375/04 Polyurethanes
• CPC Class Codes: C08J 9/0066 Use of inorganic compounding ingredients
• CPC Class Codes: D06N 2203/068 Polyurethanes
• CPC Class Codes: D06N 2205/10 Particulate form, e.g. powder, granule
• CPC Class Codes: D06N 2205/20 Cured materials, e.g. vulcanised, cross-linked
• CPC Class Codes: D06N 7/0086 characterised by the cushion backing, e.g. foamed polyurethane
• CPC Class Codes: Y10T 428/23979 Particular backing structure or composition
• CPC Class Codes: Y10T 428/23986 With coating, impregnation, or bond
• CPC Class Codes: Y10T 428/23993 Composition of pile or adhesive

Abstract

The present invention is a polyurethane carpet backing prepared from a polyurethane-forming composition wherein fly ash is included as a filler material. High loadings of fly ash can be obtained without detriment to the process for preparing a polyurethane carpet backing, or adverse effect to the physical properties of the carpet backing.

Claims

1. A polyurethane-forming composition useful for preparing a polyurethane precoat, polyurethane laminate coat, or polyurethane foam coat comprising:

(a) a polyol;

(b) a chain extender;

(c) a polyisocyanate;

(d) a catalyst;

(e) a filler wetting agent; and

(f) a filler, wherein the filler includes Class F fly ash.

2. The polyurethane-forming composition of claim 1 wherein the composition additionally includes:

(1) a surfactant; and

(2) a blowing agent.

3. The polyurethane-forming composition of claim 1 wherein the polyol has an average functionality of from about 1.4 to about 3.0.

4. The polyurethane-forming composition of claim 1 wherein the polyol has an average functionality of from about 1.6 to about 2.8.

5. The polyurethane-forming composition of claim 1 wherein the polyol is a mixture of two or more polyols.

6. The polyurethane-forming composition of claim 5 wherein the polyol mixture has an average functionality of from about 1.97 to about 2.5.

7. The polyurethane-forming composition of claim 5 wherein the polyol mixture has an average functionality of from about 1.98 to about 2.4.

8. The polyurethane-forming composition of claim 5 wherein the polyol mixture has an average functionality of from about 1.99 to about 2.3.

9. The polyurethane-forming composition of claim 1 wherein the filler includes at least 50 percent Class F fly ash, by weight of total filler.

10. The polyurethane-forming composition of claim 1 wherein the filler includes at least 75 percent Class F fly ash, by weight of total filler.

11. The polyurethane-forming composition of claim 1 wherein the filler includes at least 90 percent Class F fly ash, by weight of total filler.

12. The polyurethane-forming composition of claim 1 wherein substantially all of the filler is Class F fly ash.

13. The polyurethane-forming composition of claim 1 wherein the filler wetting agent is selected from the group consisting of sodium lauryl sulfate, oleoylsarconsine, cocoamide and triisopropanolamine stearate.

14. A backed carpet having a polyurethane backing that includes at least one coat of polyurethane that is prepared from a polyurethane-forming composition comprising:

(a) a polyol;

(b) a chain extender;

(c) a polyisocyanate;

(d) a catalyst;

(e) a filler wetting agent; and

(f) a filler, wherein the filler includes Class F fly ash.

15. The backed carpet of claim 14 wherein the polyurethane-forming composition additionally includes:

(1) a surfactant; and

(2) a blowing agent.

16. The backed carpet of claim 14 wherein the carpet backing includes:

(a) a polyurethane precoat; and

(b) a polyurethane laminate coat.

17. The backed carpet of claim 16 wherein the precoat and laminate coat each includes Class F fly ash.

18. The backed carpet of claim 16 wherein the carpet backing additionally includes a polyurethane foam coat.

19. The backed carpet of claim 18 wherein the precoat, laminate coat and foam coat each includes Class F fly ash.

20. The backed carpet of claim 14 wherein the carpet backing includes a polyurethane precoat and a polyurethane foam coat.

21. The backed carpet of claim 20 wherein the foam coat includes Class F fly ash.

22. The backed carpet of claim 20 wherein the precoat and the foam coat each includes Class F fly ash.

23. The backed carpet of claim 14 wherein the filler wetting agent is selected from the group consisting of sodium lauryl sulfate, oleoylsarconsine, cocoamide and triisopropanolamine stearate.

24. A polyurethane-forming composition useful for preparing a polyurethane precoat, polyurethane laminate coat, or polyurethane foam coat comprising:

(a) a polyol;

(b) a chain extender;

(c) a polyisocyanate;

(d) a catalyst; and

(e) a filler, wherein the filler includes Class F fly ash.

25. A backed carpet having a polyurethane backing that includes at least one coat of polyurethane that is prepared from a polyurethane-forming composition of claim 24.

26. The backed carpet of claim 25 wherein the precoat and laminate coat each includes Class F fly ash.

27. The backed carpet of claim 25 wherein the precoat, laminate coat and foam coat each includes Class F fly ash.

28. A backed carpet having a backing comprised of polyurethane and a filler wherein the filler is comprised of Class F fly ash.

29. The backed carpet of claim 28 wherein the backed carpet includes a precoat and laminate coat.

30. The backed carpet of claim 29 wherein the precoat and/or the laminate coat comprises polyurethane and Class F fly ash.

31. The backed carpet of claim 28 wherein the filler includes at least 90 percent Class F fly ash, by weight of total filler.

32. The backed carpet of claim 31 wherein substantially all of the filler is Class F fly ash.