Note: Descriptions are shown in the official language in which they were submitted.
~ 9518
B~CKGROUND OF THE INVENTION
During the p~st decade 9 polyolefins ha~?e been
used extensively as backing material in the production
of carpets. Normally, t~e polyolefinic carpet backing
is lubricated to minImize shattering of the backing
fibers or rib60ns and to reduce wear on the tufting
needles. The lubrlcant also prevents excessive heat
build up on the needles which can cause fusion of the
fiber polymer. The w~ter soluble copoly(oxyethyLene-
10 oxypropylene) derivatives have been folmd effective for
this use since they do not readily penetrate into the
polyolefin as do lubricants such as mineral oil or the
fatt~ acids or esters thereof. The advantages of the
oopoly(oxyethylene-oxypropylene) derivatives are their r
exceptionally good tufting lubricity and their water
solubillty since it is preferred to apply the lubricant
to the backing from an aqueous bath. However, one of ~he
great disad~antages of the use of these materials has
heen their tendency to d~grade the strength properties of
20 the polyolefin backing during heat aging of the a~pet.
SUMMARY OF THE INVENTION
The instant inven~ion pertains to a lubricant
composition f~ polyolefin carpe~ backings, such as poly-
propylene, having desirable thermal stability and lubricity
that does not cause degradation of the polyolefin backing.
This lubricant composition contains a major ~mount of a
random or block copoly(oxyethylene-oxypropylene) glycol
2. ~
9518
or monoether and minor amounts of a hindered phenol
stabilizer, a coupling agent, a we~ting agent and,
optionally, a corrosion ~nhibitor, as hereinafter defined.
P~ .
In the production of carpets, whether with
synthetic or natural fIbers, a carpet backing is employed
which can be either w~ven, spun ~onded or needle punched.
During the manufacture process heat build up can become
a pro~lem and it is therefore necessary to use some form
of lubrication to min~mize t~e problem. This invention
pertains to a specifically defined lubricant composition
suitable for use in carpet manufacturing process in which
the carpe~ backing is a polyolefin material, such as,
polypropylene or blends thereof with other polyolefins or
copolymers of polypropylene. The polypropylen~ find
particular favor in the industry because of the desirable
properties of fibers, films, ribbons, etc.~ thereof. These
materials are all w~ll known in the art and ~hose skilled
in the ~anufacture of carpets are fully familiar with the
wide variety of polypropylene carpet backings that can be
`, used. The lubricant compositions of this inventlon can be
used in any carpet manufacturing process employing any of
the suitable polypropylene carpet backings. In this
application, the term polypropylene carpet backing i~
intended to mean those backings containing polypropylene
alone, blends thereof or copolymers thereof.
When using the lubricant compositions of this
- invention they are employed in the conventional manner by
applying them to ~he backing using any of the known
3.
95~8
~3~ 3
procedures. The manner in which the lubricant is app]ied
to the backing is of no critical irnportance.
The block or random copoly(o~ye~hylene-oxy
propylene) glycol or monoether thereof which makes up a
major amount of the lubricant composi~ion is represented
by the structural formula
C~3
2 4 q 2 r
Wherein R''' is hydrogen or alkyl of from 1 to 12 carbon v
10 atoms, preferably 2 to 8 carbon atoms; q and r are
integers, such that q comprises from 25 to 75 weight
percent, preferably 35 to 65 weight percent, of the sum
of q and r, and wherein said glycol or monoe~her has a
number average molecular weight of from 500 to 30,000,
preferably from 1000 to 5000. The concentration of this
component in the lubricant composition should be above
about 60 weight percent. An amount of from about 60 to
98 weight percent can be used, preferably from about 60 to
about 94 weight percent and most preferably, from about
20 70 to 80 weight percent. These copoly(oxyethylene-oxy-
propylene) glycols and monoethers are well known and many
of them are commercially available. Illustrative thereof
are the copoly(oxyethylene-oxypropylene) glycols having
average molecular weights of 750, 1,000, 2,200, 2,400,
3,300, 3,800, 4,000, 4,400 or 5,500 and the methyl, propyl,
butyl, hexyl, 2-ethylhexyl, decyl and dodecyl monoethers
thereof wherein the oxyethylene content therein can be 30,
38, 42, 50, 56, 64, 70 or 75 mole percent.
The hindered phenol stabilizers are present in
30 the lubricant composi~ion at a concentration of from
9518
~ 9 3
about 0.1 to about 5 weight percent, preferably from
about 0.2 to about 2 weight percent. These stabilizers
are those represented by the structural Eormula
HO~CnH2n~x
R
wherein R is ~i) an alkyl group of from 1 to about 6
carbon atoms, preferably 4 to 6 carbon atoms, and most
preferably the ~ertiary butyl group when X is either -COOR'
or R
~OOCcmH2mscm~2mcoocnH2n4~H
or ~ii) a hydrogen atom or an alkyl group of from 1 to abou~
6 carbon atoms, preferably 4 to 6 carbon atom~ when X is
R I R
HO ~ CH ~ OH
R R
R' is alkyl of from about 6 to about 22 carbon atoms;
preferably 12 to 18 earbon atoms and n and m are integers
of from 2 to 4, preferably 2 or 3. Many of these hindered
phenols are known and illustrative thereof one can mention,
octadecyl beta-(3,5-di-t-butyl-4-hydro~yphenyl)propinnate,
bis[2-(3,5-di-t-butyl-4 hydroxyphenethyl)carbonylo~y-
ethyl]sulfide and 1,1,3-triphenylolpropane.
It was found that only those hindered phenols
defined by the above formula yield lubricant compositions
which do not discolor the lubricant or ~e carpet backing
on standing or on heat aging. Thus, for example, other
hindered phenols such as 2,6-di-t-butyl-4-methylphenol,
2,6-di-t-butylphenol 9 phenyl alpha-naphthylamine,
g51
~ 3
2,2'-methylenebis (4-methyl-6-t~butylphenol), 2,4-bis(4-
hydroxy-3,5-di-t-butylphenoxy)-6-~n-octylthio~-1,3,5-
triazine and 1,3,5-trimethyl-2,4,6-tris(3,5-di-t-butyl-
hydroxybenzyl)phenol, were found unsatisfactory and we
were ~mable to produce the~Dally stable carpet backing
lubricants with these materials.
The lubrican~ composition contains a coupling
agent to dissolve the hindered phenol ~tabilizer in both
the copoly(oxyethylene-oxypropylene~ glycol or monoether
and the water with which it is diluted. Thi5 coupling
agent is present in ~he lubricant composition at a
concentration of from about 2 to about 35 weight percent,
pr~ferably from about S to about 30 weight percent. The
suitable coupling agents are those represented by the
structural formula R"O(CH2CH20~pH , wherein R" is alkyl
of from about 8 to 22 carbon atoms, preferably from 11
to 18 carbon atoms, phenyl or alkylphenyl wherein the
alkyl group thereof has from 1 to about 18 carbon atoms,
preferably from about 6 to 12 carbon atoms, and p is an
integer having the value of from about 3 to about 40,
preferably from 7 to 20. These compounds are well known
and commercially available; they are the adducts of from
about 9 to about 15 moles of ethylene oxide with ClO to
C20 linear aliphatic alcohols or alkyl phenols such as
octylphenol. Illustrative of commercial products are
TERGITOL N~nionic 15-S-9, or Nonionic NPX, Igepal CA-S30
or RC-630 and Triton X-100. (Regis~ered trademarks).
The lubrica~ing eomposition also contains from
about 0.05 to about 2.5 weight percent, preferably from
abou~ 0.1 ~o about 1 weight percent, of a bulk wetting agent
which is a random copclymer of the following struc~ure
9518
CH3
3 (Me2sio~x[Meosic3H6coc2H4)d(ocHcH2~bo~e~ 5iMe3
Wherein Me is methyl, x is from about 15 to about 100,
- preferably from ahout 20 to 75, d is from 5 to 30,
preferably from about 7 to 20, b is from 0 to about 50,
preferably from 0 to about 30, and y is from about 2.5 to
about 7.5, preferably fr~m about 3.2 to about 5.1. These
silicone alkylene oxide copolymer bulk wetting agents are
known commercially a~ailable materials and require no
further description ~o enable one skilled in the art to
, fully understand which compounds are intended.
The presence of a corrosion inhibitor is not
critical to this invention and it is used solely to
prevent corrosion o machine parts. When present it can
- be present at a concentration up to about 10 weight percent,
preferably from ahout 0.5 to 5 weight percent. Any of the
; known corrosion inhibitors that are miscible with the
lubrican~ composition and used in the textile art can be
used and illustrative thereof one can mention, tricresyl
phosphite, triisopropanolamine, tetrapropenylsuccinic
anhydride, sodium benzoate, the phosphate inhibitors,
and the like.
The lubricant compositions of this invention are
produced by mixing ~he components by conventlonal mixing
procedures. The manner of mi~ing is not critical.
Normally, these compositions are diluted with water before
they are applied to the fabrlc. The conc ntration thereof
in the aqueous mixture can vary from about 5 to 30 weight
percent, preferably from about 10 to 20 weight percent.
The lubricant composition is applied to the fabric or
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7.
951
~ 3
carpet backing by any conventional means such as padding,
dipping, roller coating, spraying or any other suitable
procedure generally employed. After it has been applied
to the carpet backing at a lubricant loading of from
about 2 to S w~ight percent, the carpet is manufactured by
conventional tufting or o~her procedure. The lubricant
compos~tions of this invention were evaluated for thei.r
thermal s~ability and the inertness or prevention of
degradation of carpet backing by padding woven polypropylene
backing with a 20 weight percent aqueous mixture of khe
lubricant to obtain a 4 to 5 weight percent lubricant
loading on the backing. The backing was then heat set in
an oven at 350F. for two minutes and six inch (warp) by
1 inch (fill) strips were cut therefrom for evaluation.
The strips were hung in an oven set at 230F. to 258F.
with a 10 gram weight attached to the end of each strip.
The heat aged samples were removed from the oven at
different intervals and their tensile strengths were
determined with an Instron Tensile Tester by the procedure
described in ASTM D 2646.
The following examples further serve to illustrate
the invention. Parts and percentages are by weight un-
less otherwise specified.
Example 1
A lubricant composition was prepared containlng
82.7 par~s of the butyl monoether of the random copoly-
~oxyethylene-oxypropylene) glycol having an average
molecular weight of about 4400 and containing 64 mole
percent oxyet~ylene units, 15 parts by weight of the
adduct of 9 moles of ethylene oxide per mole of a
9518
~ 3
Cll to C15 mixture of linear aLlcohols as the coupling
agent, one part of stearyl bet:a-C3,5-dl-t-butyl-4-
hydroxyphenyl~ propionate as t:he stabilizer, one part of
tetrapropenylsuccinic anhydrîcle as corrosion inhibitor
and 0.3 part of
; CH3
Me3sio~M~2sio)72~Meosic3H6(oc~H4~2o(ocHcH2~29oMe~5 1SiMe3
as the bulk wetting agent. An aqueous lubricant compo-
sition was prepared contalning 20 weight percent of the
above lubricant composition and this was padded on to
polypropylene carpet backing fabric to obtain a 4 to 5
weight percent loading of the lubricant on the backing.
The backing was heat set at 350F. for 2 minutes and then
the tensile strength was determined on strips by the
procedure previously described.
For comparative purposes the ~ame polypropylene
carpet backing was coated with aqueous com~ositions
containing the same uninhibited copoly~oxyethylene-
- oxypropylene) derivative (Control I), the same inhibited
copoly(oxyethylene-oxypropylene) derivative contai~ing
1 weight percent of diphenylol propane (Control II), the
the same copoly(oxyethylene-oxypropylene) derivative
containing 1 weight percent of 2,6-di-t-butyl-4-methyl-
phenol (Control III) and ~he ~ensile strength at break
was determlned. The same test was also carried out on
the uncoated carpet backing (Control IV~. The results
of this evaluation are set forth below after the carpet
backing specimens had been heat aged at 240F. for 116
hours and 138 hours.
.,
9.
.
~ 3 951~
Tensile Stren~th at Break, lb.
_ 116 hours 138 hours
Lubricant Composition
of Exa~lple 1 7~.8 77.5
Control I less than 1
Control II less than 1
Control III less than 1
Control IV 80 81
As can be seen the lubricant composition containing the
defined stabilizer of this invention showed no harmful
effect on the polypropylene carpet backing. Whereas all
of the other lubricant compositions, Controls II and III,
containing conventional stabilizers and the uninhibited
lubricant (Control I) showed excessive deterioration of the
backing and, in fact, complete strength loss within 24
hours of heat aging. This shows that the lubricant eompo-
sition of Example 1 can be used to lubrieate the poly-
propylene carpet backing without fear of causing any
significant degradation or deterioration thereof. While
Control IV showed no degradation, the non-lubricated
carpet backing would present problems during the carpet
manufacturing process. The results indicate that the
lubricant compositions of this invention do not have a
degrading effect on the polypropylene carpet backing.
. .
Example 2
A lubricant composition was prepared containing
77.7 parts of the butyl monoether of the random copoly-
(oxyethylene-oxypropylene~ glycol having an average
molecular weight of about 4400 and containing 64 mole
percent oxyethylene units, 20 parts by weight of the
10 .
9518
~ 3
adduct of 9 moles of ethylene oxide per mole of a
Cll to C15 mixture of linear alcohols, one part of
bis[2-C3,5-di-t-butyl-4-hydrox~-phenethyl) carbonyl~
oxyet~yl] sulfide, one part of tetrapropenylsuccinic
anhydride and 0.3 part of
CH3
Me3SiOCMe2SiO~7~[MeOSiC3H6(OC2H~2~(OCHCH2)29OMe~5 1SiMe3
An aqueous lubricant composition was prepared containing
~0 weight percent of the a~ove lubricant composition and
this was padded on to polypropy~ene carpet backing fabric
to obtain a 4 to 5 weight percent loading of the lubricant
on the backing. The backing was heat set at 350F for 2
minutes and then the tensile strength was determined on
strips by the procedure previously described.
For comparative purposes the same polypropylene
carpet backing was coated with aqueous compositions
containing the same uninhibited copoly(oxyethylene-
oxypropylene) deriva~ive (Control I), the same inhibited
copoly~oxyethylene-oxypropylene) derivative containing 1
weight percent of 2,4,6-tris(3,5-di-~-butyl-hydroxy-
benzyl)phenol (Control II), the same copoly(oxyethylene-
oxypropylene) derivative containing 1 weight percent of
2,4-bis(4-hydroxy-3,5-di-butylphenoxy)-6-(n-octylthio)-
1,3,5-triazine (Control III) and the tensile s~rength
at break was determined. The same test was also carried
out on the ~mcoated carpet backing (Control IV). The
results of t:his evaluation are set forth below after the
carpe~ backi.ng specimens had ~een heat aged at 240F. for
116 hours.
11 .
~6~3 9518
Ten~ile Strength at Break, lb.
l'5 ho~:r~ _
Lubri~ant Composi~ion
of Example 2 78.5
Con~rol I less than 1
Control II less than 1
Control III less than 1
Control rv 80
As can be seen the lubricant composition containing the
defined stabilizer of this invention showed no harmful
effect on the polypropylene carpet backing. Whereas, all
of the other lubricant compositions, Control I and Controls
II and III, containing conventional stabilizers showed
excessive deterioration of the backing and, in fact, complete
strength loss within 24 hours o heat aging. This shows
that the lubricant composition of Example 2 can be used to
lubricate the polypropylene carpet backing without fear of
causing any degradation or deterioration thereof.
Example 3
A lubricant composition was prepared containing
82.7 parts of the butyl monoether of the random copoly-
(oxyethylene-oxypropylene) glycol having an average
molecular weight of about 4400 and containing 64 mole
percen~ oxyethylene units, 15.0 parts by weight of the
adduct of 9 moles of ethylene oxide per mole of a
Cll to C15 mixture of linear alcohols, one part of 1,1,3-
triphenylol propane, one part of tetrapropenylsuccinic
anhydride and 0.3 part o~ the silicone wettin~ agent
employed in Ex*mple 1. An aqueous lubricant composition
.~
12.
9518
was prepared containing 2Q weigh~ percent of the above
lu~r~cant composition and t~s ~as padded on to polypropylene
carpet back~ng fa~ric to o~t:ain a 4 to 5 weight percent
loading of the lubricant on the backing. The backing was
~eat set at 350F. for 2 minutes and then the tensile
strength was determined on strips ~y the procedure
previously described.
For comparative purposes the same polypropylene
carpet backing was coated with an aquPous compo~ition
1~ containing the same uninhibited copoly(oxyethylene-
oxypropylene3 derivative (Control I~, and the tensile
strength at break was determined. The same test was also
carried out on the uncoated carpet backing {Control II).
The results of this evaluation are set forth below after
the carpet backing specimens had been heat aged at 250F.
for 112 hours.
Tensile Strength at Break, lb.
112 hours
. ~
Lubricant Composition
20 of Example 3 79
Control I less than 1
Control II 75
~' As can be seen the lubricant composition containing the
defined stabilizer of this invention showed no harmful
efect on the polypropylene carpet backing. W~ereas,
the lubricant composition of Control I showed excessive
deterioration of t~e backing and, in fact, complete
strength loss within 24 hours of Eleat aging. Thls shows
that the lubricant composition of Example 3 can be used
to lubricate the polypropylene carpet backing without
9518
~0~
fear of causing any degradation or deterioration thereof.
Similar results are obtained when on_ uses the
2-ethylhexyl monoether or the diol in the preparation o~
the lubricant composition.
14.
