Note: Descriptions are shown in the official language in which they were submitted.
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CARPET BACKING DERIVED FROM BLOCK COPOLYMER COMPOSITIONS
The invention is relating to carpet backings based on block
copolymers derived from a vinyl aromatic and a conjugated diene and
more in particular styrene and butadiene and/or isoprene
respectively.
More in particular the invention is relating to a carpet backing
for polypropylene, polyester or polyamide carpets.
Up to now, backings of polypropylene, polyester or polyamide
carpets are mainly obtained by applying either a carboxylated
copolymer of styrene and butadiene as a latex, optionally mixed with
10 a foaming agent, and a vulcanizing agent on the backside of a
carpet, followed by a laborious and expensive drying and
vulcanisation step, or by applying a plastisol of PVC on the carpet
back.
Such initial carpets can usually be obtained by tufting
15 polypropylene, polyester or polyamide yarns through a fabric of the
same or anyhow a compatible starting material. The function of the
backing is anchoring of.the tufted yarns.
In addition it is generally known that conventional carpet
backing processes may require the use of primers to adhere the
20 backings or other methods to improve adhesion, such as corona
discharge treatment or flame treatment.
For example the Japanese patent application No. 02255739
disclosed a continuous sheet-like crosslinked foam consisting of a
resin mixture composition, which contained 10-55 wt~ of a block
25 copolymer, of which the two terminal blocks were consisting of
styrene polymer and the middle block was consisting of ethylene-
butylene copolymer or ethylene propylene copolymer, 40-85 wt% of
polypropylene based resin and 5-40 wt% of polyethylene based resin,
which could be stuck with a separate adhesive or bonding agent to a
30 plastic film or sheet, onto another foam or onto various surface
skin materials such as a metal foil, paper, non-woven cloths of
2 t 67686
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natural fibres or synthetic fibres, vinyl leather and the like. In
order to form a composite material, which might be used inter alia
as buffering material for lining or backing domestic products such
as carpets. However, it could clearly be derived from said -~
application that in order to reach sufficient adhesion between the
continuous sheet-like crosslinked foam and a surface skin to which
it is stuck, the surface of the continuous sheet-like crosslinked
foam should be subjected to a corona discharge treatment or flame
treatment.
It will be appreciated that as well the foaming of the starting
composition of block copolymer, polypropylene and polyethylene as
the subsequent sticking of the foamed sheet to a surface of another
layer represented additional process steps and costs.
Recent pressures from governmental and environmental agencies
have placed strong emphasis on the need for many plastic articles to
be prepared from completely recyclable components. The recycling
operation generally involves heating and melting the usual waste
polymer articles, to temperatures in excess of the melting point of
each of the components ~herein. The resultant molten plastic mass is
then ~sed to form a new structure or article using conventional
extrusion moulding etc. operations. The temperatures encountered in
the recycling operations cause even the small or residual quantities
of backing composition to char and/or discolour upon prolonged
heating to above 175 C or for shorter durations of temperatures of
above about 200 C, which are required for e.g. blow moulding of the
reclaimed polymer, thereby visibly fouling or darkening the
reclaimed plastic.
Such operations are not possible with carpet backing up to now
used.
It will be appreciated, that the backing polymer composition of
said carpets must be sufficiently compatible with said carpet fabric
polymers to provide acceptable physical properties of the reclaimed
polymer blend in the articles to be reused.
Therefore the primary object of the present invention is to
provide such carpets, which have to be completely recyclable without
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any significant charge to environment and at costs as low as
possible.
Another object of the present invention is to provide an
c economically attractive process to produce such carpets aimed at.
S From U.S. patent No. 3,772,234 were known petroleum wax
,- compositions comprising:
a) a petroleum wax predominating in paraffin wax, and
b) 7.5-30% by weight based on the composition of a block copolymer
having at least one essentially completely hydrogenated
polybutadiene block, the block prior to hydrogenation having a
1~2-content in the range from 13 to 45~ and in particular in the
ranges from 13 to 17~ (column 1, lines 30-35) and from 25-31
(column 4, lines 33-39).
Although it was indicated that said petroleum wax compositions
lS could in principle be used for paper or film coating or carpet
backing, due to the formation of tight bond with paper or other
fibrous products and metal foils or continuous webs such as
glassine, it will be appreciated that the type of petroleum waxes
used in the disclosed c~positions are certainly not sufficiently
compa~ible with polypropylene or polyester carpet fibres to enable
an easy recycling by manufacturing novel articles from waste carpet
mass by normal processing.
Moreover, the indicated viscosities of said compositions at
300 F in centipoises were clearly regarded as too low for efficient
carpet backing processing aimed at.
It will be appreciated by a person skilled in the art that for
the manufacture of said recyclable carpets, the carpet backing must
meet a combination of several requirements:
a) the backing composition must be sufficiently compatible with all
the other ingredients of the carpet,
b) the backing composition should have a melt viscosity low enough
to allow a complete penetration into the tufts of the upper
layer to obtain sufficient anchoring of said tufts at the chosen
processing conditions. For loop pile tufted carpets the
anchoring should be > 3 kg, while for cut pile the anchoring
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W O 95/03447 2 1 6 7 6 8 6 PCT~EPg4/02397
should be > 1 kg. Normal processing temperatures range from
150 to 200 C,
c) the backing composition must provide a sufficient stoutness of
the carpet back under using conditions,
d) the carpet backing composition may not become tacky under
storage, transport or use conditions of the final carpet, and .
e) it should be possible to add significant amounts of dispersed
fillers and/or flame retarders to the carpet backing composition
for economic reasons, such as calcium carbonate or silica,
magnesium hydroxide or alluminium oxide trihydrate.
As a result of extensive research and experimentation, it has
now been surprisingly found that the recyclable carpets aimed at,
are obtainable by means of the application of a block copolymer
composition, comprising at least:
lS a) a block copolymer, containing at least two termi n~l poly(vinyl-
aromatic) blocks and at least one internal poly(conjugated
diene) block, the original ethylenical unsaturation in which may
optionally be selectively hydrogenated, which block copolymer
may optionally be g~afted with a polar entity,
b) a non-aromatic plasticizing oil,
c) a terminal block compatible resin,
on the back side of a carpet fabric.
The amount of said block copolymer composition applied on the
carpet back according to the present invention is in the range from
100-1600 g/m of carpet back surface and preferably in the range of
from 200 to 1000 g~m .
The block copolymers which have been found to be suitably
applied, preferably are linear triblock copolymers or multi-armed
(more than 2 arms) radial or star shaped block copolymers, the
blocks of which have been pre~o~in~tly derived from styrene and
butadiene and/or isoprene respectively. The poly(conjugated diene)
blocks may optionally have been hydrogenated up to a substantial
degree, i.e. more than 80~ of the ethylenic unsaturation.
With the term "predominantly derived from" is meant that the
3~ main monomer of the respective individual blocks optionally may be
W O 95/03447 2 1 6 7 6 8 6 PCT~EPg4/023g7
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mixed with minor amounts of another comonomer and more in particular
with minor amounts of the main monomer of the other blocks.
Examples of the vinyl aromatic monomers may be selected from
~~ styrene, ~-methylstyrene, p-methylstyrene, m-methylstyrene, o-
S methylstyrene, p-tert-butylstyrene, dimethylstyrene,
vinylnaphthalene and the like and mixtures thereof and conjugated
diene monomers may be selected from butadiene, isoprene, piperylene
and the like, and mixtures thereof.
Of these monomers styrene and butadiene or isoprene or mixtures
thereof are preferred. Most preferably block copolymers have been
found to be used, which only contain substantially pure
poly(styrene) blocks and substantially pure poly(butadiene) or
poly(isoprene) blocks.
Examples of such block copolymers which can be suitably used are
lS Cariflex, Kraton D and G block copolymers (Cariflex and Kraton are
trade marks) and more preferably Cariflex KX 139, Cariflex TR-1102,
Kraton G 1652, Kraton G 1726 block copolymers are used.
It will be appreciated that also mixtures of hydrogenated and
non-hydrogenated or par~ially hydrogenated block copolymers can be
used as starting ingredients for the block copolymer composition, in
addition to individual grades of hydrogenated block copolymers or
non-hydrogenated block copolymers or partially hydrogenated block
copolymers.
It will be appreciated that the poly(conjugated diene) blocks of
the block copolymers to be used for the compositions of the present
invention, can be selectively hydrogenated and/or may be grafted
with a polar entity, such as carboxylic acids or derivatives
thereof, epoxy compounds, silane compounds, amines or amides.
Representative examples of block copolymers grafted with
unsaturated acid derivatives are known from US patent No. 4,007,311,
US patent No. 4,264,747 and ~uropean patent applications 0085115,
0173380, OZ15501, 0301665.
Preferably the grafting of polar entities will be performed on
the selectively hydrogenated poly(conjugated diene) blocks. More
preferably unsaturated carboxylic acid or esters or anhydrides
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2 1 67686
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thereof, will be grafted to said hydrogenated poly(conjugated
diene)blocks.
Preferred examples of such grafting agents are maleic anhydride,
fumaric acid or esters thereof, itaconic acid or esters or anhydride -~
S thereof, acrylic acid or methacrylic acid or esters of these acids
and preferably glycidyl acrylate. More preferably maleic anhydride ,
or acrylic acid esters are used.
Examples of commercial block copolymers grafted with maleic acid
anhydride are Kraton FG 1901 and FG 1921 X.
Mixtures of unmodified hydrogenated block copolymers and of
modified hydrogenated block copolymers and preferably those block
copolymers, the basic blocks of which are structurally related or
more preferably similar, can also be used for the hot melt
compositions to be used for the present invention. It will be
appreciated that the use of functionalized, selectively hydrogenated
block copolymers as constituent in the hot melt compositions to be
used according to the present invention, only will be necessary with
reference to the desired compatibility with polar thermoplastic
polymers of the yarns a~plied for the starting carpet. In particular
said ~odified hydrogenated block copolymer alone or mixed with non-
modified block copolymers will primarily be used in case of
polyamide carpets.
In addition, such individual block copolymer grades may
themselves actually comprise blends of a predominant part by weight
of triblock copolymer as hereinbefore defined and a minor part
(<20 ~wt) of a diblock copolymer, which originated from the living
precursor block copolymer before (partial~ coupling and termination
or may consist of triblock copolymers only.
The terminal blocks in the optionally selectively hydrogenated
block copolymers have usually apparent molecular weights, ranging
from 3,000 to 100,000 and preferably from 5,000 to 20,000, and the
internal, optionally selectively hydrogenated poly(conjugated diene)
blocks usually have apparent molecular weights in the range of from
10,000 to 300,000 and preferably from 30,000 to 100,000. The
initially prepared poly(conjugated diene) blocks usually contain
W O 95/03447 2 1 6 7 6 8 6 PCTfiEP94/02397
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from 5 to 50 mol-, relative to the co~jugated diene molecules, of
vinyl groups originating from 1,2 polymerization and more preferably
from 5 to 15% in case of use of non-hydrogenated block copolymers
; and from 25-40~ in case of use substantially completely hydrogenated
S block copolymers.
,- The complete block copolymer to be used according to the present
invention, is normally containing bound vinyl aromatic in an amount
of from 20 to 60% by weight and preferably from 25 to 50~ by weight.
The apparent molecular weight of the total block copolymer will
normally be in the range of from 20,000 to 350,000 and preferably in
the range of from 40,000 to 200,000 and more preferably in the range
from 40,000 to 150,000.
As component (b) various plasticizing oils are useful in the
compositions to be used according to the present invention.
Plasticizing oils which have been found useful include petroleum
derived oils, olefin oligomers and low molecular weight polymers, as
well as vegetable and animal oil and their derivatives.
The petroleum derived oils which may be employed are relatively
high boiling materials,~.containing only a minor proportion of
aromatic hydrocarbons preferably less than 20 percent and more
preferably less than 15 percent by weight of the oil most preferably
the oil may be totally non-aromatic. The oligomers may be
polypropylene, polybutenes, hydrogenated polyisoprene, hydrogenated
polybutadiene, polypiperylene and copolymers of piperylene and
isoprene, having average molecular weights between 350 and 10,000.
Vegetable and animal oils include glyceryl esters of the usual
fatty acids and polymerization products thereof.
Examples of a preferred paraffinic oil are Primol 352 (Primol is
a trade mark) Catenex SM 925, Catenex SM 956 (Catenex is a trade
mark1 and the Napvis and Hyvis (trade marks) polyolefins, having a
molecular weight in the range of from 500 to 6,000.
As component (c) various terminal block compatible resins are
useful in the compositions used according to the present invention.
Examples of the terminal poly(vinyl aromatic) block modifying
resins include coumarone-indene resin, polyphenylene ethers and more
W O 95/03447 PCT~EP94/02397
21 67686
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particularly poly(2,6-dimethyl-1,4-phenylene ether), polystyrene
resin, vinyltoluene-alphamethylstyrene copolymer resin, polyindene
resin, or poly(methyl indene) resin.
Examples of such commercial resins are Hercures HM 100, Hercures
A 120, Hercures A 100, Endex 160, Kristalex F 120, Kristalex F 5140,
Nevchem NL 140 and Piccotex 120. (Hercures, Endex, Kristalex,
Nevchem and Piccotex are trade marks.)
Preferred modifying resins are optionally substituted
polystyrene resins.
The weight ratio of the components a), b) and c) of the starting
hot melt composition to be used for the process of the present
invention, is normally in the range of from 30 to 200 parts by
weight and preferably from 80 to 170 parts by weight and more
preferably from 120 to 170 parts by weight, of plastici~ing oil per
1~ 100 parts by weight of block copolymer and from 30 to 150 parts by
weight and preferably from 75 to 125 parts by weight of end block
compatible resin per 100 parts by weight of block copolymer.
The block copolymer compositions as specified hereinbefore, can
be applied on the carpe~ back either by several methods known in
principle for application of a hot melt composition or by the
application of the hereinbefore specified block copolymer
composition in a finely powdered form, e.g. obtained by cryogenic
milling, as specified in the copending European application
No. 93203636.1 filed December 22, 1993, in a suitable layer and
2~ heating said layer by e.g. IR irradiation to achieve a continuous
backing layer.
Said starting hot melt compositions have been found to provide
an optimal melt viscosity of < 500 Pa.s at the usual processing
temperatures in the range of from 150-200 C, and more preferably in
the range from 0.5 to 100 Pa.s in that temperature range. Moreover,
they have appeared to give a hardness of the final backing layer of
from 40 to 60 shore A, whereas the amount of hot melt aimed at to be
applied on the carpet back for economically attractive carpet
manufacturing of the hereinbefore specified type of from 100 to 1600
3~ g/m and preferably from 200 to 1000 g/m could be reached.
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g _
It will be appreciated that the hot melt composition may
optionally contain, in addition to the three before-mentioned main
components one or more auxiliary agents such as stabilizers,
; fillers, colouring agents and slip agents.
S The stabilizers or antioxidants optionally used in accordance
,- with the practice of the present invention include high molecular
weight hindered phenols and multifunctional phenols such as sulphur
and/or phosphorus containing phenols. Hindered phenols are well
known to those skilled in the art and may be characterized as
phenolic compounds, which also contain sterically bulky radicals in
close proximity to the phenolic hydroxyl group thereof In
particular tertiary butyl groups or amyl groups generally are
substituted onto the benzene ring in at least one of the ortho
positions relative to the phenolic hydroxy group.
1~ Representatives of such stabilizers are commercially available
under the trade marks Sumilizer and Irganox, e.g. Sumilizer GM and
GS, Irganox lOlO.
As additional auxiliaries, inorganic and organic fillers can be
used, which are well known in the art. Examples of such fillers
include calcium carbonate, aluminium silicate, clay, talc, titanium
dioxide, bentonites, kaolin, barytes, mica, silica, barium sulfate
or mixtures thereof. A preferred filler is calcium carbonate. The
fillers can be incorporated in amounts up to 400 parts by weight per
lO0 parts by weight of block copolymer and preferably from l50-
2~ 250 parts and which has a particle size of _> l ~ and more preferably
in the range from 5-50 ~.
Examples of commercial fillers of that type are Durcal 5 and
Millicarb (both are trade marks).
It will be appreciated as surprising by a person skilled in the
art, that when applying a hot melt on a carpet fabric according to
the present invention by one step processing techniques, such as hot
melt coating extrusion-coating or powder coating carpet backings
could be obtained, showing a very good anchoring of the e.g.
polypropylene tufts. Depending on the backing weight, a tuft
3~ anchoring of 3-8 kg is obtainable. Moreover, the bonding of the
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- 10 -
backing layer to the upper layer and the optional secondary backing
may be more than 3 N/5 cm, as determined by a 180 T-peel strength
test.
On the other hand the carpet backings obtainable according to
the present invention appeared to show an attractive flexibility in
combination with an attractive stoutness of the total carpet. It is
preferred that backing layer has a total thickness in the range of
from 0.1 to 5 mm and preferably from 0.2 to 0.5 mm.
For some of the use purposes of the recyclable carpets e.g.
automotive carpets to be produced according to the present
invention, the hot melt composition or powdered composition can be
straightly applied on the carpet fabric in one step.
For carpet embodiments requiring higher wear resistance like
e.g. domestic tufted carpets or institutional carpets, the
application of a precoat composition, based on said starting hot
melt composition having a melt viscosity of < 20 Pa.s at processing
temperatures in the range of from 150-120 C and more preferably
having a melt viscosity in the range from 0.5 to 15 Pa.s in that
temperature range, on t~e fabric as a first step, followed by
application of a second layer of a hot melt block copolymer
composition, showing a relatively higher melt viscosity as second
step, is preferred.
For carpet embodiments requiring higher wear resistance, most
preferably a precoating layer of the block copolymer composition is
applied as hot melt by extrusion coating and a subsequent layer is
applied in the form of a fine powder, which layer is subsequently
fused into a continuous layer by heat treatment.
The amount of precoat composition to be applied on the carpet
back can vary from 100 to 1600 g/m and preferably from 100 to
500 g/m . Carpet backings thus obtained show a very good tuft
anchoring together with good filament binding resulting in good
wear-out properties.
It will be appreciated that according to a further alternative
embodiment of the present invention an additional secondary backing
or web, composed of polypropylene or jute, can be applied for
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special purposes. This web can be conveniently applied in the same
coating step(s) as the backing itself.
It will be appreciated that the outside of the applied hot melt
: composition layer of the carpet after cooling can, if desired, be
additionally coated with a relatively thin layer, providing an anti-
~~ slip and/or an adhesive thin coating to fix and keep the carpet in
its exact position e.g. by applying a usual adhesive coating.
The application of the block copolymer composition can be
carried out by means of a variety of usual application techniques.
Preferably a hot melt extrusion coating or powder coating process
will be used and more preferably in combination with a subsequent
roll take off equipment to compress sheet and carpet fabric.
It will be appreciated that another aspect of the invention is
formed by easily and fully recyclable carpets, having a back layer
derived from the hereinbefore specified block copolymer
compositions, showing a hardness of from 40 to 60 shore A,
containing an amount of hot melt composition in the range from lO0
to 1600 g/m and having a thickness of from O.l to 5 mm and
preferably from 0.2 to ~.5 mm, and having a basic carpet fabric
derived from polypropylene or polyamide or polyester yarns.
Another aspect of the invention is formed by the block copolymer
compositions to be used for carpet backing and providing a fully
recyclable carpet, which moreover shows an attractive combination of
properties and which can be obtained with relatively low
manufacturing costs due to the rather simple backing technique.
Accordingly the invention is also relating to block copolymer
compositions for backing of easily and fully recyclable carpets,
characterized in that they comprise:
a) lO0 parts by weight of a block copolymer containing at least two
terminal poly(vinylaromatic) blocks and at least one internal
poly(conjugated diene) block, the original ethylenic
unsaturation in which may optionally be selectively
hydrogenated,
b) 30 to 250 parts by weight of a non-aromatic plasticizing oil, as
specified hereinbefore,
21 67686
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c) 30 to 200 parts by weight of a termi n~l block compatible resin,
as specified hereinbefore.
More preferably said melt compositions for backing of easily and
completely recyclable carpets comprise: -.
a) 100 parts by weight of a block copolymer containing at least two
terminal poly(vinylaromatic) blocks and at least one internal ~~
poly(conjugated diene) block, the original ethylenic
unsaturation in which may optionally be selectively
hydrogenated,
b) 80-180 parts by weight of plasticizing oil as
~pecified
hereinbefore,
c) 70-160 parts by weight of end block compatible resin, as
specified hereinbefore,
Optionally an inorganic filler and more preferably calcium
carbonate may be included up to an amount of 500 parts by weight.
Such block copolymer compositions may be prepared according to
methods known per se, such as high shear mixing or mixing under
heating until the desired melt viscosity is reached.
A further aspect of~the present invention is formed by the
fluffy shredded recyclable carpets, which can be reprocessed into
useful products by means of compacting and subsequent extrusion.
The invention will be further illustrated by the following
examples, however without restricting its scope to these
embodiments.
Example l
A hot melt composition (l) prepared by high shear mixing in an
extruder and containing 70 parts by weight Kraton G 1652 and
30 parts by weight Cariflex KX139, (a commercial available styrene-
butadiene block copolymer, having Mw 92.000 and styrene content 40~
and melt flow rate at 200 C/5 kg of 20 g/min (ISO 1133)), 140 parts
by weight of Catenex SM 925, (commercial available paraffinic/-
naphthenic oil (64/34) density 15 C 867 kg/m3, pour point -15 C),
80 parts by weight of Kristalex F-120, (commercial available low
mol. weight thermoplastic hydrocarbon polymer derived largely from
alpha-methylstyrene, 118 C softening point), 1 part by weight
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Kemamide E (Kemamide is a trade mark for a commercially available
ecrucamide (slip agent), mol. weight 335, density 130 g/ml: 0.8~5)
and 1 part by weight of Irganox 1010, having melt viscosity of 30
.~ Pa.s at 160 C and of 13 Pa.s at 180 C, was applied on the backside
S of a loop pile polypropylene carpet fabric, containing 2-10
piles/cm and each pile consisting of about 100-140 filaments, by
means of an extrusion coating process. The experiments were carried
out on a carpet coating equipment, using several mill rolls.
The hot extruded sheet (melt temperature in the die was 170 C)
was directly applied on the carpet back side.
The bonding force between the backing composition and the PP
fabric was determined by means of a T peel test.
The tuft anchoring was measured by means of pulling one tuft
until release from the carpet backing.
The measured properties have been listed in the Table.
Example 2
A hot melt composition (2), containing 100 parts by weight of
Cariflex TR-1102, 114 parts by weight of Catenex SM 925, 80 parts by
weight of Kristalex F-lZ0, 200 parts by weight of Durcal 5 (a
commercial calcium carbonate powder), 1 part by weight of Kemamide E
and 1 part by weight of Irganox 1010, having a melt viscosity at
160 C of 82 Pa.s and at 180 C of 32.2, was applied in the same way
as described in example 1 to the same PP carpet fabric back side.
The measured properties have been listed in the Table.
Example 3
A hot melt composition (3), containing 100 parts by weight of
Cariflex KX 139, 100 parts by weight of Catenex SM 925, 50 parts by
weight of Kristalex F-120, 200 parts by weight of Durcal 5, 1 part
by weight of Kemamide E and 1 part by weight of Irganox 1010, having
a melt viscosity at 160 C of 95.2 Pa.s and at 180 C of 30 Pa.s, was
applied in the same way as described in example 1 to the same PP
carpet fabric back side.
The measured properties have been listed in the Table.
Example 4
A hot melt composition (4), containing 100 parts of Kraton G
W O 95/03447 2 1 6 7 6 8 6 PCT~EP94/02397
.
- 14 -
1652, 140 parts by weight of Primol 352 (a commercially available
paraffinic oil; density at 15 C: 685 kg/m3; pouring point -18 C),
100 parts by weight of Kristalex F-120, 200 parts by weight of
Durcal 5, 1 part by weight of Kemamide E and 1 part by weight of
Irganox 1010, having a melt viscosity at 160 C of 156 Pa.s and at
180 C of 39 Pa.s was applied in the same way as described in example ~~
1 to the same PP carpet fabric back side.
The measured properties have been listed in the Table.
Example 5
The hot melt composition (1), as specified in example 1, was
applied on a back-side of a polyamide PET carpet fabric, containing
from 10-20 piles/cm and each pile comprising from 100 to
140 filaments by means of an extrusion coating process. The
experiments were carried out as specified in example 1.
1~ The measured properties have been listed in the Table.
Example 6
A hot melt composition containing 100 parts of Cariflex
TR KX 139, 30 parts by weight of Catenex SM 956, 100 parts by weight
of Hercures A 100, 1 par.t by weight of Kemamide E and 1 part by
weigh~ of Irganox 1010, having a melt viscosity at 180 C of 13 Pa.s,
was applied in the same way as described in example 1 to the same PP
carpet fabric back side.
On top of this precoat a hot melt composition (4) in powdered
form with an average particle size of 350 ~m was applied in a powder
coating equipment.
A tuft anchoring of > 3 kg and a good binding of the filaments
was obtained.
Example 7
A hot melt composition containing 100 parts of Kraton G 1726,
100 parts by weight of Hercures A 120, 140 parts by weight of
Catenex SM 925, 50 parts of 3urcal 5, 1 part Kemamide E and 1 part
Irganox 1010, having a melt viscosity at 180 C of 0.7 Pa.s, was
applied in the same way as described in example 1 to the same PP
carpet fabric back side. On top of this precoat a hot melt
composition (2) in powdered form with an average particle size of
~WO 95/03447 - 15 - PCTIEW4/02397
500 ~m was applied in a powder coating equipment.
Excellent tuft anchoring, filament binding and delaminating
force (ASTM D3936) of the textile backing were obtained.
- Example 8
S 50 Parts KRG 1726, 50 parts KRG 1652, 150 parts Hercures A 120,
,- 175 parts Catenex SM 925, 50 parts Durcal 5, 1 part Kemamide E, 1
part Irganox 1010, having a melt viscosity at 160 C of about l Pa.s,
was applied in the same way as describred in example 1 to the same
PP carpet.
On top of this precoat a composition (2) in powder form with an
average particle size of 500 ~m was applied in a powder coating
equipment.
Excellent tuft achoring (ASTM D1335), filament binding (measured
by Lisson test tDIN 54322), Drum test tDIN S4323), and chair castor
test tDIN 54324)), and delaminating force tASTM D3936) were
measured.
2 1 6 7~86
WO 95/03447 PCT/E~94/02397
-- 16 --
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~VO 95/03447 PCTIEP94/02397
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Z N a)
_~ Ll as
~ ' ~ ~ :
V L O O O
O ^ -I r _ -- o o O
U
V V V
L~V
o ~ ~ ~ ~ ~
W O 95/03~7 2 1 6 7 6 8 6 PCT~EI94/023.7
- 18 -
In the subsequent table the physical properties are listed of a
blend of recycled carpet of polypropylene fabric, backed with a
Kraton G block copolymer containing composition according to the
invention, obtained by shredding and compacting the carpet, and
mixing the obtained particles with virgin PP homopolymer. For
comparison the physical properties of a PP homopolymer, a PE -,
copolymer and the pure recycled carpet are listed.
PP
homopol. virgin
virgin PP + recycl. copol. recycled
homopol. carpet (EP) carpet
1 2~ 3 4
Ingredient
SS 6500X 100 70 - 100
Carpet - 30
SMA 6100K (copol)V - - 100
Flex Modulus MPa~ 79 914 1004 390
Izod Impact Strength
at 23 C kJ/m2 3.1 5.0 6.0 8.5
at 0 C 2.1 3.3 4.4 5.8
at -23 C 1.9 2.3 3.7 5.0
MFR, 230 C/2.16 kg
g/10 min 12 17 11 33
Containing ca. 5~ wt G-1652
~ Measured at 190 C/2.16 kg
x a commercially available polypropylene homopolymer,
mol. weight 260.000 to 280.000; melt index = 12
v a commercially available polypropylene copolymer
(15~ PE content) melt index = 11
W O 95/0344'1 2 1 6 7 6 8 6 PCT~EW4/02397
.
-- 19 --
From the preceding table, it will be appreciated that the
recycled carpet after shredding and compacting may be easily blended
with virgin PP homopolymer to provide properties of the blend of a
; quality of (filled) toughened PP.
