US3717526A - Production of textile articles - Google Patents
Production of textile articles Download PDFInfo
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- US3717526A US3717526A US00038505A US3717526DA US3717526A US 3717526 A US3717526 A US 3717526A US 00038505 A US00038505 A US 00038505A US 3717526D A US3717526D A US 3717526DA US 3717526 A US3717526 A US 3717526A
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- process according
- article
- vinyl chloride
- vinyl
- copolymer
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- Expired - Lifetime
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- 239000004753 textile Substances 0.000 title claims abstract description 28
- 238000004519 manufacturing process Methods 0.000 title description 8
- 238000000034 method Methods 0.000 claims abstract description 57
- 239000000203 mixture Substances 0.000 claims abstract description 42
- BZHJMEDXRYGGRV-UHFFFAOYSA-N Vinyl chloride Chemical compound ClC=C BZHJMEDXRYGGRV-UHFFFAOYSA-N 0.000 claims abstract description 28
- 239000006260 foam Substances 0.000 claims abstract description 24
- 238000007664 blowing Methods 0.000 claims abstract description 23
- 229920000642 polymer Polymers 0.000 claims abstract description 23
- 239000004014 plasticizer Substances 0.000 claims abstract description 15
- 229920001577 copolymer Polymers 0.000 claims description 26
- 150000003839 salts Chemical class 0.000 claims description 16
- 239000004156 Azodicarbonamide Substances 0.000 claims description 13
- XOZUGNYVDXMRKW-AATRIKPKSA-N azodicarbonamide Chemical compound NC(=O)\N=N\C(N)=O XOZUGNYVDXMRKW-AATRIKPKSA-N 0.000 claims description 13
- 235000019399 azodicarbonamide Nutrition 0.000 claims description 13
- IRIAEXORFWYRCZ-UHFFFAOYSA-N Butylbenzyl phthalate Chemical group CCCCOC(=O)C1=CC=CC=C1C(=O)OCC1=CC=CC=C1 IRIAEXORFWYRCZ-UHFFFAOYSA-N 0.000 claims description 10
- XTXRWKRVRITETP-UHFFFAOYSA-N Vinyl acetate Chemical compound CC(=O)OC=C XTXRWKRVRITETP-UHFFFAOYSA-N 0.000 claims description 10
- VJRITMATACIYAF-UHFFFAOYSA-N benzenesulfonohydrazide Chemical compound NNS(=O)(=O)C1=CC=CC=C1 VJRITMATACIYAF-UHFFFAOYSA-N 0.000 claims description 10
- 239000000835 fiber Substances 0.000 claims description 10
- JQCXWCOOWVGKMT-UHFFFAOYSA-N diheptyl phthalate Chemical compound CCCCCCCOC(=O)C1=CC=CC=C1C(=O)OCCCCCCC JQCXWCOOWVGKMT-UHFFFAOYSA-N 0.000 claims description 6
- 239000004604 Blowing Agent Substances 0.000 claims description 5
- KCXZNSGUUQJJTR-UHFFFAOYSA-N Di-n-hexyl phthalate Chemical compound CCCCCCOC(=O)C1=CC=CC=C1C(=O)OCCCCCC KCXZNSGUUQJJTR-UHFFFAOYSA-N 0.000 claims description 5
- 239000000463 material Substances 0.000 claims description 5
- 229920001778 nylon Polymers 0.000 claims description 5
- 229920000915 polyvinyl chloride Polymers 0.000 claims description 5
- 239000004800 polyvinyl chloride Substances 0.000 claims description 5
- QQONPFPTGQHPMA-UHFFFAOYSA-N propylene Natural products CC=C QQONPFPTGQHPMA-UHFFFAOYSA-N 0.000 claims description 5
- 125000004805 propylene group Chemical group [H]C([H])([H])C([H])([*:1])C([H])([H])[*:2] 0.000 claims description 5
- MQIUGAXCHLFZKX-UHFFFAOYSA-N Di-n-octyl phthalate Natural products CCCCCCCCOC(=O)C1=CC=CC=C1C(=O)OCCCCCCCC MQIUGAXCHLFZKX-UHFFFAOYSA-N 0.000 claims description 4
- 150000001336 alkenes Chemical class 0.000 claims description 4
- BJQHLKABXJIVAM-UHFFFAOYSA-N bis(2-ethylhexyl) phthalate Chemical compound CCCCC(CC)COC(=O)C1=CC=CC=C1C(=O)OCC(CC)CCCC BJQHLKABXJIVAM-UHFFFAOYSA-N 0.000 claims description 4
- YVDYGBNMUBYYDF-UHFFFAOYSA-N 1-ethenoxytridecane Chemical compound CCCCCCCCCCCCCOC=C YVDYGBNMUBYYDF-UHFFFAOYSA-N 0.000 claims description 3
- OEPOKWHJYJXUGD-UHFFFAOYSA-N 2-(3-phenylmethoxyphenyl)-1,3-thiazole-4-carbaldehyde Chemical compound O=CC1=CSC(C=2C=C(OCC=3C=CC=CC=3)C=CC=2)=N1 OEPOKWHJYJXUGD-UHFFFAOYSA-N 0.000 claims description 3
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 claims description 3
- 239000005977 Ethylene Substances 0.000 claims description 3
- 239000004677 Nylon Substances 0.000 claims description 3
- 229920000297 Rayon Polymers 0.000 claims description 3
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 claims description 3
- AFSIMBWBBOJPJG-UHFFFAOYSA-N ethenyl octadecanoate Chemical compound CCCCCCCCCCCCCCCCCC(=O)OC=C AFSIMBWBBOJPJG-UHFFFAOYSA-N 0.000 claims description 3
- UIWXSTHGICQLQT-UHFFFAOYSA-N ethenyl propanoate Chemical compound CCC(=O)OC=C UIWXSTHGICQLQT-UHFFFAOYSA-N 0.000 claims description 3
- 238000009408 flooring Methods 0.000 claims description 3
- 238000010438 heat treatment Methods 0.000 claims description 3
- JRZJOMJEPLMPRA-UHFFFAOYSA-N olefin Natural products CCCCCCCC=C JRZJOMJEPLMPRA-UHFFFAOYSA-N 0.000 claims description 3
- 229920000728 polyester Polymers 0.000 claims description 3
- 229940049964 oleate Drugs 0.000 claims description 2
- ZQPPMHVWECSIRJ-KTKRTIGZSA-N oleic acid Chemical compound CCCCCCCC\C=C/CCCCCCCC(O)=O ZQPPMHVWECSIRJ-KTKRTIGZSA-N 0.000 claims description 2
- -1 e.g. Polymers 0.000 description 6
- 229920002994 synthetic fiber Polymers 0.000 description 5
- 239000012209 synthetic fiber Substances 0.000 description 5
- 239000004743 Polypropylene Substances 0.000 description 4
- 230000006866 deterioration Effects 0.000 description 4
- 239000002245 particle Substances 0.000 description 4
- 229920001155 polypropylene Polymers 0.000 description 4
- NBOCQTNZUPTTEI-UHFFFAOYSA-N 4-[4-(hydrazinesulfonyl)phenoxy]benzenesulfonohydrazide Chemical compound C1=CC(S(=O)(=O)NN)=CC=C1OC1=CC=C(S(=O)(=O)NN)C=C1 NBOCQTNZUPTTEI-UHFFFAOYSA-N 0.000 description 3
- 229920002972 Acrylic fiber Polymers 0.000 description 3
- 238000005187 foaming Methods 0.000 description 3
- 229910052788 barium Inorganic materials 0.000 description 2
- DSAJWYNOEDNPEQ-UHFFFAOYSA-N barium atom Chemical compound [Ba] DSAJWYNOEDNPEQ-UHFFFAOYSA-N 0.000 description 2
- 229910052793 cadmium Inorganic materials 0.000 description 2
- BDOSMKKIYDKNTQ-UHFFFAOYSA-N cadmium atom Chemical compound [Cd] BDOSMKKIYDKNTQ-UHFFFAOYSA-N 0.000 description 2
- 239000003795 chemical substances by application Substances 0.000 description 2
- 239000011248 coating agent Substances 0.000 description 2
- 238000000576 coating method Methods 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- XBCFRZRVCDUSGX-UHFFFAOYSA-N phenylmethanesulfonohydrazide Chemical compound NNS(=O)(=O)CC1=CC=CC=C1 XBCFRZRVCDUSGX-UHFFFAOYSA-N 0.000 description 2
- 229920005989 resin Polymers 0.000 description 2
- 239000011347 resin Substances 0.000 description 2
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 description 2
- 150000003751 zinc Chemical class 0.000 description 2
- OCVODYGWTBCBRL-UHFFFAOYSA-N 2-methylbenzenesulfonohydrazide Chemical compound CC1=CC=CC=C1S(=O)(=O)NN OCVODYGWTBCBRL-UHFFFAOYSA-N 0.000 description 1
- VEXZGXHMUGYJMC-UHFFFAOYSA-M Chloride anion Chemical compound [Cl-] VEXZGXHMUGYJMC-UHFFFAOYSA-M 0.000 description 1
- 244000068988 Glycine max Species 0.000 description 1
- 235000010469 Glycine max Nutrition 0.000 description 1
- 239000008037 PVC plasticizer Substances 0.000 description 1
- 229920001944 Plastisol Polymers 0.000 description 1
- QYKIQEUNHZKYBP-UHFFFAOYSA-N Vinyl ether Chemical class C=COC=C QYKIQEUNHZKYBP-UHFFFAOYSA-N 0.000 description 1
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 1
- 230000032683 aging Effects 0.000 description 1
- SNRUBQQJIBEYMU-UHFFFAOYSA-N dodecane Chemical group CCCCCCCCCCCC SNRUBQQJIBEYMU-UHFFFAOYSA-N 0.000 description 1
- 230000004927 fusion Effects 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000000178 monomer Substances 0.000 description 1
- 239000004999 plastisol Substances 0.000 description 1
- 229920001567 vinyl ester resin Polymers 0.000 description 1
- 229920002554 vinyl polymer Polymers 0.000 description 1
- 229910052725 zinc Inorganic materials 0.000 description 1
- 239000011701 zinc Substances 0.000 description 1
Classifications
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
- D06N7/0005—Floor covering on textile basis comprising a fibrous substrate being coated with at least one layer of a polymer on the top surface
- D06N7/0007—Floor covering on textile basis comprising a fibrous substrate being coated with at least one layer of a polymer on the top surface characterised by their relief structure
- D06N7/0013—Floor covering on textile basis comprising a fibrous substrate being coated with at least one layer of a polymer on the top surface characterised by their relief structure obtained by chemical embossing (chemisches Prägen)
Definitions
- the process of the invention is one for producing a textile article backed with vinyl chloride polymer foam fusible at a temperature of below 150 C., which comprises applying to the textile article a foamable composition comprising polyvinyl chloride or a copolymer of vinyl chloride and a minor proportion of comonomer, a plasticizer, and a nitrogen-evolving blowing system active at a temperature below 150 C., and heating the treated article to activate the blowing system.
- the process is particularly useful for backing carpets, and also flooring material, which contain synthetic fibers sensitive to or damaged by high temperatures (such as 150 C. or above), such as for example, nylon, acrylic, olefin, e.g., polypropylene, polyester or viscose fibers.
- carpets and other textile materials which can be backed by foamed vinyl chloride polymer according to the process of the invention need not, of course, consist wholly of synthetic fiber but can include other materials that in themselves are heat resistant.
- the vinyl chloride polymer foam gives good adhesion to synthetic fibers, and because the process is operated below 150 C. there is little tendency for the synthetic fibers to deteriorate as a result of being overheated.
- the foamable composition can be applied to the textile article in paste form by spreading on to synthetic woven or non-woven articles, the paste being subsequently foamed.
- a textile article can be backed with the polymer foam by fusing a sheet of the foamed polymer on to the back of the article.
- the invention further provides a textile article backed with a foamed polyvinyl chloride or a foamed copolymer of vinyl chloride and a minor proportion of comonomer, the foamed polymer being fusible at a temperature below 150 C.
- the textile article is a carpet containing synthetic fibers sensitive to or damaged by high temperatures.
- the vinyl chloride polymers which are most useful are polyvinyl chloride and copolymers of vinyl chloride and a minor proportion of comonomer which is generally from 2 to 14 percent by weight and preferably from 2 to percent by weight of the copolymer. Excellent results are obtained when the proportion of comonomer is from 2 to 5 percent by weight of the copolymer.
- Convenient vinyl chloride copolymers which are used in accordance with this invention include copolymers of vinyl chloride with such comonomers as vinylidene halides such as vinylidene chloride, vinyl ethers such as acetyl vinyl ether and tridecyl vinyl ether, olefins such as ethylene and propylene, vinyl esters such as vinyl acetate, vinyl stearate and vinyl propionate and the like.
- the copolymers should preferably be paste forming resins and they can also contain a third copolymerizable monomer.
- the vinyl chloride polymer foams used in the process of the invention are fusible at a temperature of below 150 C.
- the temperature of fusion of the foam is within the range to C. and in the process foaming takes place at a corresponding temperature, the extent of the expansion being from 100 to 500 percent.
- plasticizer which gives low plastisol viscosity and slow ageing.
- suitable plasticizers include butylbenzylphthalate, dihexyl, diheptyl and dioctyl phthalate.
- the nitrogen-evolving blowing systems generally comprise a mixture of conventional blowing agents and a metallic salt acting as a modifying agent or kicker.
- Conventional blowing agents which are used in accordance with this invention are azodicarbonamide, p,p'-oxybisbenzenesulfonyl hydrazide, benzenesulphonhydrazide and toluene sulfonhydrazide, among others.
- the blowing agents are used as mixtures such as a mixture of azodicarbonamide with benzenesulphonhydrazide or toluene sulphonhydrazide or a mixture of p,p'-oxybisbenzenesulfonyl hydrazide with benzenesulphonhydrazide or toluene sulphonhydrazide.
- the most preferred blowing system comprises a mixture of azodicarbonamide and benzenesulphonhydrazide, the benzenesulphonhydrazide being in a proportion of between 5 and 50 percent by weight of the azodicarbonamide and preferably between 10 and 40 percent by weight of the azodicarbonamide.
- a particularly useful blowing system is that in which azodicarbonamide and benzenesulphonhydrazide are present in a proportion by weight of about 7 parts to 3 parts.
- the finest particle size of azodicarbonamide is employed and the particles have a high specific area.
- the surface area of the particles is preferably greater than 3.8 square meters per gram and the particle size is below 10 microns.
- the operating temperatures of the process of the invention is modified by the presence of the metallic salt in the blowing agent.
- metallic salts include cadmium, zinc, barium and lead. Mixtures of these salts can also be used and the particularly preferred mixtures are of cadmium and zinc salts or barium and zinc salts.
- the most preferred salts are lead salts, in particular lead oleates.
- the blowing system is preferably used in a ground paste form.
- the blowing system tends to decompose at room temperature and this difficulty is overcome if plasticizers such as epoxidized soya bean oil are incorporated into the blowing system.
- EXAMPLE 1 This example illustrates a process according to the invention for the production of a carpet containing acrylic fibers backed with a vinyl chloride copolymer foam.
- a foamable composition comprising a copolymer of vinyl acetate and vinyl chloride containing percent by weight of vinyl acetate, was first prepared by adding to 100 parts by weight of the copolymer a paste comprising 65 parts by weight of a plasticizer and 6 parts by weight of a nitrogen-evolving blowing system.
- the plasticizer used was butylbenzylphthalate and the blowing system was a mixture of 3 parts azodicarbonamide, 1 part benzene-sulphonhydraz'ide and 2 parts liquid lead kicker.
- the foamable composition was then fed into the hopper of a screw extruder and extruded through a slit die maintained at a temperature of 145 C. on to the back of a synthetic carpet containing acrylic fibers.
- EXAMPLE 2 This example illustrates a process according to the invention for the production of a carpet containing polypropylene fibers backed with a vinyl chloride copolymer foam.
- a foamable composition comprising a copolymer of vinyl acetate and vinyl chloride containing 3 percent by weight of vinyl acetate, was first prepared by adding to 100 parts by weight of the copolymer a paste comprising 65 parts by weight of a plasticizer and 6 parts by weight of a nitrogen-evolving blowing system.
- the plasticizer used was a mixture of 40 parts of butylbenzyl-phthalate and 25 parts of dioctylphthalate, and the blowing system comprises 2.5 parts of azodicarbonamide, 1.5 parts of benzenesulphonhydrazide and 2 parts of liquid lead kicker.
- the foamable composition was then fed into the hopper of a screw extruder and extruded through a slit die maintained at a temperature of 145 C. on to the back of a synthetic carpet containing polypropylene fibers.
- EXAMPLE 3 This example illustrates a process according to the invention for the production of a carpet backed with a vinyl chloride copolymer foam.
- Example 1 The foamable composition described in Example 1 was made into a paste. A layer of the composition 1 millimeter thick, representing a coating weight of 1,250 grams per square meter, was spread on to a synthetic carpet containing propylene fibers.
- the treated carpet was then heated in an air circulated oven at a temperature of 145 C. for a period of 12 minutes and a foam expansion of 350 percent was achieved.
- EXAMPLE 4 This example illustrates a process according to the invention for the production of a carpet backed with a vinyl chloride copolymer foam.
- Example 2 The foamable composition described in Example 2 was made into a paste. A layer of the composition 1 millimeter thick, representing a coating weight of 1,250 grams per square meter, was spread on to a synthetic carpet containing nylon fibers.
- the treated carpet was then heated in an air circulated oven at a temperature of C. for a period of 12 minutes and a foam expansion of 350 percent was obtained.
- a process for producing a textile article backed with vinyl chloride polymer foam fusible at a temperature below about C. which comprises applying to the textile article a foamable composition comprising a vinyl chloride polymer, a plasticizer and a nitrogenevolving blowing system active at a temperature below about 150 C. and heating the treated article.
- the vinyl chloride polymer is selected from the group consisting of polyvinyl-chloride and copolymers of vinyl chloride with vinylidene chloride, vinyl acetate, vinyl stearate, vinyl propionate, acetyl vinyl ether, tridecyl vinyl ether, ethylene and propylene.
- blowing system is composed of nitrogen-evolving blowin g agents.
- blowing system is selected from the group consisting of a mixture of azodicarbonamide with bcnzencsulphonhydrazide or toluencsulphonhydrazide or a mixture of p,p'-oxybisbenzenesulfonylhydrazide with benzenesulphonhydrazide or toluenesulphonhydrazide.
- plasticizer is selected from the group consisting of butylbenzylphthalate, dihexyl phthalate, diheptyl phthalate or dioctyl phthalate.
- a process for producing a textile article backed with vinyl chloride polymer foam fusible at a temperature below about C. which comprises forming a sheet of foamed vinyl chloride polymer from a foamable composition comprising a vinyl chloride polymer, a plasticizer and a nitrogen-evolving blowing system active at a temperature below about 150 C. and fusing said sheet to said article.
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- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- General Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
- Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
- Laminated Bodies (AREA)
Abstract
A process for adhering a foam backing to textile articles by applying a foamable composition of a vinyl chloride polymer, a plasticizer and a nitrogen-evolving blowing system which is active at a temperature below 150* C. to textile articles and thereafter applying heat to the treated article.
Description
United States Patent 1 1 11 1 3,717,526 Visnovsky et al. 1 1 Feb. 20, 1973 541 PRODUCTION OF TEXTILE ARTICLES 3,032,828 5/1962 1mmcl ul v.156 711 x 2,962,407 ll 1960 A k I 1 lflvcnlorsl Lflbomir Visnovskyr Waterloo; 3,239,365 3/1966 m i Pierre Slordeur, Melle, both of 2,703,775 3/1955 Panagrossi et al ..l56/78 Belgium [73] Assignee: Monsanto-Europe S.A., Brussels,
Belgium Primary Examiner-Stephen J. Lechert, Jr. Att0rney-Neal E. Willis, John E. Maurer and Robert [22] Filed: May 18, 1970 wexler [2i] Appl. No.: 38,505
[30] Foreign Application Priority Data [57] ABSTRACT May 19. 1969 Great Britain ..25368/69 A Process for adhfling a foam backing to textile articles by applying a foamable composition of a vinyl [52] US. Cl. ..l56/78, 156/244, 156/306 Chloride p y r, a p asticizer and a nitrogen-evolving [51] Int. Cl. ..B32b 5/18 blowing system which is active at a temperature below [58] Field of Search ..l5 6/78, 79, 242, 244, 306; 150 C. to textile articles and thereafter applying heat 161/160 to the treated article.
[56] References Cited 21 Claims, N0 Drawings UNITED STATES PATENTS 2,943,949 7/1960 Petty ..l56/78 PRODUCTION OF TEXTILE ARTICLES BACKGROUND OF THE INVENTION This invention relates to the production of textile articles backed with a foamed resin.
It has been found that conventional blowing systems used in the process of foaming of vinyl chloride polymers do not work satisfactorily at lower temperatures. This is a considerable disadvantage when it is wished to apply the foam to articles which are not resistant to elevated temperatures. For this reason a process for applying to an article a foam which is fusible at a relatively low temperature is especially useful.
SUMMARY OF THE INVENTION Accordingly the process of the invention is one for producing a textile article backed with vinyl chloride polymer foam fusible at a temperature of below 150 C., which comprises applying to the textile article a foamable composition comprising polyvinyl chloride or a copolymer of vinyl chloride and a minor proportion of comonomer, a plasticizer, and a nitrogen-evolving blowing system active at a temperature below 150 C., and heating the treated article to activate the blowing system.
The process is particularly useful for backing carpets, and also flooring material, which contain synthetic fibers sensitive to or damaged by high temperatures (such as 150 C. or above), such as for example, nylon, acrylic, olefin, e.g., polypropylene, polyester or viscose fibers. Carpets and other textile materials which can be backed by foamed vinyl chloride polymer according to the process of the invention need not, of course, consist wholly of synthetic fiber but can include other materials that in themselves are heat resistant. The vinyl chloride polymer foam gives good adhesion to synthetic fibers, and because the process is operated below 150 C. there is little tendency for the synthetic fibers to deteriorate as a result of being overheated.
DESCRIPTION OF THE PREFERRED EMBODIMENTS In the process for producing a textile article backed with a vinyl chloride polymer foam the foamable composition can be applied to the textile article in paste form by spreading on to synthetic woven or non-woven articles, the paste being subsequently foamed. Also a textile article can be backed with the polymer foam by fusing a sheet of the foamed polymer on to the back of the article.
The invention further provides a textile article backed with a foamed polyvinyl chloride or a foamed copolymer of vinyl chloride and a minor proportion of comonomer, the foamed polymer being fusible at a temperature below 150 C. Preferably the textile article is a carpet containing synthetic fibers sensitive to or damaged by high temperatures.
The vinyl chloride polymers which are most useful are polyvinyl chloride and copolymers of vinyl chloride and a minor proportion of comonomer which is generally from 2 to 14 percent by weight and preferably from 2 to percent by weight of the copolymer. Excellent results are obtained when the proportion of comonomer is from 2 to 5 percent by weight of the copolymer. Convenient vinyl chloride copolymers which are used in accordance with this invention include copolymers of vinyl chloride with such comonomers as vinylidene halides such as vinylidene chloride, vinyl ethers such as acetyl vinyl ether and tridecyl vinyl ether, olefins such as ethylene and propylene, vinyl esters such as vinyl acetate, vinyl stearate and vinyl propionate and the like. The copolymers should preferably be paste forming resins and they can also contain a third copolymerizable monomer.
The vinyl chloride polymer foams used in the process of the invention are fusible at a temperature of below 150 C. Usually the temperature of fusion of the foam is within the range to C. and in the process foaming takes place at a corresponding temperature, the extent of the expansion being from 100 to 500 percent.
It is preferred to use a solvating type of plasticizer which gives low plastisol viscosity and slow ageing. Examples of suitable plasticizers include butylbenzylphthalate, dihexyl, diheptyl and dioctyl phthalate.
The nitrogen-evolving blowing systems generally comprise a mixture of conventional blowing agents and a metallic salt acting as a modifying agent or kicker. Conventional blowing agents which are used in accordance with this invention are azodicarbonamide, p,p'-oxybisbenzenesulfonyl hydrazide, benzenesulphonhydrazide and toluene sulfonhydrazide, among others. The blowing agents are used as mixtures such as a mixture of azodicarbonamide with benzenesulphonhydrazide or toluene sulphonhydrazide or a mixture of p,p'-oxybisbenzenesulfonyl hydrazide with benzenesulphonhydrazide or toluene sulphonhydrazide. The most preferred blowing system comprises a mixture of azodicarbonamide and benzenesulphonhydrazide, the benzenesulphonhydrazide being in a proportion of between 5 and 50 percent by weight of the azodicarbonamide and preferably between 10 and 40 percent by weight of the azodicarbonamide.
A particularly useful blowing system is that in which azodicarbonamide and benzenesulphonhydrazide are present in a proportion by weight of about 7 parts to 3 parts.
The best results are obtained when the finest particle size of azodicarbonamide is employed and the particles have a high specific area. Thus the surface area of the particles is preferably greater than 3.8 square meters per gram and the particle size is below 10 microns.
The operating temperatures of the process of the invention is modified by the presence of the metallic salt in the blowing agent. Specific examples of metals whose salts are useful include cadmium, zinc, barium and lead. Mixtures of these salts can also be used and the particularly preferred mixtures are of cadmium and zinc salts or barium and zinc salts. However, the most preferred salts are lead salts, in particular lead oleates.
It is found that the blowing system is preferably used in a ground paste form. When ground with normal PVC plasticizers the blowing system tends to decompose at room temperature and this difficulty is overcome if plasticizers such as epoxidized soya bean oil are incorporated into the blowing system.
The invention is illustrated by the following examples:
EXAMPLE 1 This example illustrates a process according to the invention for the production of a carpet containing acrylic fibers backed with a vinyl chloride copolymer foam.
A foamable composition comprising a copolymer of vinyl acetate and vinyl chloride containing percent by weight of vinyl acetate, was first prepared by adding to 100 parts by weight of the copolymer a paste comprising 65 parts by weight of a plasticizer and 6 parts by weight of a nitrogen-evolving blowing system. The plasticizer used was butylbenzylphthalate and the blowing system was a mixture of 3 parts azodicarbonamide, 1 part benzene-sulphonhydraz'ide and 2 parts liquid lead kicker.
The foamable composition was then fed into the hopper of a screw extruder and extruded through a slit die maintained at a temperature of 145 C. on to the back of a synthetic carpet containing acrylic fibers.
On examination it was found that the foam had adhered to the carpet and there had been no deterioration of the acrylic fibers.
EXAMPLE 2 This example illustrates a process according to the invention for the production of a carpet containing polypropylene fibers backed with a vinyl chloride copolymer foam.
A foamable composition comprising a copolymer of vinyl acetate and vinyl chloride containing 3 percent by weight of vinyl acetate, was first prepared by adding to 100 parts by weight of the copolymer a paste comprising 65 parts by weight of a plasticizer and 6 parts by weight of a nitrogen-evolving blowing system. The plasticizer used was a mixture of 40 parts of butylbenzyl-phthalate and 25 parts of dioctylphthalate, and the blowing system comprises 2.5 parts of azodicarbonamide, 1.5 parts of benzenesulphonhydrazide and 2 parts of liquid lead kicker.
The foamable composition was then fed into the hopper of a screw extruder and extruded through a slit die maintained at a temperature of 145 C. on to the back of a synthetic carpet containing polypropylene fibers.
On examination it was found that the foam had adhered to the carpet and there had been no deterioration of the propylene fibers.
EXAMPLE 3 This example illustrates a process according to the invention for the production of a carpet backed with a vinyl chloride copolymer foam.
The foamable composition described in Example 1 was made into a paste. A layer of the composition 1 millimeter thick, representing a coating weight of 1,250 grams per square meter, was spread on to a synthetic carpet containing propylene fibers.
The treated carpet was then heated in an air circulated oven at a temperature of 145 C. for a period of 12 minutes and a foam expansion of 350 percent was achieved.
On examination it was found that the foam had adhered to the carpet and there had been no deterioration of the polypropylene fibers.
EXAMPLE 4 This example illustrates a process according to the invention for the production of a carpet backed with a vinyl chloride copolymer foam.
The foamable composition described in Example 2 was made into a paste. A layer of the composition 1 millimeter thick, representing a coating weight of 1,250 grams per square meter, was spread on to a synthetic carpet containing nylon fibers.
The treated carpet was then heated in an air circulated oven at a temperature of C. for a period of 12 minutes and a foam expansion of 350 percent was obtained.
On examination it was found that the foam had adhered to the carpet and there had been no deterioration of the nylon fibers.
While theinvention has been described hereinabove with regard to certain illustrative embodiments, it is not so limited since many modifications and variations are possible in the light of the above teachings. It is understood therefore that the invention may be practiced otherwise than as specifically described without departing from the spirit and scope of the invention.
We claim:
1. A process for producing a textile article backed with vinyl chloride polymer foam fusible at a temperature below about C. which comprises applying to the textile article a foamable composition comprising a vinyl chloride polymer, a plasticizer and a nitrogenevolving blowing system active at a temperature below about 150 C. and heating the treated article.
2. A process according to claim 1 in which the textile article is a carpet.
3. A process according to claim 1 in which the textile article is a flooring material.
4. A process according to claim 1 in which the textile article contains fibers sensitive to or damaged by temperatures above about 150 C.
5. A process according to claim 4 in which the article contains nylon, acrylic, olefin, polyester or viscose fibers.
6. A process according to claim 1 in which the foamable composition is applied to the article in paste form by spreading said composition on a woven or nonwoven article, the paste being subsequently foamed.
7. A process according to claim 1 in which the vinyl chloride polymer is selected from the group consisting of polyvinyl-chloride and copolymers of vinyl chloride with vinylidene chloride, vinyl acetate, vinyl stearate, vinyl propionate, acetyl vinyl ether, tridecyl vinyl ether, ethylene and propylene.
8. A process according to claim 7 in which said comonomer is present in a minor proportion based on the weight of the copolymer.
9. A process according to claim 8 in which said comonomer is present in an amount of from 2 to 10 percent based on the weight of the copolymer.
10. A process according to claim 8 in which said comonomer is present in an amount of from 2 to 5 percent based on the weight of the copolymer.
11. A process according to claim 1 in which said blowing system is composed of nitrogen-evolving blowin g agents.
12. A process according to claim I] in which said blowing system is selected from the group consisting of a mixture of azodicarbonamide with bcnzencsulphonhydrazide or toluencsulphonhydrazide or a mixture of p,p'-oxybisbenzenesulfonylhydrazide with benzenesulphonhydrazide or toluenesulphonhydrazide.
13 A process according to claim 12 in which said mixture contains from about to about 40 percent by weight of the mixture of azodicarbonamide.
14. A process according to claim 1 in which said copolymer is fusible at a temperature of from about 135 C. to 150C.
15. A process according to claim 1 in which said plasticizer is selected from the group consisting of butylbenzylphthalate, dihexyl phthalate, diheptyl phthalate or dioctyl phthalate.
16. A process according to claim 1 in which said composition contains a metallic salt or mixtures of metallic salts.
17. A process according to claim 16 in which said metallic salt is a lead salt.
18. A process according to claim 17 in which said lead salt is a lead oleate.
[9. A process for producing a textile article backed with vinyl chloride polymer foam fusible at a temperature below about C. which comprises forming a sheet of foamed vinyl chloride polymer from a foamable composition comprising a vinyl chloride polymer, a plasticizer and a nitrogen-evolving blowing system active at a temperature below about 150 C. and fusing said sheet to said article.
20. A process according to claim 19 in which said article is a carpet.
21. A process according to claim 19 in which said sheet is fused to said article by directly applying a foaming layer of the foamable composition to said article.
Claims (20)
1. A process for producing a textile article backed with vinyl chloride polymer foam fusible at a temperature below about 150* C. which comprises applying to the textile article a foamable composition comprising a vinyl chloride polymer, a plasticizer and a nitrogen-evolving blowing system active at a temperature below about 150* C. and heating the treated article.
2. A process according to claim 1 in which the textile article is a carpet.
3. A process according to claiM 1 in which the textile article is a flooring material.
4. A process according to claim 1 in which the textile article contains fibers sensitive to or damaged by temperatures above about 150* C.
5. A process according to claim 4 in which the article contains nylon, acrylic, olefin, polyester or viscose fibers.
6. A process according to claim 1 in which the foamable composition is applied to the article in paste form by spreading said composition on a woven or non-woven article, the paste being subsequently foamed.
7. A process according to claim 1 in which the vinyl chloride polymer is selected from the group consisting of polyvinyl-chloride and copolymers of vinyl chloride with vinylidene chloride, vinyl acetate, vinyl stearate, vinyl propionate, acetyl vinyl ether, tridecyl vinyl ether, ethylene and propylene.
8. A process according to claim 7 in which said comonomer is present in a minor proportion based on the weight of the copolymer.
9. A process according to claim 8 in which said comonomer is present in an amount of from 2 to 10 percent based on the weight of the copolymer.
10. A process according to claim 8 in which said comonomer is present in an amount of from 2 to 5 percent based on the weight of the copolymer.
11. A process according to claim 1 in which said blowing system is composed of nitrogen-evolving blowing agents.
12. A process according to claim 11 in which said blowing system is selected from the group consisting of a mixture of azodicarbonamide with benzenesulphonhydrazide or toluenesulphonhydrazide or a mixture of p,p''-oxybisbenzenesulfonylhydrazide with benzenesulphonhydrazide or toluenesulphonhydrazide.
13. A process according to claim 12 in which said mixture contains from about 10 to about 40 percent by weight of the mixture of azodicarbonamide.
14. A process according to claim 1 in which said copolymer is fusible at a temperature of from about 135* C. to 150* C.
15. A process according to claim 1 in which said plasticizer is selected from the group consisting of butylbenzylphthalate, dihexyl phthalate, diheptyl phthalate or dioctyl phthalate.
16. A process according to claim 1 in which said composition contains a metallic salt or mixtures of metallic salts.
17. A process according to claim 16 in which said metallic salt is a lead salt.
18. A process according to claim 17 in which said lead salt is a lead oleate.
19. A process for producing a textile article backed with vinyl chloride polymer foam fusible at a temperature below about 150* C. which comprises forming a sheet of foamed vinyl chloride polymer from a foamable composition comprising a vinyl chloride polymer, a plasticizer and a nitrogen-evolving blowing system active at a temperature below about 150* C. and fusing said sheet to said article.
20. A process according to claim 19 in which said article is a carpet.
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
GB25368/69A GB1249074A (en) | 1969-05-19 | 1969-05-19 | Production of foamed resins |
Publications (1)
Publication Number | Publication Date |
---|---|
US3717526A true US3717526A (en) | 1973-02-20 |
Family
ID=10226540
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US00038505A Expired - Lifetime US3717526A (en) | 1969-05-19 | 1970-05-18 | Production of textile articles |
Country Status (4)
Country | Link |
---|---|
US (1) | US3717526A (en) |
BE (1) | BE750363A (en) |
DE (1) | DE2023431B2 (en) |
GB (1) | GB1249074A (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4018962A (en) * | 1975-04-09 | 1977-04-19 | Pedlow J Watson | Arc and fireproofing tape |
Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2703775A (en) * | 1952-02-01 | 1955-03-08 | Connecticut Hard Rubber Co | Bonded silicone rubber products and method of making same |
US2943949A (en) * | 1957-10-23 | 1960-07-05 | Congoleum Nairn Inc | Decorative plastic surface covering and process therefor |
US2962407A (en) * | 1955-11-07 | 1960-11-29 | Monsanto Chemicals | Method for preparing laminated foam structures |
US3032828A (en) * | 1960-03-29 | 1962-05-08 | Us Rubber Co | Process of making fabric-foam laminates |
US3239365A (en) * | 1963-04-29 | 1966-03-08 | Congoleum Nairn Inc | Resilient decorative surface covering and method of making same |
-
1969
- 1969-05-19 GB GB25368/69A patent/GB1249074A/en not_active Expired
-
1970
- 1970-05-13 DE DE2023431A patent/DE2023431B2/de active Pending
- 1970-05-13 BE BE750363D patent/BE750363A/en unknown
- 1970-05-18 US US00038505A patent/US3717526A/en not_active Expired - Lifetime
Patent Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2703775A (en) * | 1952-02-01 | 1955-03-08 | Connecticut Hard Rubber Co | Bonded silicone rubber products and method of making same |
US2962407A (en) * | 1955-11-07 | 1960-11-29 | Monsanto Chemicals | Method for preparing laminated foam structures |
US2943949A (en) * | 1957-10-23 | 1960-07-05 | Congoleum Nairn Inc | Decorative plastic surface covering and process therefor |
US3032828A (en) * | 1960-03-29 | 1962-05-08 | Us Rubber Co | Process of making fabric-foam laminates |
US3239365A (en) * | 1963-04-29 | 1966-03-08 | Congoleum Nairn Inc | Resilient decorative surface covering and method of making same |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4018962A (en) * | 1975-04-09 | 1977-04-19 | Pedlow J Watson | Arc and fireproofing tape |
Also Published As
Publication number | Publication date |
---|---|
BE750363A (en) | 1970-11-13 |
GB1249074A (en) | 1971-10-06 |
DE2023431A1 (en) | 1971-02-11 |
DE2023431B2 (en) | 1973-10-18 |
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