CARPET COMPOSITIONS HAVING LAMINATED FILM BACKINGS AND METHODS FOR MAKING SAME

A carpet composition comprising a tufted yarn locked in place by a laminated film and methods of making same are disclosed.

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Description
CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority to copending U.S. Provisional Patent Application No. 62/672,694, filed May 17, 2018. The entire disclosure of the aforementioned patent application is incorporated by reference herein.

FIELD OF THE INVENTION

The present invention pertains to carpets and carpet products having an improved recyclability and lower cost. The present invention further pertains to carpets and carpet products comprising a greige good and an adhesive layer. More particularly, the present invention pertains to carpets and carpet products where the adhesive layer is attached to the greige good by lamination and provides for locking of the turf fibers in place. The present invention further pertains to methods of making such carpet or carpet product as described herein.

BACKGROUND OF THE INVENTION

Most conventional carpets comprise a primary backing with yarn tufts in the form of cut or uncut loops extending upwardly from the backing to form a pile surface. In the case of tufted carpets, the yarn is inserted into a primary backing by tufting needles and a binder (carpet coating) is applied thereto. In the case of non-tufted or bonded pile carpets, the fibers are embedded and actually held in place by the binder composition. In both cases, the carpet construction can also include a secondary backing bonded to the primary backing. The secondary backing provides extra padding to the carpet, absorbs noise, adds dimensional stability and often functions as a thermal insulator. Similar techniques are used in both the preparation of continuous (rolled) carpets as well as carpet tiles.

The conventional carpet coatings comprise polyurethanes, styrene-butadiene resin (SBR) latex, hot melts, various extruded films, and/or powder coated films. These conventional carpet coatings are expensive, difficult to recycle, and, in some cases, their use results in low strength, and often require large production lines and costly manufacturing processes.

Accordingly, there is still a need to obtain carpets and carpet products exhibiting a high tuft bind strength, as well as improved recyclability and low cost. Still further, there is a need for the manufacture of such carpets or carpet products. These needs and other needs are at least partially satisfied by the present invention.

SUMMARY OF THE INVENTION

In accordance with the purpose(s) of the invention, as embodied and broadly described herein, the invention, in one aspect, relates to a carpet comprising: (a) a greige good comprising: i) a primary backing having a face surface and a back surface; ii) a plurality of fibers attached to the primary backing material, wherein a portion of the plurality of fibers extends from the face surface of the primary backing and wherein a second portion of the plurality of fibers are exposed on the back surface of the primary backing in a form of backstitches; and; and (b) a film laminated on the backstitches to secure the plurality of fibers in place.

Also disclosed herein is a method of making a carpet comprising: (a) providing a greige good comprising: i) a primary backing material having a face surface and a back surface; and ii) a plurality of fibers attached to the primary backing material, wherein a portion of the plurality of fibers extends from the face surface of the primary backing and wherein a second portion of the plurality of fibers are exposed on the back surface of the primary backing in a form of backstitches; (b) providing a film; and (c) laminating the film on the backstitches to secure the plurality of fibers in place.

Additional aspects of the invention will be set forth, in part, in the detailed description 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

FIGS. 1(a-e) show exemplary 3 D primary backings as described herein.

FIG. 2 shows an exemplary inventive carpet structure as described herein.

FIG. 3 shows a photograph of backstitches of turf prior to and after lamination.

FIG. 4 shows a photograph of backstitches of turf after lamination process.

FIG. 5 shows a photograph of backstitches of turf after lamination with a perforation showing grass fibers.

FIG. 6 shows a schematic illustration of an exemplary aspect of a method of making a carpet.

FIG. 7 shows a photograph of an exemplary method of film lamination.

FIG. 8 shows a photograph of an exemplary Watershed Geo® type turf with a laminated film.

 DETAILED DESCRIPTION OF THE INVENTION

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 compositions, articles, devices, systems, and/or methods are disclosed and described, it is to be understood that this invention is not limited to the specific compositions, articles, devices, 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.

The following description of the invention is also provided as an enabling teaching of the invention in its best, currently known aspect. To this end, those of ordinary skill in the relevant art will recognize and appreciate that changes and modifications 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 relevant art will recognize that many modifications and adaptations to the present invention are possible and can even be desirable in certain circumstances and are thus also a part of the present invention. Thus, the following description is provided as illustrative of the principles of the present invention and not in limitation thereof.

Various combinations of elements of this disclosure are encompassed by this invention, e.g. combinations of elements from dependent claims that depend upon the same independent claim.

Moreover, it is to be understood that unless otherwise expressly stated, it is in no way intended that any method set forth herein be construed as requiring that its steps be performed in a specific order. Accordingly, where a method claim does not actually recite an order to be followed by its steps or it is not otherwise specifically stated in the claims or descriptions that the steps are to be limited to a specific order, it is no way intended that an order be inferred, in any respect. This holds for any possible non-express basis for interpretation, including: matters of logic with respect to arrangement of steps or operational flow; plain meaning derived from grammatical organization or punctuation; and the number or type of aspects described in the specification.

All publications mentioned herein are incorporated herein by reference to disclose and describe the methods and/or materials in connection with which the publications are cited.

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. As used in the specification and in the claims, the term “comprising” may include the aspects “consisting of” and “consisting essentially of.” Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. In this specification and in the claims which follow, reference will be made to a number of terms which shall be defined herein.

As used herein, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to a “polymer” or a “film” includes aspects having two or more polymers or films unless the context clearly indicates otherwise.

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 will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint. It is also understood that there are a number of values disclosed herein, and that each value is also herein disclosed as “about” that particular value in addition to the value itself. For example, if the value “10” is disclosed, then “about 10” is also disclosed. It is also understood that each unit between two particular units are also disclosed. For example, if 10 and 15 are disclosed, then 11, 12, 13, and 14 are also disclosed.

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.

“Carpet composition” as used herein includes carpet tiles, area rugs, broadloom carpet, and synthetic or artificial turfs or grass. To that “broadloom carpet” means a broadloom textile flooring product manufactured for and intended to be used in roll form.

As used herein the terms “synthetic turf” or “artificial turf,” or “artificial grass” can be issued interchangeably and include any form of artificial grass or turf conventionally used, for example, in athletic playing surfaces such as football, baseball, and soccer fields, and in other applications where an alternative to natural grass is desired. These applications include at least playgrounds, residential and commercial lawns, and other landscaping, jogging paths, paintball fields, tennis courts, putting greens, dog runs, landfill covers, medians and other areas near roadways, and airport grounds near runways.

The definition of carpet composition herein does not include products that would be known to one of ordinary skill in the art as “resilient flooring.” As an example, products that fall under the category of resilient flooring include, but are not limited to, linoleum, vinyl tiles, cork tiles, rubber tiles and floor mats.

As used herein, “reclaimed carpet material” refers generally to any material obtained from a prior manufactured carpet product. The prior manufactured carpet product can be a post-consumer product, such as, for example, a post residential, a post commercial, a post-industrial carpet, or a reclaimed artificial grass. In aspects where the reclaimed carpet material comprises an artificial grass, the reclaimed artificial grass can be collected from any field, from, for example, an indoor, an outdoor, or a gym, after any amount of use. As used herein, “reclaimed synthetic turf material” refers generally to any material obtained from a prior manufactured synthetic turf product. The prior manufactured synthetic turf product can be a post use or post-consumer product recovered from a point of original installation. Alternatively, the reclaimed carpet material can be a pre-consumer product, such as manufacturing remnants or quality control failures. In the aspects where the reclaimed carpet material is the reclaimed artificial grass, the artificial grass can be also a pre-consumer product.

As used herein, the term “by weight,” when used in conjunction with a component, unless specially stated to the contrary is based on the total weight of the formulation or composition in which the component is included. For example, if a particular element or component in a composition or article is said to have 8% by weight, it is understood that this percentage is in relation to a total compositional percentage of 100%.

A weight percent of a component, or weight %, or wt. %, unless specifically stated to the contrary, is based on the total weight of the formulation or composition in which the component is included.

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.

The term “fiber” as used herein includes fibers of extreme or indefinite length (i.e. filaments) and fibers of short length (i.e., staple fibers).

The term “yarn” as used herein refers to a continuous strand or bundle of fibers.

The term “polyamide,” as utilized herein, is defined to be any long-chain polymer in which the linking functional groups are amide (—CO—NH—) linkages. The term polyamide is further defined to include copolymers, terpolymers and the like, as well as homopolymers, and also includes blends of two or more polyamides.

The term “polyester,” as utilized herein, refers to a composition comprising a long-chain synthetic polymer composed of at least 85% by weight of an ester of a substituted aromatic carboxylic acid, including but not restricted to substituted terephthalic units, p(—R—O—CO— C6H4—CO—O—)x and parasubstituted hydroxy-benzoate units, p(—R—O—CO—C6H4—O—)x.

As defined herein, the term “polyolefin” refers to any class of polymers produced from a simple olefin (also called an alkene with the general formula CnH2n) as a monomer.

As used herein, the term “copolymer” refers to a polymer formed from two or more different repeating units (monomer residues). By way of example and without limitation, a copolymer can be an alternating copolymer, a random copolymer, a block copolymer, or a graft copolymer.

The term “linear” as used to describe ethylene polymers is used herein to mean the polymer backbone of the ethylene polymer lacks measurable or demonstrable long chain branches, e.g., the polymer is substituted with an average of less than 0.01 long branch/1000 carbons.

As used herein, the term “substantially,” in, for example, the context “substantially free” refers to a composition having less than about 1% by weight, e.g., less than about 0.5% by weight, less than about 0.1% by weight, less than about 0.05% by weight, or less than about 0.01% by weight of the stated material, based on the total weight of the composition.

It is further understood that the term “substantially similar,” when used in reference to a composition, refers to at least about 60% by weight, e.g., at least about 65%, at least about 70%, at least about 75%, at least about 80%, at least about 85%, at least about 90%, at least about 91%, at least about 92%, at least about 93%, at least about 94%, at least about 95%, at least about 96%, at least about 97%, at least about 98%, at least about 99%, or about 100% by weight, based on the total weight of the composition, of a specified feature or component.

The term “homogeneous ethylene polymer” as used to describe ethylene polymers is used in the conventional sense in accordance with the original disclosure by Elston in U.S. Pat. No. 3,645,992, the disclosure of which is incorporated herein by reference. As defined herein, homogeneous ethylene polymers include both substantially linear ethylene polymers and homogeneously branched linear ethylene.

The terms “substantially linear ethylene polymer” or “SLEP,” are used interchangeably, and refer specifically to homogeneously branched ethylene polymers that have long chain branching. The term does not refer to heterogeneously or homogeneously branched ethylene polymers that have a linear polymer backbone. For substantially linear ethylene polymers, the long chain branches have the same comonomer distribution as the polymer backbone, and the long chain branches can be as long as about the same length as the length of the polymer backbone to which they are attached. The polymer backbone of substantially linear ethylene polymers is substituted with about 0.01 long chain branches/1000 carbons to about 3 long chain branches/1000 carbons, from about 0.01 long chain branches/1000 carbons to about 1 long chain branches/1000 carbons, and from about 0.05 long chain branches/1000 carbons to about 1 long chain branches/1000 carbons.

Long chain branching is defined herein as a chain length of at least 6 carbons, above which the length cannot be distinguished using 13C nuclear magnetic resonance spectroscopy. The presence of long chain branching can be determined in ethylene homopolymers by using 13C nuclear magnetic resonance (NMR) spectroscopy and is quantified using the method described by Randall (Rev. Macromol. Chem. Phys., C29, V. 2&3, p. 285-297), the disclosure of which is incorporated herein by reference.

Substantially linear ethylene polymers are homogeneously branched ethylene polymers and are disclosed in U.S. Pat. No. 5,272,236 and U.S. Pat. No. 5,278,272, the disclosures of which are incorporated herein by reference. Homogeneously branched substantially linear ethylene polymers are available from The Dow Chemical Company as AFFINITY™ polyolefin plastomers and from Dupont Dow Elastomers JV as ENGAGE™ polyolefin elastomers. Homogeneously branched substantially linear ethylene polymers can be prepared via the solution, slurry, or gas phase polymerization of ethylene and one or more optional α-olefin comonomers in the presence of a constrained geometry catalyst, such as the method disclosed in European Patent Application 416,815-A, the disclosure of which is incorporated herein by reference. In some aspects, a solution polymerization process is used to manufacture the substantially linear ethylene polymer used in the present invention.

The term “heterogeneously branched ethylene polymer” refers to a polymer having a distribution of branching different from and broader than the homogeneous branching ethylene/α-olefin interpolymer at similar molecular weight. In further aspects, the “heterogeneous” and “heterogeneously branched” mean that the ethylene polymer is characterized as a mixture of interpolymer molecules having various ethylene to comonomer molar ratios. Alternatively, heterogeneously branched linear ethylene polymers can be defined as having a SCBDI less than about 50% and more typically less than about 30%. HBEPs and SLEPs also differ from the class of polymers known conventionally as heterogeneously branched traditional Ziegler polymerized linear ethylene interpolymers, for example, ultra low density polyethylene (“ULDPE”), very low density polyethylene (“VLDPE”), linear low density polyethylene (“LLDPE”) medium density polyethylene (“MDPE”) or high density polyethylene (“HDPE”) made, for example, using the technique disclosed by Anderson et al. in U.S. Patent. No. 4,076,698, in that substantially linear ethylene interpolymers are homogeneously branched interpolymers. Further, in accordance with the present invention, the polymer composition does not comprise more than 20% by weight of heterogeneously branched linear ethylene polymers, as measured by the total weight of the polymer composition.

Heterogeneously branched ethylene polymers are typically characterized as having molecular weight distributions, Mw/Mn in the range of from about 3.5 to about 4.1 and, as such, are distinct from substantially linear ethylene polymers and homogeneously branched linear ethylene polymers in regards to both compositional short chain branching distribution and molecular weight distribution.

As described herein, in some aspects to determine the strength of the inventive carpet, the Tuft Bind Test according to ASTM D-1335 is used. The Tuft Bind Test determines the amount of force that is necessary to pull the yarn from its primary backing. It is desirable to obtain carpets with highest tuft bind values possible. It is understood that the carpet that withstands a high amount of force lasts longer, and the original appearance is preserved due to fewer snags.

As described herein, in some aspects to determine the wet and/or dry strength, delamination strength test according to ASTM D-3936 is utilized. The delamination strength test is design to measure an amount of force needed to remove a secondary backing from the carpet composition. The strength according to ASTM D-3936 is measured by determining the highest peak for each of the middle five inches of 6″ pull (jaw separation) and averaging the values and is reported in pounds/inch (lb/in). It is further understood that the higher amount of force needed to remove a secondary backing from the carpet composition, the better durability of the carpet is expected.

In some aspects of the present invention, woven textiles can be used. Woven textiles have the appearance of two-sets of parallel threads interlaced at generally right angles to each other in the plane of the fabric. “Warp” yarns lie along the length of the fabric and “weft” or “fill” yarns lie in the transverse direction, i.e. across the width of the fabric. The type of yarns used to produce a woven textile can be monofilament, multifilament, a combination of each type, or slit film yarns. In some aspects of the invention, the term “tape-spun” yarn refers to yarn having a slit film yarn in the warp direction and spun (relatively short staple length) yarn in the weft direction. In other aspects of the invention, the term “tape-tape” yarn refers to yarn having a slit film yarn both in the warp and the weft directions.

While aspects of the present invention can be described and claimed in a particular statutory class, such as the system statutory class, this is for convenience only and one of skill in the art will understand that each aspect of the present invention can be described and claimed in any statutory class. Unless otherwise expressly stated, it is in no way intended that any method or aspect set forth herein be construed as requiring that its steps be performed in a specific order. Accordingly, where a method claim does not specifically state in the claims or descriptions that the steps are to be limited to a specific order, it is no way intended that an order be inferred, in any respect. This holds for any possible non-express basis for interpretation, including matters of logic with respect to arrangement of steps or operational flow, plain meaning derived from grammatical organization or punctuation, or the number or type of aspects described in the specification.

Carpets

The present invention may be understood more readily by reference to the following detailed description of various aspects of the invention and the examples included therein and to the Figures and their previous and following description. In some aspects, the invention relates to a carpet comprising a greige good. In still further aspects, the greige good of the current disclosure comprises: a primary backing having a face surface and a back surface; and a plurality of fibers attached to the primary backing material, wherein a portion of the plurality of fibers extends from the face surface of the primary backing and wherein a second portion of the plurality of fibers are exposed on the back surface of the primary backing in a form of backstitches. In still further aspects, the carpet described herein comprises a film laminated on the backstitches to secure the plurality of fibers in place.

In certain aspects, the present invention pertains to any carpet constructed with a primary backing component and includes tufted carpet and non-tufted carpet such as needle punched carpet. To form the tufted carpet, yarn is tufted through the primary backing component such that the longer length of each stitch extends through the face surface of the primary backing component.

In yet other aspects, the carpet composition disclosed herein can be any carpet composition known in the art. In certain aspects, the carpet composition is rug, broadloom carpet, carpet tile, artificial turf or grass, or geo turf. Some exemplary aspects can include WatershedGeo® type turf with a film laminated to the primary backing. In still further aspects, the carpet composition disclosed herein is recyclable. In yet other aspects, the carpet composition is at least about 50% recyclable, at least about 60% recyclable, at least about 70% recyclable, at least about 80% recyclable, at least about 90% recyclable, or 100% recyclable. It is further understood that the carpet compositions disclosed herein can comprise any amount of recyclable material in any component. In yet other aspects, the recyclable material used in any component of the carpet composition can be recycled multiple times.

Fibers

Carpets described herein comprise a plurality of fibers. In some aspects, the plurality of fibers described herein can be present in yarn. In other aspects, the plurality of fibers are present as separate fibers. In some aspects, the plurality of fibers are present in tufts of yarn. In some aspects, a portion of the plurality of the fibers are exposed at the back surface of the primary backing component. In yet other aspects, a portion of the plurality of the fibers are exposed at the back surface of the primary backing component in a form of backstitches.

In certain aspects, the plurality of fibers can comprise any thermoplastic polymer known in the art. In still further aspects, the plurality of fibers can comprise a polyamide, a polyolefin, a polyester, or a combination thereof.

In some aspects, the polyamide as described herein can comprise one or more of nylon 6, nylon 66, nylon 10, nylon 612, nylon 12, nylon 11, or any combination thereof. In other aspects, the polyamide as described herein is nylon 6 or nylon 66. In yet other aspects, the polyamide as described herein is nylon 6. In a yet further aspect, polyamide as described herein is nylon 66.

In some aspects, polyester as described herein comprises polyethylene terephthalate (PET) homopolymers and copolymers, polybutylene terephthalate (PBT) homopolymers and copolymers, and the like, including those that contain comonomers such as cyclohexanedimethanol, cyclohexanedicarboxylic acid, and the like. In yet other aspects, the polyester described herein can comprise polyethylene terephthalate, polypropylene terephthlate, polybutylene terephthalate, copolymers thereof, or any combination thereof.

In some aspects, the polyolefins as described herein include, but are not limited to, polyethylene, polypropylene, both homopolymer and copolymers, poly(l-butene), poly(3-methyl-l-butene), poly(4-methyl-1-pentene) and the like, as well as combinations or mixtures of two or more of the foregoing. In certain aspects, the polyolefin as described herein comprises polyethylene and copolymers thereof, a polypropylene and copolymers thereof, or a combination thereof. In other aspects, the polyolefin comprises polyethylene. In yet other aspects, the polyolefin comprises polypropylene.

In still further aspects, the polyolefin described herein can comprise a low density polyethylene (LDPE), a linear low-density polyethylene (LLDPE), ultra low density polyethylene (ULDPE), very low density polyethylene (VLDPE), medium density polyethylene (MDPE), high density polyethylene (HDPE), a grafted polyethylene, heterogeneously branched ethylene polymer (HBEP), substantially linear ethylene polymer (SLEP), polypropylene, or a combination thereof.

In certain aspects, the plurality of fibers can comprise from 0 wt % to 100 wt % of a recycled polymer, including exemplary values of about 10 wt %, about 20 wt %, about 30 wt %, about 40 wt %, about 50 wt %, about 60 wt %, about 70 wt %, about 80 wt %, about 90 wt %, about 95 wt %, and about 99 wt %. It is further understood that recycled polymer can be present in any amount between any two foregoing values.

In still further aspects, the plurality of fibers can further comprise natural fibers, acrylics, viscose, rayon, cellulose acetate, linen, silk, cotton, wool, or any combination thereof.

As understood by one of ordinary skill in the art, the plurality of fibers can comprise any type or form of fibers. For example, and without limitation, the plurality of fibers can comprise staple fibers or bulked continuous filament fibers.

Primary Backing

In still further aspects, the carpet composition described herein comprises a primary backing. In some aspects, the primary backing can be present in any amount. In the aspects, where the carpet composition is a synthetic grass, the primary backing makes up from about 1 wt % to about 25 wt %, including exemplary values of about 5 wt %, about 10 wt %, about 15 wt %, and about 20 wt % of a synthetic turf. In certain aspects, the primary backing can comprise a thermoplastic polymer. In certain aspects, the thermoplastic polymer can comprise any thermoplastic polymer known in the art. In still further aspects, the thermoplastic polymer present in the primary backing can comprise a polyamide, a polyolefin, a polyester, or a combination thereof. It is understood that the polyamide can comprise any of polyamides described above. It is further understood that the polyolefin described herein can comprise any of the polyolefins described above. In still further aspects, the polyesters present in the primary backing can comprise any of polyesters described above. In yet further aspects, the blends of polymers present in the primary backing can comprise any blends of any polymers described above.

In certain aspects, the thermoplastic polymer composition present in the primary backing can comprise from 0 wt % to 100 wt % of a recycled polymer, including exemplary values of about 10 wt %, about 20 wt %, about 30 wt %, about 40 wt %, about 50 wt %, about 60 wt %, about 70 wt %, about 80 wt %, about 90 wt %, about 95 wt %, and about 99 wt %. It is further understood that recycled polymer can be present in any amount between any two foregoing values.

In certain aspects, the primary backing component comprises a polyolefin, a polyester, a polyamide, or a combination thereof. The primary backing component can be woven and non-woven. In certain aspects, the primary backing component can comprise non-woven webs, or spunbonded materials. In certain aspects, the primary backing comprises a non-woven batting. In some aspects, the primary backing component can comprise a combination of woven and non-woven materials. In still further aspects, the primary backing component can comprise a combination of woven and spunbonded materials. In still further aspects, the primary backing component can comprise a combination of non-woven and spunbonded materials. In still further aspects, the primary backing component can comprise a combination of woven, non-woven, and spunbonded materials. In yet other aspects, the primary backing can comprise felt. In some aspects, the primary backing component comprises a polyolefin polymer. In other aspects, the polyolefin polymer comprises polypropylene. In yet other aspects, the primary backing component is a slit film polypropylene sheet such as that sold by Propex or Synthetic Industries owned by Shaw Industries. In yet further aspects, the primary backing component can comprise polyester. In still further aspect, the primary backing component can comprise polyamide. In yet further aspects, the primary backing component can comprise a combination of polyamide and polyester. In the certain aspects, the polyamide is nylon. In some other aspects, the primary backing can comprise a woven polyethylene terephthalate (PET). In yet other aspects, the primary backing can comprise a woven PET having a post-consumer and/or post-industrial content. In still further aspects, the primary backing can be present as a single layer. In yet other aspects, the primary backing can be provided as a double layer. In still further aspects, the primary backing can be provided as a multilayer. In such aspects, the primary backing has two or more layers. In still further aspects the primary backing can have a three dimensional structures. Without wishing to be bound by a theory, such structures can enhance product functionality and performance. For example and without limitation, such structures can provide improvements in cushioning, cooling, drainage, and installation. It is understood that such structures can have any thickness that would be needed in a desirable application. In some aspects, such structures can have a thickness from about 0.1 inch to about 3 inches, including exemplary values of about 0.5 inch, about 1 inch, about 1.5 inches, about 2 inches, and about 2.5 inches. In still further aspects, such structures can be made by any methods known in the art. In some exemplary aspects, such structures can be made by extrusion, needling, airlaying, and the like. Some exemplary structures are shown in FIG. 1(a-e).

In yet certain aspects, the primary backing component can be a spun-bond primary backing component. The spun bond 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 primary backing component can comprise a bi-component filament of a sheath-core type. In some aspects, the polymeric core component can have 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 can comprise 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 primary backing component can be commercially available from Bonar. In yet other aspects, a polyester non-woven primary backing can be commercially available from Freudenberg.

Film

In still further aspects, the carpet composition described herein comprises a film. In still further aspects, the film is a polymer film. In still further aspects, the film comprises a first thermoplastic polymer. In certain aspects, the polymer film comprises polymers and copolymers of polyolefins, polyurethane, polyester, polyvinylchloride, polyamide, and polyethylene vinyl acetate, and the like. In certain aspects, the first thermoplastic polymer can comprise a polyamide, a polyolefin, a polyester, or combination thereof.

In some aspects, the polyamide as described herein can comprise one or more of nylon 6, nylon 66, nylon 10, nylon 612, nylon 12, nylon 11, or any combination thereof. In other aspects, the polyamide as described herein is nylon 6 or nylon 66. In yet other aspects, the polyamide as described herein is nylon 6. In a yet further aspect, polyamide as described herein is nylon 66.

In some aspects, polyester as described herein comprises polyethylene terephthalate (PET) homopolymers and copolymers, polybutylene terephthalate (PBT) homopolymers and copolymers, and the like, including those that contain comonomers such as cyclohexanedimethanol, cyclohexanedicarboxylic acid, and the like. In yet other aspects, the polyester described herein can comprise polyethylene terephthalate, polypropylene terephthlate, polybutylene terephthalate, copolymers thereof, or any combination thereof.

In some aspects, the polyolefins as described herein include, but are not limited to, polyethylene, polypropylene, both homopolymer and copolymers, poly(l-butene), poly(3-methyl-l-butene), poly(4-methyl-1-pentene) and the like, as well as combinations or mixtures of two or more of the foregoing. In certain aspects, the polyolefin as described herein comprises polyethylene and copolymers thereof, a polypropylene and copolymers thereof, or a combination thereof. In other aspects, the polyolefin comprises polyethylene. In yet other aspects, the polyolefin comprises polypropylene.

In still further aspects, the polyolefin described herein can comprise a low density polyethylene (LDPE), a linear low-density polyethylene (LLDPE), ultra low density polyethylene (ULDPE), very low density polyethylene (VLDPE), medium density polyethylene (MDPE), high density polyethylene (HDPE), a grafted polyethylene, heterogeneously branched ethylene polymer (HBEP), substantially linear ethylene polymer (SLEP), polypropylene, or a combination thereof.

In still further aspects, the film described herein can further comprise polyvinyl butyral (PVB), acrylic based materials, ethylene acrylic acetate (EAA), ethylene vinyl acetate (EVA), ethylene methyl acrylate (EMA), or a combination thereof.

It will be understood that the film described herein can comprise any of the polymers described herein or their combination. In some aspects, any of the polymers described above can be present in an amount of greater than 0 wt % to 100 wt %. In some exemplary aspects, the film comprises a homogenous polyester present from greater than 0 wt % to 100 wt %, including exemplary values of about 5 wt %, about 10 wt %, about 20 wt%, about 30 wt %, about 40 wt %, about 50 wt %, about 60 wt %, about 70 wt %, about 80 wt %, and about 90 wt %. In still further exemplary aspects, the homogenous polyester can comprise polyethylene terephthalate, polypropylene terephthlate, or polybutylene terephthalate. In still further aspects, the homogeneous polyester can comprise polyethylene terephthalate.

In yet other exemplary aspects, the film described herein can comprise a mixture of a homogeneous polyester with a biaxially-oriented polyethylene terephthalate. In exemplary aspects, the biaxially-oriented polyethylene terephthalate is Mylar® from Dupont Tejjin Films.

In still further exemplary aspects, the film can comprise a homogeneous polypropylene that can be present in an amount of greater than 0 wt % to 100 wt %, including exemplary values of about 5 wt %, about 10 wt %, about 20 wt%, about 30 wt %, about 40 wt %, about 50 wt %, about 60 wt %, about 70 wt %, about 80 wt %, and about 90 wt %.

In certain aspects, the polymer film is an extruded film. In yet other aspects, the polymer film is a blown film. In a yet further aspect, the polymer film is a cast film. In a still further aspect, the polymer film is an engineered film. The term “engineered film” as used herein refers to a polymer film comprising same or different polymers and copolymers, wherein the film is formed by various techniques to ensure desirable properties. In some aspects, the engineered film is a reinforced film. In some aspects, and without limitation, the engineered reinforced film can comprise a plurality of layers of the same or different polymers or copolymers. In other aspects, the engineered film can comprise layers of polyethylene film sandwiched with a layer of polyester. In yet further aspects, the engineered film can comprise layers of polyethylene and polypropylene, or layers of polyethylene and chemically resistant ethylene vinyl alcohol (EVOH) copolymer.

In some aspects, the polymer film is continuous. In other aspects, the polymer film is substantially free of perforations or pinholes. In yet other aspects, the polymer film is continuous and substantially free of perforations.

In still further aspects, the polymer film is a composite film comprising polyethylene and polypropylene. In yet other aspects, the polymer film can comprise a polypropylene core. In yet other aspects, the polymer composite film can comprise at least two layers. In other aspects, the polymer composite film can comprise at least three layers. It is understood that each layer of the polymer composite film can be same or different and can comprise any of the polymers listed above. In some aspects, the composite film comprises at least three layers, and wherein each outer layer of the composite film comprises polyethylene.

In certain aspects, the first thermoplastic polymer composition present in the film can comprise from 0 wt % to 100 wt % of a recycled polymer, including exemplary values of about 10 wt %, about 20 wt %, about 30 wt %, about 40 wt %, about 50 wt %, about 60 wt %, about 70 wt %, about 80 wt %, about 90 wt %, about 95 wt %, and about 99 wt %. It is further understood that recycled polymer can be present in any amount between any two foregoing values.

In still further aspects, the film described herein can have any thickness. It is understood that the thickness of the film can be determined by one of ordinary skill in the art depending on the specific application. In still further aspects, the film can have thickness from about 0.001 inch to about 0.010 inch, including exemplary values of about 0.002 inch, about 0.003 inch, about 0.004 inch, about 0.005 inch, about 0.006 inch, about 0.007 inch, about 0.008 inch, and about 0.009 inch.

In some aspects, the carpet composition described herein does not comprise a precoat material. In other aspects, the carpet composition described herein can further comprise a precoat material. In such exemplary aspects, the precoat material can be optionally applied to the greige goods. In aspects where the precoat material is present, it can comprise any precoat material known in the art. For example, and without limitation, in aspects where precoat material is present, it can comprise an aqueous precoat material. In some exemplary aspects, the aqueous precoat material can, for example, be added as a dispersion or as an emulsion. In certain aspects, 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 and/or emulsions, and any combination thereof.

In still further aspects where precoat material is present, the precoat composition can also comprise a latex. In yet other aspects, where precoat comprises the latex composition, the latex further comprises a carboxylated styrene-butadiene (XSB) latex copolymer, a styrene-butadiene resin (SBR) latex, a BDMMA latex, an acrylic latex, an acrylic copolymer, a styrene copolymer, or a combination thereof.

In some aspects, the polymer present in the primary backing is a second thermoplastic polymer. In still further aspects, the polymer present in the plurality of fibers is a third thermoplastic polymer. In certain aspects, the first thermoplastic polymer present in the film is substantially similar to the second thermoplastic polymer present in the primary backing. In still further aspects, the first thermoplastic polymer present in the film is substantially similar to the third thermoplastic polymer present in the plurality of fibers. In still further aspects, the first thermoplastic polymer present in the film is substantially similar to the second thermoplastic polymer present in the primary backing and the third thermoplastic polymer present in the plurality of fibers.

In some aspects, the first thermoplastic polymer present in the film is the same as the second thermoplastic polymer present in the primary backing. In other aspects, the first thermoplastic polymer present in the film is the same as the third thermoplastic polymer present in the plurality of fibers. In still further aspects, the first thermoplastic polymer present in the film is a blend of the second thermoplastic polymer present in the primary backing and the third thermoplastic polymer present in the plurality of fibers.

Secondary Backing

In certain aspects, the composition can further comprise a secondary backing. In some aspects, the secondary backing can be inserted in between the primary backing and the film prior to lamination. It should be understood, that in those aspects where a secondary backing is present between the primary backing and film prior to lamination, a portion of the film can be laminated to the secondary backing while a second portion of the film can be laminated to backstitches exposed on the back surface of the primary backing. In still further aspects, rather than being present between the primary backing and the laminated film, the secondary backing can be applied to the exposed underside of the laminated film. This can be applied with a separate adhesive material. In the aspects where a separate adhesive material is used, the separate adhesive material can be any material known in the art.

In one aspect the secondary backing comprises a woven material. In another aspect, the secondary backing comprises a tape-tape yarn, or a tape-spun yarn. In certain aspects, the secondary backing is a tape-tape yarn woven material. In one aspect, the secondary backing comprises a polyolefin. In a yet further aspect, the polyolefin comprises polypropylene. In certain exemplary aspects, the material for the secondary backing material can be a conventional material, for example and without limitation, the woven polypropylene fabric sold by Propex. Such secondary backings 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 material used with the present invention 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. In yet other exemplary aspects, a fiberglass mesh produced by Saint Gobain can be utilized.

In further aspects, the secondary backing material is 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.

In some aspects, the secondary backing 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.

In yet other aspects, the secondary backing comprising a non-woven material. In certain aspects, the secondary backing 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 bi-component filament of a sheath-core type. In some aspects, the polymeric core component can have 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.

In some aspects, the secondary backing material 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).

In some aspects, when properly selected substantially linear ethylene polymers or homogeneously branched linear ethylene polymers are used as the secondary backing materials, the low flexural modulus of these polymers offers advantages in ease of carpet installation and general carpet handling. Substantially linear ethylene polymers, in particular, when employed as a secondary backing material, show enhanced mechanical adhesion to polypropylene which improves the consolidation and delamination resistance of the various carpet layers and components, i.e., polypropylene fibers, fiber bundles, the primary backing component. In some aspects, good abrasion resistance is especially important in commercial carpet cleaning operations as good abrasion resistance generally improves carpet durability.

In certain aspects, the secondary backing material comprising a substantially linear ethylene polymer or homogeneously branched linear ethylene polymer can provide a substantial fluid and particle barrier which enhances the hygienic properties of carpet.

In some further aspects, use of the secondary backing material comprising a substantially linear ethylene polymer or homogeneously branched linear ethylene polymer can allow totally recyclable carpet products particularly where the carpet comprises polypropylene fibers.

The secondary backing material can comprise a homogeneously branched ethylene polymer. The homogeneously branched ethylene polymer can have a single melting peak between −30° C. and 150° C., as determined using differential scanning calorimetry. In some aspects, the homogeneously branched ethylene polymer used in the secondary backing material of this invention, is a substantially linear ethylene polymer characterized as having (a) a melt flow ratio, l10/l2>5.63; (b) a molecular weight distribution, Mw/Mn, as determined by gel permeation chromatography and defined by the equation: (Mw/Mn)<(l10l2)−4.63; (c) a gas extrusion rheology such that the critical shear rate at onset of surface melt fracture for the substantially linear ethylene polymer is at least 50 percent greater than the critical shear rate at the onset of surface melt fracture for a linear ethylene polymer, wherein the linear ethylene polymer has a homogeneously branched short chain branching distribution and no long chain branching, and wherein the substantially linear ethylene polymer and the linear ethylene polymer are simultaneously ethylene homopolymers or interpolymers of ethylene and at least one C3-C20 a-olefin and have the same l2 and Mw/Mn, and wherein the respective critical shear rates of the substantially linear ethylene polymer and the linear ethylene polymer are measured at the same melt temperature using a gas extrusion rheometer; and (d) a single differential scanning calorimetry, DSC, melting peak between −30° C. and 150° C.

In certain aspects, the molecular weight distribution (Mw/Mn) for the substantially linear ethylene polymers and homogeneous linear ethylene polymers used in the present invention is generally from about 1.8 to about 2.8. Substantially linear ethylene polymers are known to have excellent processability, despite having a relatively narrow molecular weight distribution. Unlike homogeneously and heterogeneously branched linear ethylene polymers, the melt flow ratio (l10/l2) of substantially linear ethylene polymers can be varied essentially independently of their molecular weight distribution, Mw/Mn.

In some aspects, the secondary backing material comprising homogeneously branched ethylene polymers includes interpolymers of ethylene and at least one α-olefin prepared by a solution, gas phase, a slurry polymerization process, or a combination thereof. In some aspects the α-olefins are represented by the following formula:


CH2═CHR

where R is a hydrocarbyl radical. Further, R may be a hydro-carbyl radical having from one to twenty carbon atoms and as such the formula includes C3-C20 α-olefins. In other aspects, α-olefins for use as comonomers include propylene, 1-butene, 1-isobutylene, 1-pentene, 1-hexene, 4-methyl-1-pentene, 1-heptene and 1-octene, as well as other comonomer types such as styrene, halo- or alkyl-substituted styrenes, tetrafluoro-ethylene, vinyl benzocyclobutene, 1,4-hexadiene, 1,7-octadiene, and cycloalkenes, e.g., cyclopentene, cyclo-hexene and cyclooctene. In certain aspects, the comonomer will be 1-butene, 1-pentene, 4-methyl-1-pentene, 1-hexene, 1-heptene, 1-octene, or mixtures thereof, as secondary backing materials comprised of higher α-olefins will have especially improved toughness. In yet other aspects, the comonomer will be 1-octene and the ethylene polymer will be prepared in a solution process.

In certain aspects, the density of the substantially linear ethylene polymer or homogeneously branched linear ethylene polymer, as measured in accordance with ASTM D-792, does not exceed about 0.92 g/cc, and is generally in the range from about 0.85 g/cc to about 0.92 g/cc, from about 0.86 g/cc to about 0.91 g/cc, and from about 0.86 g/cc to about 0.90 g/cc.

In yet further aspects, the molecular weight of the homogeneously branched linear ethylene polymer or substantially linear ethylene polymer can be characterized using a melt index measurement according to ASTM D-1238, Condition 190° C./2.16 kg (formerly known as “Condition (E)” and also known as l2). Melt index is inversely proportional to the molecular weight of the polymer. Thus, the higher the molecular weight, the lower the melt index, although the relationship is not linear. The melt index for the homogeneously branched linear ethylene polymer or substantially linear ethylene polymer is generally from about 1 grams/10 minutes (g/10 min) to about 500 g/10 min, about 2 g/10 min to about 300 g/10 min, from about 5 g/10 min to about 100 g/10 min, from about 10 g/10 min to about 50 g/10 min, and about 25 to about 35 g/10 min.

In some other aspects, an additional measurement can be useful in characterizing the molecular weight of the homogeneous linear ethylene polymer or the substantially linear ethylene polymer and can be performed using a melt index measurement according to ASTM D-1238, Condition 190° C./10 kg (formerly known as “Condition (N)” and also known as l10). The ratio of the l10 and the l2 melt index terms is the melt flow ratio and is designated as l10/l2. For the substantially linear ethylene polymer, the l10/l2 ratio indicates the degree of long chain branching, i.e., the higher the l10/l2 ratio, the more long chain branching in the polymer. The l10/l2 ratio of the substantially linear ethylene polymer is at least about 6.5, at least about 7, or at least about 8. The l10/l2 ratio of the homogeneously branched linear ethylene polymer is generally less than about 6.3.

In some aspects, the ethylene polymers can have a relative low modulus. That is, the ethylene polymer is characterized as having a 2% secant modulus less than about 24,000 psi (163.3 MPa), less than about 19,000 psi (129.3 MPa), and less than about 14,000 psi (95.2 MPa), as measured in accordance with ASTM D790.

In certain aspects, the ethylene polymers described herein are substantially amorphous or totally amorphous. That is, the ethylene polymer is characterized as having a percent crystallinity less than about 40 percent, less than about 30 percent, more less than about 20, and less than about 10 percent, as measured by differential scanning calorimetry using the equation:


percent crystallinity %=(Hf/292)×100, where Hf is the heat of fusion in Joules/gram.

In other aspects, the homogeneously branched ethylene polymer (HBEP) can be used alone or can be blended or mixed with one or more synthetic or natural polymeric material. In some aspects, the polymers for blending or mixing with homogeneously branched ethylene polymers used in the present invention include, but are not limited to, another homogeneously branched ethylene polymer, low density polyethylene, heterogeneously branched LLDPE, heterogeneously branched ULDPE, medium density polyethylene, high density polyethylene, grafted polyethylene (e.g. a maleic anhydride extrusion grafted heterogeneously branched linear low polyethylene or a maleic anhydride extrusion grafted homogeneously branched ultra low density polyethylene), ethylene acrylic acid copolymer, ethylene vinyl acetate copolymer, ethylene ethyl acrylate copolymer, polystyrene, polypropylene, polyester, polyurethane, polybutylene, polyamide, polycarbonate, rubbers, ethylene propylene polymers, ethylene styrene polymers, styrene block copolymers, and vulcanates.

In further aspects, the secondary backing material can comprise a blend of at least two polyethylenes, wherein the polyethylene can comprise a homogeneously branched ethylene polymer (HBEP) or a substantially linear ethylene polymer (SLEP), or mixtures thereof. In other aspects, the secondary backing material can comprise a blend of at least three or four, or more polyethylenes, wherein the polyethylenes comprise a homogeneously branched ethylene polymer (HBEP) or a substantially linear ethylene polymer (SLEP), or mixtures thereof. Still further, the secondary backing material can comprise a polyethylene comprising at least about 80% by weight of at least one (or two or more) HBEP or SLEP as measured by weight of the polyethylene, including exemplary values of about 85, 90, 95, 97, 98, or about 99% by weight of the polyethylene, where any value can comprise an upper or a lower endpoint, as appropriate.

In the aspects, where the blend of at least two (or three or more) polyethylenes is used, the amount of each polyethylene can be individually varied in the amounts of, for example, from about 1, 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 97 or about 98% by weight of the total blend, where any value can be used for the individual components, and any value can be used as an upper or a lower endpoint, as appropriate.

The density of the polyethylene components in the blend can be from about 0.860, 0.870, 0.880, 0.885, 0.890, 0.895, 0.900, 0.905, or about 0.910 g/cc, where any value can comprise an upper or a lower endpoint, as appropriate.

The actual blending or mixing of various polymers may be conveniently accomplished by any technique known in the art including, but not limited to, melt extrusion compounding, dry blending, roll milling, melt mixing, such as in a Banbury mixer, and multiple reactor polymerization. In some aspects, the blends or mixtures include a homogeneously branched ethylene polymer and a heterogeneously branched ethylene α-olefin interpolymer, wherein the α-olefin is a C3-C8 α-olefin prepared using two reactors operated in parallel or in series with different catalyst systems employed in each reactor. Multiple reactor polymerizations are described in copending applications U.S. Ser. No. 08/544,497, filed Oct. 18, 1995 and U.S. Ser. No. 08/327,156, filed Oct. 21, 1994, the disclosures of all three of which are incorporated herein by reference. In some aspects, multiple reactor polymerizations comprise non-adiabatic solution loop reactors as described in provisional applications U.S. Ser. No. 60/014,696 and U.S. Ser. No. 60/014,705, both filed Apr. 1, 1996, the disclosures of all of which are incorporated herein by reference.

In another aspect, the secondary backing material can comprise a modified homogeneously branched ethylene polymer. In particular, in certain aspects of the invention the at least one homogeneously branched ethylene polymer that can be present within the secondary backing material can be modified by the addition of at least one adhesive polymeric additive. Suitable adhesive polymeric additives include, for example and without limitation, polymer products comprised of (1) one or more ethylenically unsaturated carboxylic acids, anhydrides, alkyl esters and half esters, e.g., acrylic acid, methacrylic acid, maleic acid, maleic anhydride, itaconic acid, fumaric acid, crotonic acid and citraconic acid, citraconic anhydride, succinnic acid, succinnic anhydride, methyl hydrogen maleate, and ethyl hydrogen maleate; esters of ethylenically unsaturated carboxylic acids, e.g., ethyl acrylate, methyl methacrylate, ethyl methacrylate, methyl acrylate, isobutyl acrylate, and methyl fumarate; unsaturated esters of carboxylic acids, e.g., vinyl acetate, vinyl propionate, and vinyl benzoate; and ethylenically unsaturated amides and nitriles e.g., acrylamide, acrylonitrile, methacrylonitrile and fumaronitrile; and (2) one or more ethylenically unsaturated hydrocarbon monomers such as aliphatic α-olefin monomers, e.g., ethylene, propylene, butene-1 and isobutene; conjugated dienes, e.g., butadiene and isoprene; and monovinylidene aromatic carbocyclic monomers, e.g., styrene, α-methylstyrene, toluene, and t-butylstyrene.

A modified homogeneously branched ethylene polymer for use in the secondary backing materials can be conveniently prepared by known techniques such as, for example, by interpolymerization or by a polymerization procedure followed by a chemical or extrusion grafting procedure. Suitable grafting techniques are described in U.S. Pat. Nos. 4,762,890; 4,927,888; 4,230,830; 3,873,643; and 3,882,194, the disclosures of all of which are incorporated herein by reference.

In some aspects, the adhesive polymeric additives for use in the present invention can include maleic anhydride grafts wherein maleic anhydride is grafted onto an ethylene polymer at a concentration of about 0.1 to about 5.0 weight percent, about 0.5 to about 1.5 weight percent. The presence of ethylene polymer/maleic anhydride grafts as adhesive polymeric additives in the present invention can improve the performance and operating window of extrusion coated homogeneously branched ethylene polymers as the secondary backing material, especially when used in connection with polar polymers such as for example, but is not limited to, nylon and polyester faced carpets. The improvement pertained to substantially higher comparative abrasion resistance and tuft bind strength. In an exemplary aspect, a composition for forming a maleic anhydride graft is the Amplify® GR 204 available from Dow Chemicals.

In further aspects, the ethylene polymers for use as the grafted host polymer include low density polyethylene (LDPE), high density polyethylene (HDPE), heterogeneously branched linear low density polyethylene (LLDPE), homogeneously branched linear ethylene polymers and substantially linear ethylene polymers. In some aspects, the host ethylene polymers have a polymer density greater than or equal to about 0.86 g/cc, 0.87 g/cc, 0.88 g/cc, 0.89 g/cc, 0.90 g/cc, 0.91 g/cc, 0.92 g/cc, 0.93 g/cc, or greater than or equal to about 0.94 g/cc. In yet other aspects, the substantially linear ethylene polymers and high density polyethylene are utilized as host ethylene polymers.

In some aspects, it is contemplated that the secondary backing material to be extruded or applied by any other technique known in the art. In some aspects, the secondary backing material of this invention may optionally include exemplary additives such as foaming agents, pH controllers, flame retardants, fillers, tackifiers, wetting agents, dispersing agents, anti-microbial agents, lubricants, dyes, anti-oxidants, and the like, which are well known to those skilled in the art, without loss of the characteristic properties.

In one aspect, the secondary backing material can further comprise one or more flame retardants sufficient to ensure the carpet structure satisfies the requirements of the radiant flux floor covering test according to the ASTM-E648 testing procedures. In particular, according to certain aspects, the carpet compositions of the present invention exhibit a Class 1 critical radiant flux of greater than 0.45 watts per cm2 as measured according to ASTM-E648. According to other aspects of the invention, the carpet compositions described herein can exhibit a Class 2 critical radiant flux in the range of from 0.22 to 0.44 watts per cm2 as measured according to ASTM-E648. In still further aspects, the carpet compositions of the present invention can exhibit an unclassifiable critical radiant flux of less than 0.22 watts per cm2 as measured according to ASTM-E648.

Exemplary flame retardants that can be incorporated into the secondary backing materials of the present invention 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, friaryl phosphates, isopropylated triphenyl phosphate, phosphate esters, magnesium hydroxide, zinc borate, bentonite (alkaline activated nanoclay and nanotubes), organoclays, aluminum trihydrate (ATH), azodicarbonamide, diazenedicarboxamide, azodicarbonic acid diamide (ADC), friaryl phosphates, isopropylated triphenyl phosphate, triazine derivatives, alkaline activated organoclay and aluminum oxide. Any desired amount of flame retardant can be used in the secondary backing material of the instant invention and the selection of such amount will depend, in part, upon the particular flame retardant used and desired carpet applications. Such amounts can be readily determined through no more than routine experimentation.

Exemplary and non-limiting fillers that can be incorporated into the secondary backing materials of the present invention can include calcium carbonate, 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 one aspect, the secondary backing material comprises inorganic filler with high heat content. In some aspects, it is for the filler to exhibit relatively high heat content. Examples of such fillers include, but are not limited to, calcium carbonate, aluminum trihydrate, talc, and barite. The exemplified high heat content fillers allow the extrudate to remain at elevated temperatures longer with the beneficial result of providing enhanced encapsulation and penetration. In this aspect, the high heat content fillers should be ground or precipitated to a size that can be conveniently incorporated in an extrusion coating melt stream. Exemplary non-limiting particle sizes for the inorganic filler material can include particle sizes in the range of from about 1 to about 50 microns. Still further, it should also be understood that the filler component can be present in any desired amount. However, in an exemplary aspect, the filler is present in an amount in the range of from about 10 weight % to about 90 weight %, based upon the total weight of the secondary backing material, including exemplary amounts of about 15 weight %, 20 weight %, 25 weight %, 30 weight %, 35 weight %, 40 weight %, 45 weight %, 50 weight %, 55 weight %, 60 weight %, 65 weight %, 70 weight %, 75 weight %, 80 weight %, and about 85 weight %. Still further, the amount of filler present can be in any range derived from any two of the above stated weight percentages.

In still another aspect, the secondary backing material can further comprise one or more tackifying additives. The tackifier can for example be tall oil or rosin based or, alternatively, can be an aliphatic or aliphatic aromatic hydrocarbon blend resin. As the tackifier is an optional component, the amount of tackifier can be, when present, in the range of from greater than 0 weight percent up to and even exceeding about 50 weight % of the secondary backing material. For example, in one aspect, the amount of tackifier can be in the range of from about 5 weight % to about 45 weight %. In still another aspect, the amount of tackifier can be in the range of from about 10 weight % to about 20 weight %.

In still further aspects, the secondary backing can further comprise dimensionally and thermally stable fabrics such as non-woven or wet-laid fiberglass scrims, as well as woven and non-woven thermoplastic fabrics (e.g. polypropylene, nylon and polyester). In some aspects, the secondary backing can comprise a fiberglass scrim, for example, Duraglass that is commercially available from Johns Manville (about 2.0 oz/sq. yard). Alternatively, in other aspects, a secondary backing can comprise a fiberglass scrim sold by Owens Corning (about 2.0 oz/sq. yard).

FIG. 2 shows an exemplary composition of the inventive carpet composition. Specifically, FIG. 2 demonstrates an exemplary carpet structure 200 as disclosed a described herein. A plurality of face fibers 202 present in a yarn is attached to or tufted into a primary backing component 204 and is extending from a face surface 204a of the primary backing component. The backstitches 210 are exposed on the back surface 204b of the primary backing. An optional secondary backing 206 can be inserted between the primary backing 204 and a film 208 prior to the lamination process.

FIG. 3 shows a photograph of the backstitches of turf prior to and after film lamination. FIG. 4 shows a photograph of fully laminated backstitches. FIG. 5 shows a photograph of the fully laminated backstitches with a perforation showing the grass fiber. These figures demonstrate that the backstitches of the turf are efficiently locked and secured in the place. FIG. 8 shows a photograph of WatershedGeo® type turf, where the film is laminated to the backside of the non woven batting to fuse the backstitches of the face fibers.

Performance Characteristics

It has been found that the inventive carpets compositions comprising laminated films demonstrate exceptional strength properties. In some aspects, the carpet composition disclosed herein exhibits a tuft bind measured according to ASTM D1335 (Tuft Bind-Pile Floor Coverings and Turf Fields) of at least 4 pounds. In yet other aspects, the carpet composition exhibits a tuft bind of at least 5 pounds, at least 6 pounds, at least 7 pounds, or at least 8 pounds. In yet other aspects, the carpet composition disclosed herein can exhibit a tuft bind of at least 7 pounds to about 13 pounds, including exemplary values of about 8 pounds, about 9 pounds, about 10 pounds, about 11 pounds, and about 12 pounds.

In some aspects, the carpet composition disclosed herein exhibits a slip bind measured according to the ASTM D1335 from about 0.5 lb to about 3 lb, including exemplary values of about 1 lb, about 1.1 lb, about 1.2 lb, about 1.3 lb, about 1.4 lb, about 1.5 lb, about 1.6 lb, about 1.7 lb, about 1.8 lb, about 1.9 lb, about 2.0 lb, about 2.1 lb, about 2.2 lb, about 2.3 lb, about 2.4 lb, about 2.5 lb, about 2.6 lb, about 2.7 lb, about 2.8 lb, and about 2.9 lb. In yet other aspects, the carpet composition can exhibit slip bind in any range between any two of the foregoing endpoints.

In still further aspects, the carpet composition disclosed herein exhibits a slip bind measured according to the ASTM D1335 from about 0.5 lb to about 1.8 lb, including exemplary values of about 0.6 lb, about 0.7 lb, about 0.8 lb, about 0.9 lb, about 1.0 lb, about 1.1 lb, about 1.2 lb, about 1.3 lb, about 1.4 lb, about 1.5 lb, about 1.6 lb, about and 1.7 lb.

Additional properties as a carpet strength and dimensional stability can be measured in three various fabric directions: fill or a machine direction, warp or a cross direction, and a diagonal direction or 45°.

It is understood that grab/tear carpet strength is referred by a maximum pull force that carpet can handle without a complete tear. Maximum grab/tear measures a maximum force needed to be applied to completely tear fabric apart. In certain aspects, the carpet composition disclosed herein exhibits a grab/tear in fill direction as measured according to ASTM D5034 at 150 min from about 75 lb to about 500 lb, including exemplary values of about 80 lb, about 85 lb, about 90 lb, about 95 lb, about 100 lb, about 120 lb, about 150 lb, about 180 lb, about 200 lb, about 220 lb, about 250 lb, about 280 lb, about 300 lb, about 320 lb, about 350 lb, about 380 lb, about 400 lb, about 420 lb, about 450 lb, and about 480 lb. In yet other aspects, the carpet composition can exhibit grab/tear in fill direction in any range between any two of the foregoing endpoints.

In certain aspects, the carpet composition disclosed herein exhibits a grab/tear in warp direction as measured according to ASTM D5034 at 150 min from about 75 lb to about 500 lb, including exemplary values of about 80 lb, about 85 lb, about 90 lb, about 95 lb, about 100 lb, about 120 lb, about 150 lb, about 180 lb, about 200 lb, about 220 lb, about 250 lb, about 280 lb, about 300 lb, about 320 lb, about 350 lb, about 380 lb, about 400 lb, about 420 lb, about 450 lb, and about 480 lb. In yet other aspects, the carpet composition can exhibit grab/tear in warp direction in any range between any two of the foregoing endpoints.

In yet other aspects, dimensional stability of the fabric can be measured by a force needed to elongate a fabric to 5% of its original dimensions in a particular direction, such as warp, weft or 45°. In such aspects, the force that causes elongation of the fabric to 5% of its original dimensions is measured according to ASTM D5034 standard. In certain aspects, the force needed to cause a 5% elongation of the in a machine direction (fill direction) can be from 30 to 100 pounds, including exemplary values of about 35, about 40, about 50, about 55, about 60, about 65, about 70, about 75, about 80, about 85, about 90, and about 95 pounds.

In yet other aspects, the force needed to cause a 5% elongation of the fabric in a cross direction (warp direction) can be from 30 to 100 pounds, including exemplary values of about 35, about 40, about 50, about 55, about 60, about 65, about 70, about 75, about 80, about 85, about 90, and about 95 pounds.

In still further aspects, the force needed to cause a 5% elongation of the fabric in a diagonal direction)(45° can be from 30 to 100 pounds, including exemplary values of about 35, about 40, about 50, about 55, about 60, about 65, about 70, about 75, about 80, about 85, about 90, and about 95 pounds.

In still further aspects, the dimensional stability of the inventive carpet composition can be measured by applying a force to stretch the fabric to 5% of its original area. This test can also be performed in various directions of the fabric. In some aspects, this dimensional stability is measured when the load is applied in a machine direction (fill direction). In other aspects, this dimensional stability is measured when the load is applied in a cross direction (warp direction). In still other aspects, this dimensional stability is measured when the load is applied in a diagonal direction)(45°.

In certain aspects, the carpet composition disclosed herein exhibits a load at 5% expansion in a machine direction (or a fill direction) as measured according to ASTM D5034 from about 20 lb to about 250 lb, including exemplary values of about 30 lb, about 40 lb, about 50 lb, about 60 lb, about 70 lb, about 80 lb, about 90 lb, about 100 lb, about 110 lb, about 120 lb, about 130 lb, about 140 lb, about 150 lb, about 160 lb, about 170 lb, about 180 lb, about 190 lb, about 200 lb, about 210 lb, about 220 lb, about 230 lb, and about 240 lb. In yet other aspects, the carpet composition can exhibit a load at 5% expansion in a machine direction in any range between any two of the foregoing endpoints.

In certain aspects, the carpet composition disclosed herein exhibits a load at 5% expansion in a cross direction (or a warp direction) as measured according to ASTM D5034 from about 20 lb to about 250 lb, including exemplary values of about 30 lb, about 40 lb, about 50 lb, about 60 lb, about 70 lb, about 80 lb, about 90 lb, about 100 lb, about 110 lb, about 120 lb, about 130 lb, about 140 lb, about 150 lb, about 160 lb, about 170 lb, about 180 lb, about 190 lb, about 200 lb, about 210 lb, about 220 lb, about 230 lb, and about 240 lb. In yet other aspects, the carpet composition can exhibit a load at 5% expansion in a cross direction in any range between any two of the foregoing endpoints.

In certain aspects, the carpet composition disclosed herein exhibits a load at 5% expansion in a diagonal direction)(45° as measured according to ASTM D5034 from about 15 lb to about 60 lb, including exemplary values of about 20 lb, about 25 lb, about 30 lb, about 35 lb, about 40 lb, about 45 lb, about 50 lb, and about 55 lb. In yet other aspects, the carpet composition can exhibit a load at 5% expansion in a cross direction in any range between any two of the foregoing endpoints.

In certain aspects, the carpet composition disclosed herein exhibits a maximum load in a diagonal direction)(45° as measured according to ASTM D5034 from about 80 lb to about 500 lb, including exemplary values of about 100 lb, about about 120 lb, about 150 lb, about 180 lb, about 200 lb, about 220 lb, about 250 lb, about 280 lb, about 300 lb, about 320 lb, about 350 lb, about 380 lb, about 400 lb, about 420 lb, about 450 lb, and about 480 lb. In yet other aspects, the carpet composition can exhibit grab/tear in warp direction in any range between any two of the foregoing endpoints.

Methods Of Making Carpets

In still further aspects, disclosed herein are the methods of making inventive carpet compositions.

In certain aspects, described herein is a method of making a carpet comprising (a) providing a greige good comprising: i) a primary backing material having a face surface and a back surface and ii) a plurality of fibers attached to the primary backing material, wherein a portion of the plurality of fibers extends from the face surface of the primary backing and wherein a second portion of the plurality of fibers are exposed on the back surface of the primary backing in a form of backstitches; (b) providing a film; and (c) laminating the film on the backstitches to secure the plurality of fibers in place.

The face of a tufted carpet can generally be made in three ways. First, for loop pile carpet, the yarn loops formed in the tufting process are left intact. Second, for cut pile carpet, the yarn loops are cut, either during tufting or after, to produce a pile of single yarn ends instead of loops. Third, some carpet styles include both loop and cut pile. One variety of this hybrid is referred to as tip-sheared carpet where loops of differing lengths are tufted, followed by shearing the carpet at a height so as to produce a mix of uncut, partially cut, and completely cut loops. Alternatively, the tufting machine can be configured so as to cut only some of the loops, thereby leaving a pattern of cut and uncut loops. Whether loop, cut, or a hybrid, the yarn on the back surface of the primary backing component comprises tight, unextended loops. The combination of tufted yarn and a primary backing component without the application of an adhesive backing material or secondary backing material is referred to in the carpet industry as raw tufted carpet or greige goods. Greige goods become finished tufted carpet with the application of secondary backing materials or any other additional backings, if present, to the back surface of the primary backing material. In the aspects of the current invention, the greige goods become finished tufted carpet with the application of the secondary backing material. Finished tufted carpet can be prepared as broad-loomed carpet in rolls typically 6 or 12 feet wide. In some other aspects, broadloom carpet can be prepared in rolls 13′6″ and 15′ feet wide. In still further aspects, the finished tufted carpet can be prepared as an artificial turf. In yet further aspects where the finished tufted carpet is prepared as an artificial turf, the inventive artificial turf can be provided in any form known in the art. In some aspects, the inventive artificial turf can be provided in a form of panels. In such aspects, the panels can be installed in any selected orientation. In still further aspects, the inventive artificial turf has a continuous length and is rolled into a roll. In such aspects, the roll is unrolled on installation site.

In another aspect, any conventional tufting or needle-punching apparatus and/or stitch patterns can be used to make the carpet compositions of the present invention. Likewise, it does not matter whether tufted yarn loops are 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. After the yarn is tufted or needle-punched into the primary backing component, the greige good can be conventionally rolled up with the back surface of the primary backing component facing outward and held until it is transferred to the backing line.

In the aspects where the secondary backing is optionally inserted between the primary backing and the film prior to the lamination process, the secondary backing can be applied by any known in the art methods. In some aspects, the secondary backing disclosed herein can be rolled on the primary backing. In other aspects, the method can comprise the use of an extruded sheet of a thermoplastic material. In some aspects, a molten thermoplastic material can be extruded through a die so as to make a sheet which is as wide as the carpet composition.

Exemplary extrusion coating configurations can include, without limitation, a monolayer T-type die, single-lip die coextrusion coating, dual-lip die coextrusion coating, a coat hanger die, and multiple stage extrusion coating. Preferably, the extrusion coating equipment is configured to apply a total coating weight of from about 4 to about 60 ounces/yd2 (OSY), including exemplary amounts of 5, 10, 15, 20, 25, 30, 35, 40, 45, 50 and 55 ounces/yd2 (OSY), and any range of coating weights derived from these values. To that end, it should be understood that the desired coating weight of the extrusion coated layers will depend, at least in part, upon the amount of any flame retardants or inorganic fillers in the extrudate.

The extrusion coating melt temperature principally depends on the particular composition of the backing composition being extruded. When the secondary backing composition describe herein is extruded, the extrusion coating melt temperature can be greater than about 350° F. and, in some aspects, in the range of from 350° F. to 650° F. In another aspect, the melt temperature can be in the range of from 375° F. to 600° F. Alternatively, the melt temperature can be in the range of from 400° F. to 550° F.

The film of the inventive carpet composition can be applied to the primary backing, or an optional secondary backing, by any known in the art methods. In some aspects, the film can be rolled on the primary backing (or the optional secondary backing).

The film can be prepared by any techniques known in the art. In some aspects, the film can be extruded. In yet other aspects, the film can be blown. In yet further aspects, the film can be cast. In still further aspects, the film can be engineered to provide desirable characteristics.

The method of the current disclosure provides a step of laminating the film on the backstitches to secure the plurality of fibers in place. In other aspects, prior to step (c) of the film lamination, the carpet composition is heated. In some aspects, this step can be called a preheating step. In these aspects, the preheating of the carpet composition can be done at a temperature between about 100° F. and about 200° F., including exemplary values of about 105° F., about 110° F., about 115° F., about 120° F., about 125° F., about 130° F., about 135° F., about 140° F., about 145° F., about 150° F., about 155° F., about 160° F., about 165° F., about 170° F., about 175° F., about 180° F., about 185° F., about 190° F., and about 195° F. In some aspects, the lamination can be done at a temperature from about 250° F. to about 400° F., including exemplary values of about 260° F., about 270° F., about 280° F., about 290° F., about 300° F., about 310° F., about 320° F., about 330° F., about 340° F., about 350° F., about 360° F., about 370° F., about 380° F., and about 390° F.

In certain aspects, the gap between two rolls can be any gap commonly utilized by lamination industry. In certain aspects, the gap can be between about 10 mil to about 250 mils, including exemplary values of about 15 mil, about 18 mil, about 20 mil, about 30 mil, about 50 mil, about 60 mil, about 70 mil, about 80 mil, about 90 mil, about 100 mil, about 110 mil, about 120 mil, about 130 mil, about 140 mil, about 150 mil, about 160 mil, about 170 mil, about 180 mil, about 190 mil, about 200 mil, about 210 mil, about 220 mil, about 230 mil, and about 240 mil.

In still further aspects, any pressure usually used in lamination industry can be applied. In some aspects, the pressure can be between 80 psi to about 150 psi, including exemplary values of about 90 psi, about 100 psi, about 110 psi, about 120 psi, about 130 psi, and about 140 psi.

In certain aspects, the film laminated to the greige good is integrally fused with the backstitches, so that substantially all of the plurality of fibers are secured in place.

FIG. 6 shows a schematic of an exemplary method of making the inventive carpet. The greige good comprising a turf yarn 602 and a primary backing with the exposed backstitches 604 is fed to the manufacturing line. This line can be optionally preheated with a heater 610. The polymer film 606 is fed from a roll and disposed on the backstitches and then is passed through lamination rolls 608 to form the carpet composition. In some exemplary aspects, an embossing pattern can be added during the lamination process using an embossing tool 612. In still other exemplary aspects, an additional step such as perforation using perforation tool 614 can be added. In still other exemplary aspects, both the embossing and perforation step can be present. FIG. 7 shows a photograph of lamination process.

Any known in the art lamination equipment can be used, for example, equipment sold by Union Tool Corporation. An exemplary lamination equipment that can be used is a Union Tool Hot Roll Laminator MD#20962.

One skilled in the art will appreciate that, notwithstanding the particular examples described above, it is contemplated that the carpet composition may be produced by the processes known to those skilled in the art, including but not limited to direct coating and roll metering, and knife-coating and lick-roll application, as described in D. C. Blackly, Latex and Textiles, section 19.4.2, page 361, which is incorporated herein by reference.

The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.

EXAMPLES

The following examples are put forth so as to provide those of ordinary skill in the art with a complete disclosure and description of how the compounds, compositions, articles, devices, and/or methods claimed herein are made and evaluated, and are intended to be purely exemplary and are not intended to limit the disclosure. Efforts have been made to ensure accuracy with respect to numbers (e.g., amounts, temperature, etc.), but some errors and deviations should be accounted for. Unless indicated otherwise, parts are parts by weight, temperature is in ° F. or is at ambient temperature, and pressure is at or near atmospheric.

It is understood that in the Examples below, the tuft bind strength has been measured according to ASTM D1335-17; the delamination of the secondary backing has been measured according to ASTM 3936; the slip bind strength has been measured according to ASTM-D1335; Grab/Tear Fill has been measured according to ASTM-D5034; Grab/Tear Warp has been measured according to ASTM-ASTM-D5034 load@5% fill and warp have been measured according to ASTM-D5304; elongation fill and warp have been measured according to ASTM-D5304; max load 45° has been measured according to ASTM-D5304; load@5% 45° has been measured according to ASTM-D5304; and elongation 45° has been measured according to ASTM-D5304. All measurements were performed in an NVLAB accredited laboratory.

Example 1

The inventive turf composition was prepared according to the aspects described above. In this example, the inventive film used for lamination was an engineered film having a thickness of 5 mil or 0.005 inch and comprised of three layers with the outer layers comprising polyethylene and the inner layer comprising polypropylene. The backstitches were preheated using IR radiation immediately prior to lamination. It is understood that other types of preheat can be also utilized. The lamination was performed at 5-10 FPM, preheat temperature in a range from about 200° F. to about 260° F., lamination temperature of about 346° F., pressure of about 100 psi, and a lamination gap of 10-20 thousandth of inch (10-20 mils). The performance of the inventive carpet composition having a film laminated to the backstitches was compared to a number of the carpet compositions having their backstitches locked in place by other known in the art methods. The carpet compositions tested and compared to the inventive carpet composition included compositions having their backstitches locked in place by coating or spraying of polyurethane (PU), or by scattering LDPE powder. Table 1 summarizes the comparative performance data (an average of multiple (minimum 5) measurements) for such carpet compositions. Specifically, Table 1 shows comparison of turf and slip bind strengths, grab/tear, and dimensional stability of the carpet composition comprising the inventive film with the carpet compositions having their backstitches locked in place by other methods.

TABLE 1 Performance data of various carpet compositions. TRCC Adhesive Coated Coated PJ Spray Scattered Technologies Fabric Film PU PU PU LDPE Spray PU Test Direction Results (lb) Turf Bind* N/A 12.2 15.7 15.1 12.9 12.6 9 Slip Bind N/A 1.2 1.7 1.6 4.3 2.6 2 Grab/tear Warp 321 273 320 357 207 394.3 Fill 188 241 256 298 429 Diagonal 255 349 334 246 434.9 Dimensional Warp 83 83 98 77 71 60.6 stability (5% Fill 65 102 91 202 151.9 expansion) Diagonal 36 43 37 60 43.7 *minimum to pass needs to be 6.8 lb.

Example 2

The inventive carpet compositions having the backstitches locked in place by a film lamination were made using various types of turfs. The tested turfs comprised a polypropylene woven primary backing, slit tape or monofilament yarn tufted into the primary backing to provide a turf having various face densities. Fresh Rye-polypropylene and Fresh-Rey polyethylene samples refer to the turf samples having a polymer type of the relaxed thatch yarn that makes turf appearance more similar to natural grass. Performance data for such compositions was measured. The comparative results shown in Table 2 represent an average of multiple (minimum 5) measurements. Specifically, Table 2 shows tuft and slip bind strengths, along with grab/tear and dimensional stability properties for various inventive carpet compositions having their backstitches locked in place by laminating a film.

TABLE 2 Performance data of the carpet compositions having a laminated film on different turf types. Fresh Fresh Fabric Versacap Rye-PE Rye -PP Direction T thatch thatch Test Results (lb) Tuft Bind-mono N/A 8.6 8 7 Tuft Bind-thatch N/A N/A 4.6 5.6 Slip Bind- mono N/A 1.8 1 1.5 Slip Bind-thatch N/A N/A 1.6 1.3 Grab/tear Warp 231.3 307.3 306.6 Fill 151.2 250.2 252.7 Diagonal 205.6 268 277.3 Dimensional Warp 84.1 91.5 92.5 stability (5% Fill 76.9 94.7 99.1 expansion) Diagonal 37.3 49.8 50.6

While certain exemplary aspects of the invention have been described and disclosed, it will be apparent to those skilled in the art that various changes and modifications may be made that will achieve some or even all of the advantages of the invention without departing from the spirit and scope of the invention.

Claims

1. A carpet composition comprising:

(a) a greige good comprising: i) a primary backing material having a face surface and a back surface; ii) a plurality of fibers attached to the primary backing material, wherein a portion of the plurality of fibers extends from the face surface of the primary backing and wherein a second portion of the plurality of fibers are exposed on the back surface of the primary backing in a form of backstitches; and
(b) a film laminated on the backstitches to secure the plurality of fibers in place.

2. The carpet composition of claim 1, wherein the carpet composition does not comprise a precoat.

3. The carpet composition of claim 1, wherein the film comprises a first thermoplastic polymer.

4. The carpet composition of claim 3, wherein the first thermoplastic polymer comprises a polyamide, a polyolefin, a polyester, or combinations thereof.

5. The carpet composition of claim 4, wherein the primary backing comprises a second thermoplastic polymer.

6. The carpet composition of claim 5, wherein the plurality of fibers comprises a third thermoplastic polymer.

7. The carpet composition of claim 6, wherein the first thermoplastic polymer is substantially similar to the second and/or the third thermoplastic polymer.

8. The carpet composition of claim 6, wherein the first thermoplastic polymer is the same as the second thermoplastic polymer.

9. The carpet composition of claim 6, wherein the first thermoplastic polymer is the same as the third thermoplastic polymer.

10. The carpet composition claim 6, wherein the first thermoplastic polymer is a blend of the second and the third thermoplastic polymers.

11. The carpet composition of claim 5, wherein the second thermoplastic polymer comprises a polyamide, a polyolefin, a polyester, or combinations thereof.

12. The carpet composition of claim 6, wherein the third thermoplastic polymer comprises a polyamide, a polyolefin, a polyester, or a combination thereof.

13. The carpet composition of claim 3, wherein the first thermoplastic polymer composition comprises from 0 wt % to 100 wt % of a recycled polymer.

14. The carpet composition of claim 5, wherein the second thermoplastic polymer composition comprises from 0 wt % to 100 wt % of a recycled polymer.

15. The carpet composition of claim 6, wherein the third thermoplastic polymer composition comprises from 0 wt % to 100 wt % of a recycled polymer.

16. The carpet composition of claim 4, wherein the polyolefin comprises a polyethylene and copolymers thereof, a polypropylene and copolymers thereof, or a combination thereof.

17. The carpet composition of claim 4, wherein the polyolefin comprises, a low density polyethylene (LDPE), a linear low-density polyethylene (LLDPE), ultra low density polyethylene (ULDPE), very low density polyethylene (VLDPE), medium density polyethylene (MDPE), high density polyethylene (HDPE), a grafted polyethylene, heterogeneously branched ethylene polymer (HBEP), substantially linear ethylene polymer (SLEP), polypropylene, or a combination thereof.

18. The carpet composition of claim 4, wherein the polyester comprises polyethylene terephthalate, polypropylene terephthalate, polybutylene terephthalate, copolymers thereof, or any combination thereof.

19. The carpet composition of claim 1, wherein the film further comprises polyvinyl butyral (PVB), acrylic based materials, ethylene acrylic acetate (EAA), ethylene vinyl acetate (EVA), ethylene methyl acrylate (EMA), or a combination thereof.

20. The carpet composition of claim 1, wherein the film has a thickness from about 0.001 inch to about 0.010 inch.

21. The carpet composition of claim 1, wherein the carpet composition exhibits a tuft bind strength of at least 4 pounds as measured according to ASTM D1335.

22. The carpet composition of claim 1, wherein the carpet composition exhibits a slip bind from 1 lb to 3 lb as measured according to ASTM D1335.

23. The carpet composition of claim 1, wherein the carpet composition exhibits a grab/tear fill of 75 lb to 500 lb as measured according to ASTM D5034 at 150 min.

24. The carpet composition of claim 1, wherein the carpet composition exhibits a grab/tear warp of 75 lb to 500 lb as measured according to ASTM D5034 at 150 min.

25. The carpet composition of claim 1, wherein the carpet composition exhibits a load at 5% expansion of 30 lb to 250 lb in a machine direction as measured according to ASTM D5034.

26. The carpet composition of claim 1, wherein the carpet composition exhibits a load at 5% expansion of 30 lb to 150 lb in a cross direction as measured according to ASTM D5034.

27. The carpet composition of claim 1, wherein the carpet composition exhibits an elongation in a machine direction (fill) of 30 to 80 lbs as measured according to ASTM D5034.

28. The carpet composition of claim 1, wherein the carpet composition exhibits an elongation in a cross direction (warp) of 30 to 80 lbs as measured according to ASTM D5034.

29. The carpet composition of claim 1, wherein the carpet composition exhibits a maximum load at 45° of about 80 to about 500 lbs as measured according to ASTM D5034.

30. The carpet composition of claim 1, wherein the carpet composition exhibits a maximum load at 45° at 5% expansion of about 30 to about 100 lbs as measured according to ASTM D5034.

31. The carpet composition of claim 1, wherein the carpet composition further comprises a secondary backing.

32. The carpet composition of claim 31, wherein the secondary backing comprises a tape-tape yarn, a tape-spun yarn, or a combination thereof.

33. The carpet composition of claim 31, wherein the secondary backing further comprises a fiberglass.

34. The carpet composition of claim 1, wherein the carpet composition is recyclable.

35. The carpet composition of claim 1, wherein the carpet composition is an artificial turf.

36. A method of making a carpet composition comprising:

(a) providing a greige good composition comprising: i) a primary backing material having a face surface and a back surface; and ii) a plurality of fibers attached to the primary backing material, wherein a portion of the plurality of fibers extends from the face surface of the primary backing and wherein a second portion of the plurality of fibers are exposed on the back surface of the primary backing in a form of backstitches;
(b) providing a film;
(c) laminating the film on the backstitches to secure the plurality of fibers in place.

37. The method of claim 36, wherein the laminating is done at a temperature from about 300° F. to about 450° F.

38. The method of claim 36, wherein the carpet composition is preheated prior to the step c) to a temperature from about 150° F. to about 200° F.

39. The method of claim 36, wherein the film is integrally fused with the backstitches, so that substantially all of the plurality of fibers are secured in place.

Patent History
Publication number: 20190352845
Type: Application
Filed: May 17, 2019
Publication Date: Nov 21, 2019
Inventors: Jeffrey Thomas Coon (Dalton, GA), Philipe Aldahir (Chattanooga, TN), Rachel Fisher (Dalton, GA)
Application Number: 16/415,324
Classifications
International Classification: D06N 7/00 (20060101);