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

Abstract: An aqueous carpet coating composition includes a particulate filler, a polymeric thickener and an aqueous dispersion of a copolymer that includes vinyl acetate units and ethylene units. The dispersion stabilization system includes a) 1.5 to 3 wt % of a combination of polyvinyl alcohols including a1) one or more partially hydrolyzed polyvinyl alcohols with a degree of hydrolysis of 85 to 95 mol % and a Hoeppler viscosity of 10-33 mPa·s, and a2) one or more highly hydrolyzed polyvinyl alcohols with a degree of hydrolysis of 98 to 100 mol % and a Hoeppler viscosity of 10-33 mPa·s; and b) 1.5 to 3 wt % of an emulsifier component consisting of one or more nonionic emulsifiers and one or more anionic emulsifiers. The dispersion has a viscosity of ?1500 mPa·s and the viscosity of the coating composition is 6000 to 7000 mPa·s.

Abstract: An aqueous carpet coating composition includes a particulate filler, a polymeric thickener and an aqueous dispersion of a copolymer that includes vinyl acetate units and ethylene units. The dispersion stabilization system includes a) 1.5 to 3 wt % of a combination of polyvinyl alcohols including a1) one or more partially hydrolyzed polyvinyl alcohols with a degree of hydrolysis of 85 to 95 mol % and a Hoeppler viscosity of 10-33 mPa·s, and a2) one or more highly hydrolyzed polyvinyl alcohols with a degree of hydrolysis of 98 to 100 mol % and a Hoeppler viscosity of 10-33 mPa·s; and b) 1.5 to 3 wt % of an emulsifier component consisting of one or more nonionic emulsifiers and one or more anionic emulsifiers. The dispersion has a viscosity of ?1500 mPa·s and the viscosity of the coating composition is 6000 to 7000 mPa·s.

Abstract: A method of improving the wet tensile strength of a cellulose-containing web includes applying to the web an aqueous binder emulsion and subsequently drying and curing the binder emulsion. The aqueous binder emulsion is prepared by emulsion-polymerizing a monomer mixture comprising vinyl acetate, ethylene, and an olefinically unsaturated crosslinking monomer in the presence of a phosphate ester surfactant wherein the at least one crosslinking monomer comprises a (meth)acrylamide moiety and a cellulose-reactive moiety. The binder emulsion may be applied to a cellulose-containing web to increase wet strength, aid in creping, or both.

Abstract: This invention is directed to alkylphenol ethoxylate (APE)-free polymer binders formed by aqueous free radical emulsion polymerization and having specific peel and cure properties. The APE-free polymeric binders have a peel value, when adhered to a heated metal surface, of 35% to 200% of the peel value shown by a standard APE-based polymer binder control and exhibit a cure profile such that at least 55% cure is achieved within 30 seconds at a temperature required for cure, and a wet tensile strength at 30-seconds of cure of at least 1000 g/5 cm. Wet tensile strength is used as a measure of cure. Binders having the peel and cure properties described herein can be considered for use in crepe processes, especially DRC processes.

Abstract: A method of improving the wet tensile strength of a cellulose-containing web includes applying to the web an aqueous binder emulsion and subsequently drying and curing the binder emulsion. The aqueous binder emulsion is prepared by emulsion-polymerizing a monomer mixture comprising vinyl acetate, ethylene, and an olefinically unsaturated crosslinking monomer in the presence of a phosphate ester surfactant wherein the at least one crosslinking monomer comprises a (meth)acrylamide moiety and a cellulose-reactive moiety. The binder emulsion may be applied to a cellulose-containing web to increase wet strength, aid in creping, or both.

Abstract: This invention is directed to alkylphenol ethoxylate (APE)-free polymer binders formed by aqueous free radical emulsion polymerization and having specific peel and cure properties. The APE-free polymeric binders have a peel value, when adhered to a heated metal surface, of 35% to 200% of the peel value shown by a standard APE-based polymer binder control and exhibit a cure profile such that at least 55% cure is achieved within 30 seconds at a temperature required for cure, and a wet tensile strength at 30-seconds of cure of at least 1000 g/5 cm. Wet tensile strength is used as a measure of cure. Binders having the peel and cure properties described herein can be considered for use in crepe processes, especially DRC processes.

Abstract: This invention is directed to an improved nonwoven product comprising a nonwoven web of fibers bonded together with a sufficient amount of binder comprised of a polymer comprised of vinyl acetate, ethylene, and a crosslinking monomer to form a self-sustaining web. The improvement in the nonwoven product resides in the use of a polymer having a crystalline melting point (Tm) ranging from 35 to 90° C., preferably 50 to 80° C.; measured at a heat rate of 20° C./minute. The polymer should have a crystalline heat of fusion (Hf), which typically range from about 2 to about 50 joules per gram and a low glass transition temperature (Tg), e.g., from 10 to ?40° C., typically ?15 to ?35° C.

Abstract: This invention is directed to an aqueous polymeric binder composition that is useful in improving the wet strength of pre-moistened wipes. The binder composition comprises a blend or mixture of two components. One component is a water dispersible polymer capable of binding together the fibers composing a nonwoven web. The other component is an aqueous solution or dispersion of a polymer comprised predominantly of self-crosslinking monomer(s).

Abstract: This invention is directed to formation of a creped nonwoven web. The creped web is formed in a creping process using a polymer emulsion binder formed in an alkylphenol ethoxylate-free surfactant system. The surfactant system comprises a combination of a specific active anionic surfactant (sodium laureth sulfate containing 1 to 12 moles of ethylene oxide) and a specific active nonionic surfactant (a secondary alcohol ethoxylate containing 7 to 30 moles of ethylene oxide or an ethoxylated branched primary alcohol containing 3 to 30 moles of ethylene oxide.

Abstract: The following method is used to measure the adhesion of a polymer binder to a heated metal surface: A metal plate is attached to a heated (350° F.; 177° C.) platform and allowed to equilibrate to the temperature of the platform. A polymer emulsion binder is applied to a substrate, such as cotton fabric, and an end of the coated substrate is attached to a tensile measuring apparatus. The coated side of the coated substrate is pressed onto the heated metal plate; e.g., using a 3-lb lab roller. After a length of time to cause drying and/or partial cure of the binder (approximately 30 seconds), the metal plate and the tensile measuring device are separated at a given uniform speed. The amount of force needed to remove the substrate from the metal plate is recorded.

Abstract: This invention is directed to formation of a creped nonwoven web. The creped web is formed in a creping process using a polymer emulsion binder formed in an alkylphenol ethoxylate-free surfactant system. The surfactant system comprises a combination of a specific active anionic surfactant (sodium laureth sulfate containing 1 to 12 moles of ethylene oxide) and a specific active nonionic surfactant (a secondary alcohol ethoxylate containing 7 to 30 moles of ethylene oxide or an ethoxylated branched primary alcohol containing 3 to 30 moles of ethylene oxide.

Abstract: This invention is directed to an improved nonwoven product comprising a nonwoven web of fibers bonded together with a sufficient amount of binder comprised of a polymer comprised of vinyl acetate, ethylene, and a crosslinking monomer to form a self-sustaining web. The improvement in the nonwoven product resides in the use of a polymer having a crystalline melting point (Tm) ranging from 35 to 90° C., preferably 50 to 80° C.; measured at a heat rate of 20° C./minute. The polymer should have a crystalline heat of fusion (Hf), which typically range from about 2 to about 50 joules per gram and a low glass transition temperature (Tg), e.g., from 10 to −40° C., typically −15 to −35° C.

Abstract: This invention is directed to APE-free polymer binders formed by emulsion polymerization and having specific peel and cure properties. The APE-free polymeric binders have a peel value, when adhered to a heated metal surface, of 35% to 200% of the peel value shown by a standard APE-based polymer binder control (i.e., AIRFLEX® 105 vinyl acetate-ethylene polymer emulsion) and exhibit a cure profile such that at least 55% cure is achieved within 30 seconds at a temperature required for cure. Wet tensile strength is used as a measure of cure. The peel value is determined by a modified release and adhesion test. Binders having the peel and cure properties described herein can be considered for use in crepe processes, especially DRC processes.

Abstract: This invention is directed to an aqueous polymeric binder composition that is useful in improving the wet strength of pre-moistened wipes. The binder composition comprises a blend or mixture of two components. One component is a water dispersible polymer capable of binding together the fibers composing a nonwoven web. The other component is an aqueous solution or dispersion of a polymer comprised predominantly of self-crosslinking monomer(s).

Abstract: This invention is directed to formation of a creped nonwoven web. The creped web is formed in a creping process using a polymer emulsion binder formed in an alkylphenol ethoxylate-free surfactant system. The surfactant system comprises a combination of a specific active anionic surfactant (sodium laureth sulfate containing 1 to 12 moles of ethylene oxide) and a specific active nonionic surfactant (a secondary alcohol ethoxylate containing 7 to 30 moles of ethylene oxide or an ethoxylated branched primary alcohol containing 3 to 30 moles of ethylene oxide.

Abstract: This invention is directed an alkylphenol ethoxylate-free surfactant system for preparation of polymer emulsions. The surfactant system comprises a combination of a specific active anionic surfactant (sodium laureth sulfate containing 1 to 12 moles of ethylene oxide) and a specific active nonionic surfactant (a secondary alcohol ethoxylate containing 7 to 30 moles of ethylene oxide or an ethoxylated branched primary alcohol containing 3 to 30 moles of ethylene oxide.

Abstract: This invention is directed to APE-free polymer binders formed by emulsion polymerization and having specific peel and cure properties. The APE-free polymeric binders have a peel value, when adhered to a heated metal surface, of 35% to 200% of the peel value shown by a standard APE-based polymer binder control (i.e., AIRFLEX® 105 vinyl acetate-ethylene polymer emulsion) and exhibit a cure profile such that at least 55% cure is achieved within 30 seconds at a temperature required for cure. Wet tensile strength is used as a measure of cure. The peel value is determined by a modified release and adhesion test. Binders having the peel and cure properties described herein can be considered for use in crepe processes, especially DRC processes.

Abstract: The following method is used to measure the adhesion of a polymer binder to a heated metal surface:

Abstract: A process for forming a synthetic based nonwoven web bonded with a crosslinkable polymer wherein an aqueous polymeric emulsion containing a crosslinkable polymer is applied to the synthetic based nonwoven web, the water removed, and the crosslinkable polymer crosslinked. The crosslinkable polymer incorporates acetoacetate functionality and carboxylic acid functionality; wherein crosslinking is achieved by the reaction of the acetoacetate with an effective amount of a polyaldehyde and the reaction of the carboxylic acid with an effective amount of a polyaziridine compound.