MXPA99007984A

MXPA99007984A - Carpet, carpet backing and method for making same using homogeneously branched ethylene polymer

Info

Publication number: MXPA99007984A
Application number: MXPA/A/1999/007984A
Authority: MX
Inventors: O Bieser John; A Maugans Rexford; R Turley Robert; c kelley David; A Dibbern Joseph; F Diehl Charles; D Goins James; K Mckinney Osborne; R Peng Lichih
Original assignee: O Bieser John; A Dibbern Joseph; F Diehl Charles; D Goins James; Kelley David C; A Maugans Rexford; K Mckinney Osborne; R Peng Lichih; The Dow Chemical Company; R Turley Robert
Priority date: 1997-02-28
Filing date: 1999-08-27
Publication date: 2000-02-02

Abstract

The present invention pertains to carpet and methods of making carpet. In one aspect, the carpet includes (a) a primary backing which has a face and a back surface, (b) a plurality of fibers attached to the primary backing and extending from the face of the primary backing and exposed atthe back surface of the primary backing, (c) an adhesive backing, (d) an optional secondary backing adjacent to the adhesive backing, and (e) at least one homogeneously branched ethylene polymer. The method includes extrusion coating at least one homogeneously branched ethylene polymer onto the back surface of a primary backing to provide an adhesive backing. The method can include additional steps or procedures, either separately or in various combinations. Additional steps and procedures include washing or scouring the primary backing and fibers prior to the extrusion step, and utilizing implosion agents. The preferred homogeneously branched ethylene polymer is a substantially linear ethylene polymer. The constructions and methods described herein are particularly suited for making tufted, broad-loom carpet having improved abrasion resistance.

Description

CARPET, BASIC FIBER, AND METHOD TO MANUFACTURE THEM USING HOMOGENEOUSLY BRANCHED ETHYLENE POLYMER This invention relates to carpets and methods for making carpets, wherein, for each, the carpets comprise at least one flexible ethylene polymer backing material. In a particular case, the invention relates to a carpet and a method for manufacturing a carpet by an extrusion coating technique, wherein for each one, the carpet comprises a backing material comprised of at least one homogeneous ethylene polymer. branched mind. The present invention pertains to any carpet constructed with a primary backing material, and includes padded carpet and non-cushioned carpet, such as carpet pierced with needle. Although the specific modalities are susceptible to padded and non-cushioned carpeting, cushioned carpet is preferred. As illustrated in Figure 1, padded carpets are composite structures that include yarn (which is also referred to as a bundle of fibers), a primary backing material having a face surface and a back surface, an adhesive backing material , and optionally, a secondary backup material. To form the face surface of the cushioned carpet, it is cushioned the yarn through the primary backing material, such that the longest str of each stitch extends through the face surface of the primary backing material. Normally, the primary backing material is made from a spun or non-spun material, such as a thermoplastic polymer, more commonly polypropylene. The face of a cushioned carpet is usually done in three ways. First, for the loop pile carpet, loops of thread formed in the quilting process are left intact. Second, for the carpet of cut hairs, the loops of thread are cut, either during the cushioning or after, to produce a pile of ends of a single thread instead of loops. Third, some carpet styles include both cut and cut hairs. A variety of this hybrid is referred to as ripped-off carpet, where loops of different lengths are cushioned followed by the tearing of the carpet at a height such as to produce a mixture of uncut, partially cut, and completely cut loops. Alternatively, the quilting machine can be configured to cut only some of the loops, thus leaving a pattern of cut and uncut loops. Whether laced, cut, or a hybrid, the yarn on the back side of the primary backing material comprises tight non-stred loops. The combination of cushioned yarn and a material of primary backing without the application of an adhesive backing material or a secondary backing material, is referred to in the carpet industry as raw cushioned carpet or raw fabrics. Raw fabrics become finished cushion rugs when an adhesive backing material and an optional secondary backing material is applied to the back side of the primary backing material. The finished quilted carpet can be prepared as a wide spun carpet in rolls usually of 1.82 or 3.65 meters wide. In an alternative way, the carpet can be prepared as carpet mosaics, usually 45.72 centimeters per side in the United States, and 50 centimeters per side elsewhere. The adhesive backing material is applied to the back face of the primary backing material to secure the thread to the primary backing material. Typically, the adhesive backing material is applied by a tray applicator using a roller, a rolling roller or a bed, or a blade (also called a scalpel) on a roller or a bed. Adherently applied adhesive backing materials do not substantially pass through the primary backing material. More often, the adhesive backing material is applied as a single coating or layer. The degree or tenacity to which the thread is fixed is referred to as safe of cushioning or padding link strength. Carpets with sufficient cushion bond strength exhibit good wear resistance, and as such, have long service lives. Also, the adhesive backing material must substantially penetrate the yarn (bundle of fibers) exposed on the back side of the primary backing material, and must substantially consolidate the individual fibers within the yarn. A good penetration of the yarn and the consolidation of the fibers produce a good resistance to abrasion. Moreover, in addition to a good binding strength of the padding and abrasion resistance, the adhesive material must impart or allow a good flexibility to the carpet in order to facilitate the installation of the carpet. The secondary backing material is normally a lightweight canvas made of spun or non-spun material, such as a thermoplastic polymer, more commonly polypropylene. The secondary backing material is optionally applied to the back side of the carpet on the adhesive backing material, primarily to provide better dimensional stability to the carpet structure, as well as to provide more surface area for the application of adhesives that adhere directly . Alternative backing materials may also be applied to the back side of the adhesive backing material, and / or to the back side of the backing material secondary, if present. Alternative backing materials may include foam cushioning (e.g., foamed polyurethane), and pressure sensitive floor adhesives. Alternative backing materials may also be applied, for example, as a fabric with a better surface area, to facilitate installations with adhesive that adheres directly (for example, in commercial contract carpets, automobile carpets, and airplanes carpets, where the need for sponsorship is often minimal). Optional backup materials may also be optionally applied to improve barrier protection with respect to moisture, insects, and food materials, as well as to provide or improve fire suppression, thermal insulation, and sound-deadening properties of the carpet. Known adhesive backing materials include curable latex, urethane or vinyl systems, latex systems being more common. Conventional latex systems are low viscosity aqueous compositions that are applied at high carpet production speeds, and offer good adhesion of the fiber to the backing, cushion bond strength, and adequate flexibility. In general, an excess of water is removed, and the latex is cured by passing it through a drying oven. Styrene-butadiene rubbers (SBR) are the most common polymers used to latex adhesive backing materials. Typically, the latex backing system is heavily filled with an inorganic filler, such as calcium carbonate or aluminum trihydrate, and includes other ingredients such as antioxidants, antimicrobials, fire retardants, smoke suppressants, wetting agents, and Foaming auxiliaries. Conventional latex adhesive backing systems may have certain drawbacks. As a major drawback, typical latex adhesive backing systems do not provide a moisture barrier. Another possible drawback, particularly with a carpet having polypropylene yarn and primary and secondary polypropylene backing materials, is the polymer distinct from the latex systems together with the inorganic filler, which can reduce the recyclability of the carpet. In view of these drawbacks, some in the carpet industry have begun looking for adequate replacements for conventional latex adhesive backing systems. An alternative is the use of urethane adhesive backing systems. In addition to providing adequate adhesion to consolidate the carpet, urethane backings generally exhibit good flexibility and barrier properties, and when foamed, can eliminate the need for separate underlying cushioning (i.e., they can constitute a unitary backup system). That adhere directly). However, urethane backing systems also have significant drawbacks, including their relatively high cost, and the demanding curing requirements that they need from the application at slow speeds of carpet production in relation to latex systems. Thermoplastic polyolefins, such as ethylene-vinyl acetate (EVA) copolymers, and low density polyethylene (LDPE), have also been suggested as adhesive backing materials, due in part to their low cost, good stability in humidity, since they do not have curing requirements. There are different methods available for applying polyolefin backing materials, including powder coating, hot melt application, and film lamination or extruded sheet. However, the use of polyolefins to replace latex adhesive backings can also present difficulties. For example, U.S. Patent Number r, 240, 530, Table A, in column 10, indicates that ordinary polyolefin resins possess inadequate adhesion for use in carpet construction. Additionally, in relation to latex and other cured systems, ordinary polyolefins have relatively high application viscosities, and relatively high thermal requirements. That is, ordinary thermoplastic polyolefins are characterized by relatively high melt viscosities, and high recrystallization or solidification temperatures in relation to the viscosities to typical things and the curing temperature requirements characteristic of latex and other cured systems (thermosetting). Even ordinary elastomeric polyolefins, ie, polyolefins having low crystallinity, generally have relatively high viscosities and relatively high recrystallization temperatures. The high recrystallization temperatures result in relatively short melting times during processing, and, combined with high melt viscosities, can make it difficult to achieve adequate penetration of the yarn, especially at conventional adhesive backing application rates. One method to overcome the viscosity and recrystallization deficiencies of ordinary polyolefins is to formulate the polyolefin resin as a hot melt adhesive which usually involves formulating low molecular weight polyolefins with waxes, viscosifiers, different flow modifiers, and / or other elastomeric materials. For example, ethylene / vinyl acetate (EVA) copolymers have been used in formulated hot melt adhesive backing compositions, and other polyolefin compositions have also been proposed as hot melt backing compositions. For example, in the Patent of the United States of North America No. 3,982,051, Taft et al. Disclose that a composition comprising an ethylene / vinyl acetate copolymer, atactic polypropylene, and vulcanized rubber, is useful as a hot melt carpet backing adhesive. Unfortunately, it is generally considered that hot melt adhesive systems are not completely adequate replacements for conventional latex adhesive backings. Typical hot melt systems based on ethylene-vinyl acetate and other ethylene copolymers and unsaturated comonomers may require considerable formulation, and yet often produce inadequate binding bond strengths. However, the most significant deficiency of the typical hot melt system is its resistance to melting, which is generally too low to allow application by a direct extrusion coating technique. As such, polyolefin hot melt systems are normally applied to the primary backings by relatively slow, less efficient techniques, such as by the use of heated scalpels or rotating fusion transfer rolls. Although low-density polyethylene and high pressure non-formulated (LDPE) can be applied by a conventional extrusion coating technique, low density polyethylene resins usually have a poor flexibility, which can result in excessive stiffness of the carpet. Conversely, ordinary polyolefins that have better flexibility, such as ultra-low density polyethylene (ULDPE), and ethylene / -propylene interpolymers, still do not possess sufficient flexibility, have excessively low melt strengths, and / or They tend to resonate during extrusion coating. To overcome the difficulties of extrusion coating, ordinary polyolefins can be applied with sufficient flexibility by laminating techniques to ensure adhesion of the yarn to the proper backing; however, rolling techniques are usually expensive, and can result in extended production speeds relative to direct extrusion coating techniques. Known examples of flexible polyolefin backing materials are disclosed in U.S. Patent Nos. 3,390,035; 3,583,936; 3,745,054; and 3,914,489. In general, these disclosures describe hot melt adhesive backing compositions based on an ethylene copolymer, such as ethylene- / vinyl acetate (EVA), and waxes. Known techniques for improving the penetration of hot melt adhesive backing compositions through the yarn include the application of pressure while the raw fabric is in contact with rotating melt transfer rolls, as described, for example, in U.S. Patent Number 3,551,231. Another technique known to improve the effectiveness of hot melt systems involves the use of precoating systems. For example, Patents of the United States of North America Nos. 3,684,600; 3,583,936; and 3,745,054, describe the application of low viscosity aqueous precoat coatings to the backing surface of primary backing material, prior to the application of a hot melt adhesive composition. The hot melt adhesive backing systems disclosed in these patents are derived from multi-component formulations based on functional ethylene polymers, such as, for example, ethylene / ethyl acrylate (EEA) copolymers, and copolymers of ethylene / vinyl acetate (EVA). Although there are different systems known in the low-carpet art, there remains a need for a thermoplastic polyolefin underlayer system that provides adequate padding bond strength, good abrasion resistance, and good flexibility to replace backing systems. cured latex. There remains also a need for an application method that allows for high carpet production speeds, while achieving the desired characteristics of good quilting bond strength, abrasion resistance, barrier properties, and flexibility.

Finally, there is also a need to provide a carpet structure having fibers and backing materials that can be easily recycled without the need for extensive handling and segregation of the carpet component materials. In accordance with one aspect of the present invention, a carpet comprises a plurality of fibers, a primary backing material having a face and a back side, an adhesive backing material, and an optional secondary backing material, the plurality of fibers bonded to the primary backing material, and protruding from the face of the primary backing material, and being exposed on the back side of the primary backing material, the adhesive backing material being disposed on the back side of the primary backing material and the backing material. optional secondary backing adjacent to the adhesive backing material, wherein at least one of the plurality of fibers, the primary backing material, the adhesive backing material, or the optional secondary backing material, is comprised of at least one ethylene polymer homogeneously branched, characterized by having a chain branching distribution index a short (SCBDI) greater than, or equal to, 50 percent. Another aspect of the present invention is a method for making a carpet, the carpet including a plurality of fiber, a primary backing material having a face, a back side, an adhesive backing material, and an optional secondary backing material, the plurality of fibers being attached to the primary backing material, and protruding from the face of the primary backing material, and being exposed on the back side of the primary backing material, the method comprising the step of extrusion coating the adhesive backing material or the optional secondary backing material on the back side of the primary backing material, wherein the extrusion-coated adhesive backing material or the optional secondary backing material is comprised of at least one homogeneously branched ethylene polymer, characterized by having a short chain branching distribution index (SCBDI) greater than, or equal to, 50 percent. Another aspect of the present invention is a method for manufacturing a carpet, the carpet having a matrix of collapsed, unexpanded adhesive backing material, and comprising yarn attached to a primary backing material, the adhesive backing material comprising at least one ethylene polymer, and being in intimate contact with the primary backing material, and having substantially penetrated and substantially consolidated the yarn, the method comprising the step of adding an effective amount of at least one implosing agent to the adhesive backing material, Y then activating the implosion agent during an extrusion coating step, such that the molten or semi-molten polymer is forced into the free space of the exposed wire on the back side of the primary backing material. Another aspect of the present invention is a method for making a carpet, the carpet having a face surface, and comprising yarn, a primary backing material, an adhesive backing material, and an optional secondary backing material, wherein the Primary backing material has a rear surface opposite the face surface of the carpet, the thread is attached to the primary backing material, the adhesive backing material is applied to the back surface of the primary backing material, and the backing material optional secondary is applied on the adhesive backing material, the method comprising the step of scrubbing, washing, or grinding the back surface of the primary backing material with steam, solvent, and / or heat, prior to application of the adhesive backing material , to remove or substantially displace the processing materials. Figure 1 is an illustration of a cushioned carpet 10. Figure 2 is a schematic representation of an extrusion coating line 20 for manufacturing a carpet 70. Figure 3 consists of scanning electron microscope photomicrographs at a 20x amplification (3a) and a 50x amplification (3b), illustrating the interfaces of the different components of the carpet of Example 14. Figure 4 is to explore Electron microscope photomicrographs at a 20x magnification (4a) and a 50x magnification (4b), illustrating the interfaces of the different components of the carpet of Example 22. Figure 5 is an XY graph of the effect of penetration on the beam of fibers by the adhesive backing material on the performance of abrasion resistance of polypropylene and nylon carpet samples. Figure 6 is a cross section showing the construction of a carpet mosaic in accordance with the present invention. Figure 7 is a schematic representation of an extrusion coating line for making carpet mosaics in accordance with the present invention. The terms "intimate contact", "substantial encapsulation", and / or "substantial consolidation" are used herein to refer to the mechanical or mechanical adhesion interactions (as opposed to the chemical bond) between the different components of the carpet, without matter if one or more carpet components is or is not able to interact chemically with another component of the carpet. With respect to the mechanical adhesion or the interactions of the present invention, there may be some effective amount of intermixing or interfusion of the polymeric materials; however there is no continuous or integral fusion of different components, as determined from the visual inspection of the photomicrographs (at a 20x amplification) of the different carpet interfaces. Within this meaning, the melting of the yarn or fiber bundles or individual fibers into one another within a bundle of fibers is not considered an integral melting by itself, because the fibers are referred to herein. as a component of the carpet. The term "intimate contact" refers to the mechanical interaction between the back surface of the primary backing material, and the adhesive backing material. The term "substantial encapsulation" refers to the adhesive backing material that significantly surrounds the yarn or fiber bundles in the immediate vicinity of the interface between the back surface of the primary backing material and the adhesive backing material. The term "substantial consolidation" refers to the overall integrity and dimensional stability of the carpet, which is achieved through substantial encapsulation of the yarn or fiber bundles, and intimate contact of the back surface of the primary backing material with the backup material adhesive. A substantially consolidated carpet possesses good cohesiveness of components and good resistance to delamination with respect to the different components of the carpet. The term "integral melt" is used herein in the same sense as is known in the art, and refers to the heat bonding of carpet components using a temperature greater than the melting point of the adhesive backing material. Integral fusion occurs when the adhesive backing material comprises the same polymer as the fibers or the primary backing material, or both. However, integral melting does not occur when the adhesive backing material comprises a polymer other than the fibers and the primary backing material. The term "same polymer" means that the monomer units of the polymers are of the same chemistry, although their molecular or morphological attributes may be different. Conversely, the term "different polymer" means that, regardless of any molecular or morphological differences, the monomer units of the polymers are of different chemistries. Accordingly, in accordance with the different definitions of the present invention, a polypropylene primary backing material and a polyethylene adhesive backing material would not be integrally fused, because these carpet components are of different chemistries. The term "carpet component" is used in the present to refer separately to the fiber bundles of the carpet, the primary backing material, the adhesive backing material, and the optional secondary backing material. The term "extrusion coating" is used herein in its conventional sense to refer to an extrusion technique, wherein normally a polymer composition in the form of granules is heated in an extruder at an elevated temperature higher than its melting temperature, and then it is forced through a slot die to form a semi-molten or melted polymeric fabric. The semi-molten or melted polymeric fabric is continuously stretched lowering over raw fabrics continuously fed to coat the back side of the raw fabric with the polymer composition. Figure 12 illustrates an extrusion process of the present invention where, on tightening, the face surface of the raw fabric is oriented towards the ice roller, and the back surface of the adhesive backing material oriented is towards the pressure roller of squeeze in. Extrusion coating is different from a lamination technique. The term "laminating technique" is used herein in its conventional sense to refer to the application of adhesive backing materials to raw fabrics, first forming the adhesive backing material as a solidified or substantially solidified film or sheet, and then, in a separate processing step, reheat or raise the temperature of the film or sheet, before applying it to the back surface of primary backing material. The term "heat content" is used herein to refer to the mathematical product of the heat capacity and specific gravity of a filler. Fillers characterized by having a high heat content are used in the specific embodiments of the present invention to prolong the solidification or melting time of the adhesive backing materials. The Handbook for Chemical Technicians, Hoard J. Strauss and Milton Kaufmann, McGraw Hill Book Company, 1976, sections 1-4 and 2-1, provides information on the heat capacity and specific gravity of selected mineral fillers. The fillers suitable for use in the present invention do not change their physical condition (ie, they remain a solid material) over the temperature scales of the extrusion coating process of the present invention. The preferred high heat content fillers possess a combination of a high specific gravity and a high heat capacity. The term "implosion agent" is used herein to refer to the use of conventional blowing agents, or other compounds that produce gas, or that cause gasification when activated by heat, usually to some particular activation temperature. In the present invention, implosion agents are used to implode or force the adhesive backing material into the free space of the yarn or fiber bundles. The term "processing material" is used herein to refer to substances such as centrifugal finishing waxes, equipment oils, sizing agents, and the like, which may interfere with the adhesive or with the physical interfacial interactions of the materials of adhesive backing. The processing materials can be removed or displaced by a scrubbing or washing technique of the present invention, wherein an improved mechanical bond is realized. The terms "polypropylene carpet" and "crude polypropylene fabrics" are used herein to mean a carpet or raw fabrics substantially comprised of polypropylene fibers, regardless of whether the primary backing material for the carpet or the raw fabric is comprised of polypropylene or some other material. The terms "nylon carpet" and "nylon raw fabrics" are used herein to mean a carpet or raw fabrics substantially comprised of nylon fibers, regardless of whether the primary backing material for the carpet or raw fabric is comprised of nylon or some other material The term "linear", as used to describe ethylene polymers, is used herein to mean that the polymeric base structure of the ethylene polymer lacks measurable or demonstrable long chain branches, for example, the polymer is substituted with an average of less than 0.01 long chain branches / 1000 carbon atoms. The term "homogeneous ethylene polymer", as used to describe ethylene polymers, is used in the conventional sense in accordance with the original disclosure of Elston in U.S. Patent Number 3,645,992, to refer to a polymer of ethylene wherein the comonomer is randomly distributed within a given polymer molecule, and wherein substantially all of the polymer molecules have substantially the same molar ratio of ethylene to the comonomer. As defined herein, both substantially linear ethylene polymers and homogenously branched linear ethylene polymers are homogeneous ethylene polymers. Homogeneously branched ethylene polymers are homogeneous ethylene polymers having short chain branches, and which are characterized by a relatively short chain branching distribution index (SCBDI). high, or a relatively high composition distribution (CDBI) branching index. That is, the ethylene polymer has a SCBDI or CDBI greater than, or equal to, 50 percent, preferably greater than, or equal to, 70 percent, more preferably greater than, or equal to, 90 percent. cent, and essentially lack a measurable (crystalline) high-density polymer fraction. The SCBDI or the CDBI is defined as the weight percentage of the polymer molecules having a comonomer content within 50 percent of the average total molar comonomer content, and represents a comparison of the comonomer distribution in the polymer with the distribution of the expected comonomer for a Bernoullian distribution. The SCBDI or the CDBI of the polyolefins can be conveniently calculated from the data obtained from the techniques known in the art, such as, for example, fractionation by elution with elevation of temperature (abbreviated herein as "TREF"). ) as described, for example in Wild et al., Journal of Polymer Science, Polv. Phvs. Ed., Volume 20, page 441 (1982), L.D. Cady, "The Role of Comonomer Type and Distribution in LLDPE Product Performance," SPE Regional Technical Conference, Quaker Square Hilton, Akron, Ohio, October 1-2, pages 107-119 (1985), or in the United States Patent United States of America Number 4,798,081 and 5,008,204. However, the preferred TREF technique does not include purge quantities in the calculations of the SCBDI or the CDBI. More preferably, the distribution of the comonomer in the polymer, and the SCBDI or CDBI are determined using nuclear magnetic resonance C analysis, according to the techniques described, for example, in U.S. Patent No. 5,292,845 , and by JC Randall in Rev. Macromol. Chem. Phys., C29, pages 201-317. The terms "homogenously branched linear ethylene polymer" and "homogenously branched linear ethylene / α-olefin polymer" mean that the olefin polymer has a homogeneous or narrow short branch distribution (i.e., the polymer has a SCBDI or CDBI). relatively high), but has no long chain branching. That is, the linear ethylene polymer is a homogeneous ethylene polymer characterized by an absence of long chain branching. These polymers can be made using polymerization processes (e.g., as described by Elston in U.S. Patent No. 3,645,992), which provide a uniform short (ie, homogeneously branched) branching branch distribution. In this polymerization process, Elston uses soluble vanadium catalyst systems to make these polymers; however, others, such as Mitsui Petro-chemical Industries and Exxon Chemical Company, have reportedly used so-called catalysed systems. of a single site to make polymers that have a homogeneous structure similar to the polymer described by Elston. U.S. Patent No. 4,937,299 to Ewen et al. And U.S. Patent No. 5,218,071 to Tsutsui et al. Disclose the use of metallocene catalysts, such as hafnium-based catalyst systems, for the preparation of homogenously branched linear ethylene polymers. Homogeneously branched linear ethylene polymers are typically characterized by having a molecular weight distribution, Mw / Mn, less than 3, preferably less than 2.8, more preferably less than 2.3. Commercial examples of suitable homogeneously branched linear ethylene polymers include those sold by Mitsui Petrochemical Industries as Tafmer resins, and by Exxon Chemical Company as Exact resins, and Exceed resins. The terms "homogenous linearly branched ethylene polymer", or "homogenously branched linear ethylene / c-olefin polymer" does not refer to high pressure branched polyethylene which is known to those skilled in the art to have numerous long chain branches. The term "homogeneous linear ethylene polymer" generally refers to both linear ethylene homopolymers and linear ethylene / c-olefin interpolymers. A linear ethylene / α-olefin interpolymer has a branching short chain, and the α-olefin is usually a c-olefin of at least 3 to 20 carbon atoms (e.g., propylene, 1-butene, 1-pentene, 4-methyl-1-pentene, 1-hexene, and 1-octene). When used with reference to an ethylene homopolymer (ie, a high density ethylene polymer that does not contain comonomer, and therefore, does not have short chain branches), the term "homogeneous ethylene polymer" or "polymer" linear homogeneous ethylene "means that the polymer was made using a homogeneous catalyst system, such as, for example, that described by Elston or Ewen, or those described by Canich in US Pat. Nos. 5,026,798 and 5,055,438, or by Stevens et al., in U.S. Patent Number 5,064,802. The term "substantially linear ethylene polymer" is used herein to refer especially to homogeneously branched ethylene polymers having long chain branching. The term does not refer to heterogeneously or homogeneously branched ethylene polymers having a linear polymer base structure. For substantially linear ethylene polymers, the long chain branches have the same comonomer distribution as the base structure of the polymer, and the long chain branches can be as long as about the same length as the length of the structure base of the polymer to which they are attached. The polymeric base structure of the substantially linear ethylene polymers is substituted with about 0.01 long chain branches / 1000 carbon atoms to about 3 long chain branches / 1000 carbon atoms, more preferably about 0.01 long chain branches / 1000 atoms carbon to about 1 long chain branch / 1000 carbon atoms, and especially about 0.05 long chain branches / 1000 carbon atoms to about 1 long chain branches / 1000 carbon atoms. The long chain branching is defined herein as a chain length of at least 6 carbon atoms, above which the length can not be distinguished using nuclear magnetic resonance ° C spectroscopy. The presence of long chain branching can be determined in ethylene homopolymers by the use of nuclear magnetic resonance (NMR) C spectroscopy, and quantified using the method described by Randall (Rev. Macromol. Chem. Phvs., C29, volumes 2 and 3 pages 285-297). Although current 13C nuclear magnetic resonance spectroscopy can not determine the length of a long chain branch greater than 6 carbon atoms, there are other known techniques useful for determining the presence of long chain branches in polymers of ethylene, including the ethylene / l-octene interpolymers. Two of these methods are gel permeation chromatography coupled with a low angle laser light scattering detector (GPC-LALLS), and gel permeation chromatography coupled with a differential viscometer detector (GPC-DV). The use of these techniques for the detection of long-chain branching and the underlying theories have been well documented in the literature. See, for example Zimm, G.H. and Stockmayer, W.H., J. Chem. Phys., 17, 1301 (1949) and Rudin, A., Modern Methods of Polvmer Characterization, John Wiley & Sons, New York (1991), pages 103-112. A. Willem deGroot and P. Steve Chum, both of The Dow Chemical Company, at the October 4, 1994 conference of the Federation of Analytical Chemistry and Spectroscopy Society (FACSS) in St. Louis, Missouri, presented data demonstrating that the GPC-DV is a useful technique for quantifying the presence of long chain branches in substantially linear ethylene polymers. In particular, deGroot and Chum found that the level of long-chain branches in the substantially linear ethylene homopolymer samples measured using the Zimm-Stockmayer equation correlates well with the level of long-chain branches measured using 13C nuclear magnetic resonance. . In addition, deGroot and Chum found that the presence of octene does not change the hydrodynamic volume of the samples of polyethylene in solution, and as such, the increase in molecular weight attributable to the short chain branches of octene can be taken into account, knowing the mole percentage of octene in the sample. By deconvolution of the contribution to the molecular weight increase attributable to the short chain branches of 1-octene, deGroot and Chum showed that GPC-DV can be used to quantify the level of long chain branches in ethylene / copolymers. substantially linear octene. DeGroot and Chum also showed that a graph of Log (^ 2 'melt index) as a function of Log (Average Molecular Weight in Weight by Gel Permeation Chromatography), determined by GPC-DV, illustrates that aspects of long chain branching (but not extension of branching) long) of substantially linear ethylene polymers, are comparable to those of highly branched, high-pressure polyethylene (LDPE), and are clearly distinct from ethylene polymers produced using Ziegler-type catalysts, such as titanium complexes , and ordinary homogeneous catalysts, such as hafnium and vanadium complexes. For substantially linear ethylene polymers, the long chain branching is longer than the short chain branching resulting from the incorporation of the alpha-olefins into the polymer backbone. He Empirical effect of the presence of long chain branching in the substantially linear ethylene polymers used in the invention manifests itself as better rheological properties, which are quantified and are expressed herein in terms of gas extrusion rheometry results ( GER) and / or melt flow increments, ^ - IQ / ^ -2 'Substantially linear ethylene polymers are homogeneously branched ethylene polymers, and are disclosed in U.S. Patent No. 5,272,236 and in US Pat. U.S. Patent Number 5,278,272. The polymers of. substantially homogeneous, homogeneously branched ethylene are available from The Dow Chemical Company as AFFINITY polyolefin piastores, and from Dupont Dow Elastomers JV as polyolefin elastomers ENGAGE. Homogeneously branched substantially linear ethylene polymers can be prepared by solution, paste, or gas phase polymerization of ethylene and one or more optional alpha-olefin comonomers, in the presence of a catalyst of limited geometry, such as the method disclosed in European Patent Application Number 416,815-A. Preferably, a solution polymerization process is used to make the substantially linear ethylene polymer used in the present invention. The terms "heterogeneous" and "heterogeneously "branched" means that the ethylene polymer is characterized as a mixture of interpolymer molecules having different molar proportions of ethylene to the comonomer.The heterogeneously branched ethylene polymers are characterized by having a lower short chain branching distribution index (SCBDI). about 30 percent linearly heterogeneously branched ethylene polymers are available from The Dow Chemical Company as DOWLEX linear low density polyethylene, and as ultra-low density polyethylene resins ATTANE.The heterogeneously branched linear ethylene polymers can be prepared by the solution, paste, or phase polymerization of ethylene gas and one or more optional alpha-olefin comonomers, in the presence of a Ziegler-Natta catalyst, by processes such as are disclosed in the US Pat. the United States of America Number 4,076,698 to Anderson and The heterogeneously branched ethylene polymers are typically characterized by having molecular weight distributions, Mw / Mn, on the scale of 3.5 to 4.1, and as such, they are distinct from substantially linear ethylene polymers and linear ethylene polymers. homogeneously branched with respect to both the short chain branching distribution of the composition, and the molecular weight distribution. The substantially linear ethylene polymers used in the present invention are not in the same class as homogeneously branched linear ethylene polymers, nor linear heterogeneously branched ethylene polymers, nor are substantially linear ethylene polymers of the same kind as traditional highly branched low density polyethylene ( LDPE). The substantially linear ethylene polymers useful in this invention surprisingly have excellent processability, even when they have relatively narrow molecular weight distributions (MWD). Even more surprisingly, the melt flow rate (I- ^ Q / ^) of the substantially linear ethylene polymers can be varied in a manner essentially independent of the polydispersity index (ie, the molecular weight distribution). (Mw / Mn)). This contrasts with conventional heterogeneously branched linear polyethylene resins which have rheological properties such that as the polydispersity index increases, the I-value / l2 value also increases. The rheological properties of the ethylene polymers substantially linear also differ from homogenously branched linear ethylene polymers having relatively low, essentially fixed proportions I- | _Q / I2. We have discovered that substantially linear ethylene polymers and homogeneously branched linear ethylene polymers (ie, ethylene polymers) homogenously branched) offer unique advantages for extrusion coated underfloor applications, especially for the commercial and residential carpet markets. 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). As such, homogenously branched ethylene polymers are useful for making carpet fibers, primary backing materials, adhesive backing materials, and optional secondary backing materials. However, homogeneously branched ethylene polymers are particularly useful as adhesive backing materials for cushioned carpets and non-cushioned carpets (eg, needle-punched carpets), and are especially useful for cushioned carpets. In the present invention, during the extrusion coating of the back side of the carpet to apply an adhesive backing material, the appropriately selected substantially linear ethylene polymers, and the homogeneously branched linear ethylene polymers, it shows a good penetration of the carpet yarns (bundles of fibers), and also allows a good consolidation of the fibers inside the yarn. When used for cushioned carpets, the binding strength of the padding and the abrasion resistance of the carpet are increased by the penetration of the substantially linear ethylene polymers and linearly branched ethylene polymers homogeneously branched into the yarn. Preferably, a quilting bond strength (or quilting lock) of 3.25 pounds (1.5 kilograms) or more, more preferably 5 pounds, is achieved (2.3 kilograms) or more, and most preferably 7.5 pounds (3.4 kilograms) or more. In addition to improved wire penetration, the binding strength of the padding can also be increased by increasing the molecular weight of the polymer. However, a higher polymer molecular weight selected for a better binding strength of quilting is contrary to the requirement of a lower molecular weight of the polymer which is generally needed for good penetration of the yarn and a good possibility of extrusion coating. -Zion. As well, higher polymer densities are desirable for better chemical and barrier resistance, and nevertheless, higher densities invariably produce more rigid carpets. As such, the properties of the polymer should be selected in such a way as to maintain a balance between the possibility of extrusion coating and the resistance to abrasion, as well as between the chemical resistance and the flexibility of the carpet. When carpet raw fabrics are backed with appropriately selected substantially linear ethylene polymers, or homogeneously branched linear ethylene polymers, the low flexural modulus of these polymers offers advantages in ease of carpet installation and overall carpet handling. The substantially linear ethylene polymers, in particular, when used as an adhesive backing material, show better mechanical adhesion to polypropylene, which improves the consolidation and delamination resistance of the different layers and components of the carpet, i.e. , polypropylene fibers, fiber bundles, the primary backing material, the adhesive backing material, and the secondary backing material, when optionally applied. As a result, exceptionally good abrasion resistance and binding strength can be obtained. Good abrasion resistance is especially important in commercial carpet cleaning operations, since a good resistance to abrasion generally improves the durability of the carpet. Appropriately selected substantially linear ethylene polymers can allow the removal of secondary backing materials, and as such, can give As a result, significant savings in manufacturing costs. In addition, carpets adhesively backed with a substantially linear ethylene polymer or homogeneously branched linear ethylene polymer can provide a substantial barrier to fluids and particles, which improves the hygienic properties of the carpet. An adhesive backing material of substantially linear ethylene polymer or homogeneously branched linear ethylene polymer may allow to have fully recyclable carpet products, particularly when the carpet comprises polypropylene fibers. In addition, the mixture of a substantially linear ethylene polymer or homogeneously branched linear ethylene polymer with a fiber grade polypropylene resin, can result in a modified impact recycle composition, which is useful for injection molding. and other molding applications, as well as for reuse in carpet construction, for example, as the primary backing material, or as a blending component of the polymeric composition of adhesive backing material. That is, the polyolefin polymer blends can involve sufficiently similar chemistries, compatibilities, and / or polymer miscibilities to allow a good recyclability, without having sufficient similarities to allow an integral melting.

The preferred homogenously branched ethylene polymer has a single melting peak of between -30 ° C and 150 ° C, determined using differential scanning calorimetry. The most preferred homogenously branched ethylene polymer for use in the invention is a substantially linear ethylene polymer characterized by having: (a) a melt flow ratio, I o / I2 - 5.63, (b) a molecular weight distribution , Mw / Mn, determined by gel permeation chromatography, and defined by the equation: (Mw / Mn) < (I10 / I2) - 4.63, (c) a gas extrusion rheology such that the critical tear rate at the setting of the surface melt fracture for the substantially linear ethylene polymer is at least 50 percent greater than the index of critical tearing to the setting of the 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 ethylene polymer substantially linear and the linear ethylene polymer are simultaneously homopolymers of ethylene or interpolymers of ethylene and at least one alpha-olefin of 3 to 20 carbon atoms, and have the same I2 and ^ / ^ n 'and wherein the indices of the respective critical tear of the substantially linear ethylene polymer and the linear ethylene polymer are measured at the same melting temperature using a gas extrusion rheometer. (d) a single differential scanning calorimetry fusion peak, DSC, between -30 ° C and 150 ° C. The determination of the critical tear index with respect to the melt fracture, as well as other rheological properties, such as the "rheological processing index" (Pl), is performed using a gas extrusion rheometer (GER). The gas extrusion rheometer is described by M. Shida, R.N. Shroff and L.V. Cancio in Polymer Engineerincr Science, volume 17, number 11, page 770 (1977), and in "Rheometers for Molten Plastics" by John Dealy, published by Van Nostrand Reinhold Col. (1982) on pages 97-99. The gas extrusion rheometer experiments are performed at a temperature of 190 ° C, at nitrogen pressures of between about 250 and about 5,500 psig (between about 1.7 and about 37.4 MPa), using a die of 0.0754 millimeters in diameter, 20: 1 L / D, with an entry angle of approximately 180 °. For the substantially linear ethylene polymers used herein, the rheological processing index is the apparent viscosity (in kpoise) of a material measured by a gas extrusion rheometer, at an apparent tear tension of 2.15 x 10 dies. nas / square centimeter (2.19 x 10 kg / m2). The substantially linear ethylene polymer for use in the invention has a rheological processing index in the range of 0.01 kpoise to 50 kpoise, preferably 15 kpoise or less. The substantially linear ethylene polymers used herein, also have a rheological processing index less than, or equal to, 70 percent of the rheological processing index of a linear ethylene polymer (either a polymer polymerized with Ziegler, or a homogenously branched linear polymer, as described by Elston in U.S. Patent Number 3,645,992), having an I2 and Mw / Mn, each within 10 percent of the substantially linear ethylene polymer. An apparent tear stress versus apparent tear rate plot is used to identify the melt fracture phenomenon, and quantify the critical tear index and the critical tear stress of the ethylene polymers. According to Ramamurthy in Journal of Rheology, 20 (2), 337-357, 1986, above a certain critical flow velocity, the observed irregularities of the extrudate can be broadly classified into two main types: surface fusion fracture and fusion fracture. deep The superficial fusion fracture occurs under conditions of apparently continuous flow, and is in detail from the loss of specular film brightness, to the more severe form of "shark skin". Here, as determined using the gas extrusion rheometer described above, the establishment of the surface melt fracture (OSMF) is characterized at the beginning of the loss of the extrudate brightness where the surface roughness of the extrudate can only be detect by means of a 40x amplification. As described in U.S. Patent No. 5,278,272, at a critical tear rate to the establishment of the surface melt fracture for substantially linear ethylene interpolymers and homopolymers, it is at least 50 percent greater than the index of critical tear to the establishment of the surface melt fracture of a linear ethylene polymer having essentially the same I2 and Mw / Mn. Deep fusion fracture occurs under irregular extrusion flow conditions, and is in detail from regular distortions (rough and smooth alternating, helical, etc.), to random distortions. For commercial acceptability, in order to maximize the performance properties of films, coating, and molded articles, surface defects should be minimal, if not absent. The critical tear stress at the establishment of the deep melt fracture for the substantially linear ethylene polymers used in the invention, especially those having a density > 0.910 grams / cubic centimeter, is greater than 4 x 10 dynes / square centimeter. The critical tear rate at the establishment of the surface melt fracture (OSMF), and the establishment of the deep melt fracture (OGMF) will be used in the present based on the changes of the surface roughness and the configurations of the extruded extrudates. by means of a gas extrusion rheometer. The homogeneous ethylene polymers used in the present invention are characterized by a single melting peak of differential scanning calorimetry. The unique melting peak is determined using a differential scanning calorimeter standardized with indium and deionized water. The method involves sample sizes of 5 to 7 milligrams, a "first heat" up to approximately 140 ° C, which is maintained for 4 minutes, a cooling at 10 ° C / minute to -30 ° C, which is maintained for 3 minutes. minutes, and heating at 10 ° C / minute to 150 ° C for the "second heat". The only melting peak is taken from the heat flow curve of the "second heat" against the temperature. The total heat of the polymer melt is calculated from the area under the curve. For polymers having a density of 0.875 grams / cubic centimeter to 0.910 grams / cubic centimeter, the single melting peak may show, depending on the sensitivity of the equipment, a "shoulder" or a "hump" on the side of low fusion, which constitutes less than 12 percent, usually less than 9 percent, and more usually less than 6 percent of the total heat of fusion of the polymer. This artifice can be observed for other homogeneously branched polymers, such as Exact resins, and is discerned based on the inclination of the single melting peak, which varies monotonicly through the fusion region of the artifice. This artifice occurs within 34 ° C, usually within 27 ° C, and more usually within 20 ° C of the melting point of the single melting peak. The heat of fusion that can be attributed to an artifice can be determined separately by specific integration of its associated area under the curve of heat flow versus temperature. Whole polymer product samples and individual polymeric components are analyzed by gel permeation chromatography (GPC) in a Waters 150 high temperature chromatographic unit equipped with three columns of mixed porosity (Polymer Laboratories 103, 104, 105 and 106Á), operating at a system temperature of 140 ° C. The solvent is 1,2,4-trichlorobenzene, from which 0.3 percent by weight solutions of the samples for injection are prepared. The flow rate is 1.0 milliliters / minute, and the injection size is 100 microliters. The determination of the molecular weight is deduced using polystyrene standards of a distribution of Narrow molecular weight (from Polymer Laboratories) in conjunction with its elution volumes. Equivalent polyethylene molecular weights are determined using appropriate Mark-Houwink coefficients for polyethylene or polystyrene (as described by Williams and Ward in Journal of Polymer Science, Polymer Letters, volume 6, page 621, 1968), to derive the following equation : Polyethylene = a ^ polystyrene ^ • In this equation, a = 0.4316 and b) 1.0. The weight average molecular weight, Mw, and the number average molecular weight, Mn, are calculated in the usual manner, according to the following formula: M_: = (S w ^ _ (M_¡_3)) 3; where w.¡_ is the weight fraction of the molecules, eluting M.¡_ from the column of gel permeation chromatography in fraction i, and j = l when calculating Mw and j = -l when calculated Mn. The molecular weight distribution (Mw / Mn) for the substantially linear ethylene polymers and the homogeneous linear ethylene polymers used in the present invention is generally from about 1.8 to about 2.8. However, it is known that substantially linear ethylene polymers have excellent processability, despite having a relatively narrow molecular weight distribution. Unlike ethylene linear polymers homogeneously and heterogeneously branched, the The melt flow rate (I-LQ / I2) of the substantially linear ethylene polymers can be varied in a manner essentially independent of their molecular weight distribution, Mw / Mn. Homogeneously branched ethylene polymers suitable for use in the present invention include the interpolymers of ethylene and at least one alpha-olefin prepared by a solution, gas phase, or paste polymerization process, or combinations thereof. Suitable alpha-olefins are represented by the following formula: CH2 = CHR wherein R is a hydrocarbyl radical. In addition, R can be a hydrocarbyl radical having from 1 to 20 carbon atoms, and as such, the formula includes alpha-olefins of 3 to 20 carbon atoms. Suitable alpha-olefins to be used as the comonomers include propylene, 1-butene, 1-isobutylene, 1-pentene, 1-hexene, 4-methyl-1-pentene, 1-heptene, and 1-octene, as well as other types of comonomers, such as styrene, styrenes substituted by halogen or by alkyl, tetrafluoroethylene, benzocyclobutane vinyl, 1,4-hexadiene, 1,7-octadiene, and cycloalkenes, for example cyclopentene, cyclohexene, and cyclo-octene. Preferably, the comonomer will be 1-butene, 1-pentene, 4-methyl-1-pentene, 1-hexene, 1-heptene, 1-octene, or mixtures thereof, due to that adhesive backing materials comprised of higher alpha-olefins will have a particularly improved hardness. However, more preferably, the comonomer will be 1-octene, and the ethylene polymer will be prepared in a solution process. The density of the substantially linear ethylene polymer or homogenously branched linear ethylene polymer, measured in accordance with ASTM D-792, does not exceed 0.92 grams / cubic centimeter, and is generally in the range of about 0.85 grams / cubic centimeter to about 0.92 grams / cubic centimeter, preferably from about 0.86 grams / cubic centimeter to about 0.91 grams / cubic centimeter, and especially from about 0.86 grams / cubic centimeter to about 0.90 gram-mos / cubic centimeter. The molecular weight of the homogeneously branched linear ethylene polymer or the substantially linear ethylene polymer is conveniently indicated using a melt index measurement according to ASTM D-1238, condition 190 ° C / 2.16 kilograms (formerly known as "Condition ( E) ", and also known as I2) • The melting index is inversely proportional to the molecular weight of the polymer. Therefore, the higher the molecular weight, the lower the melting index, although the relationship is not linear. The melt index for the polymer of homogeneously branched linear ethylene or substantially linear ethylene polymer, is generally from about 1 grams / 10 minutes (g / 10 min.) to about 500 grams / 10 minutes, preferably from about 2 grams / 10 minutes to about 300 grams / 10 minutes, more preferably from about 5 grams / 10 minutes to about 100 grams / 10 minutes, especially from about 10 grams / 10 minutes to about 50 grams / 10 minutes, and more especially from about 25 to about 35 grams / 10 minutes Another useful measurement for characterizing the molecular weight of the homogeneous linear ethylene polymer or the substantially linear ethylene polymer is conveniently indicated using a melt index measurement according to ASTM D-1238, condition 190 ° C / 10 kilograms (previously known as "Condition (N)", and also known as I? o ^ • The ratio of the melting index terms I- ^ Q and I2 is the melt flow rate, and is designated as ~ L -LQ / ^ -2 - For the substantially linear ethylene polymer, the ratio Il? / - I-2 indicates the degree of long chain branching, ie, the higher the ratio IIQ / ^ 'the longer chain branching will be in The polymer The ratio I- | _Q / I2 of the substantially linear ethylene polymer is at least 6.5, preferably at least 7, especially at least 8. The ratio I10 / I2 c ^ e -'- P ° ethylene polymer homogenously branched linear is generally less than 6.3. Preferred ethylene polymers for use in the present invention have a relatively low modulus. That is, the ethylene polymer is characterized by having a 2 percent secant modulus of less than 24,000 psi (163.3 MPa), especially less than 19,000 psi (129.3 MPa), and more especially less than 14,000 psi (95.2 MPa), measured in accordance with ASTM D790. Preferred ethylene polymers for use in the present invention are substantially amorphous or completely amorphous. That is, the ethylene polymer is characterized as having a percent crystallinity of less than 40 percent, preferably less than 30 percent, more preferably less than 20 percent, and most preferably less than 10 percent, as measured by calorimetry. differential exploration, using the equation of the percentage of crystallinity = Hf / 292 * 100, where Hf is the heat of fusion in Joules / gram. The homogeneously branched ethylene polymer can be used alone, or can be mixed with one or more synthetic or natural polymeric materials. Polymers suitable for 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, linear polyethylene of heterogeneously branched low density, heterogeneously branched ultra-low density polyethylene, medium density polyethylene, high density polyethylene, grafted polyethylene (for example, a heterogeneously branched linear density low density polyethylene grafted by extrusion with maleic anhydride, or an ultra high density polyethylene) -low homogeneously branched density grafted by extrusion with maleic anhydride), ethylene-acrylic acid copolymer, ethylene-vinyl acetate copolymer, ethylene-ethyl acrylate copolymer, polystyrene, polypropylene, polyester, polyurethane, polybutylene, polyamide, polycarbonate, Rubber, ethylene-propylene polymers, ethylene-styrene polymers, styrene block copolymers, and vulcanatos. The actual mixing of the different polymers can be carried out in a convenient manner by any technique known in the art, including, but not limited to, melt extrusion composition, dry blending, roll lamination, melt blending, such as a Banbury mixer, and polymerization of multiple reactors. Preferred mixtures include a homogeneously branched ethylene polymer and a heterogeneously branched ethylene-alpha-olefin interpolymer, wherein the alpha-olefin is an alpha-olefin of 3 to 8 carbon atoms prepared using two reactors operated in parallel or in series , with different catalytic systems used in each reactor. Polymerizations of multiple reactors are described in Pending Applications of the United States of America Serial No. 08 / 544,497, filed October 18, 1995, and serial number 08 / 327,156, filed October 21, 1994. However, polymerizations of multiple preferred reactors comprise non-adiabatic solution cycle reactors, as described in the provisional applications of the United States of America with serial numbers USSN 60/014696 and USSN 60/014705, both filed on Io April 1996. A range of resin properties, processing conditions, and equipment configurations have been discovered for extrusion coated underfloor systems that provide similar or better performance than latex and polyurethane incumbent systems. . Figure 1 is an illustration of a cushioned carpet 10. The cushioned carpet 10 is made of a primary backing material 11, with the yarn 12 cushioned therethrough; an adhesive backing material 13 which is in intimate contact with the back surface of the primary backing material 11, substantially encapsulates the thread 12, and penetrates the thread 12, and fixes the individual fibers of the carpet; and an optional secondary backup material 14 applied to the back surface of the adhesive backing material 13.

Figure 2 is an illustration of an extrusion coating line 20 for manufacturing a carpet 70. Line 20 includes an extruder 21 equipped with a slot die 22, a tightening roller 24, a cooling roller 23, an extraction hood 26, a raw-cloth feeder roller 28, and a pre-heater 25. As illustrated, the clamping roller is preferably equipped with a vacuum slot 29 to draw a vacuum through approximately 60 °, or approximately 17 percent of its circumference, and is equipped with a vacuum pump 27. The slot die 22 doses an adhesive backing material in the form of a semi-molten or melted polymeric fabric 30 over the raw fabric 40, with the polymeric fabric 30 towards the roll of cooling 23, and the raw fabric 40 to the optional vacuum tightening roller 24. As illustrated, an optional secondary backing material 50 is applied over the polymeric fabric 30. The where the tightening roller 24 and the cooling roller 23 are closer to each other, it is referred to as tightening 60. The present invention is useful for the production of carpets with face yarn made of different materials, including, but not limited to. a, polypropylene, nylon, wool, cotton, acrylic, polyester, and polytrimethylene terephthalate (PTT). However, again because one of the objects of the present invention is to provide a recycled carpet As, for example, a 100 percent polyolefin carpet, the most preferred yarn comprises a polyolefin, more preferably polypropylene. More preferably, the yarn used in the present invention is a 2750 denier polypropylene yarn entangled by air, such as that produced by Shaw Industries, Inc. and sold under the designation "Permacolor 2750 type 015". The preferred primary backing material comprises a polyolefin, more preferably polypropylene. More preferably, the primary backing material is a grooved film polypropylene sheet, such as that sold by AMOCO or Synthetic Industries. Alternatively, other types of primary backing materials, such as non-spun fabrics, can also be used. Although other materials, such as polyesters, or polyamides, can be used for the primary backing material, it is preferred to use a polyolefin, so as to achieve the goal of producing a carpet made entirely of polyolefins. In addition, primary polypropylene backing materials are usually of a lower cost. The method for cushioning or needle piercing the yarn is not considered critical to the present invention. Accordingly, any quilting device or needle piercing, and conventional stitch patterns can be used. In the same way, it does not matter if the loops of Padded yarn is left uncut to produce a laced hair; cut to make a cut hair; or cut, partially cut, and not cut, to make a face texture known as torn ends. After the yarn in the primary backing material is cushioned or needle pierced, the raw fabric is usually wound with the back side of the primary backing material facing outward, and held until it is transferred to the backing line. In a preferred embodiment, the raw fabric is scrubbed or washed before an adhesive backing material is extruded thereon. In particular, yarn that is cushioned or needle punched to make the carpet often has varying amounts of processing materials, most commonly oily or waxy chemicals, known as spinning chemicals, which remain on top of it. the thread manufacturing processes. It has been found that it is preferable to remove or displace all or substantially all of these processing materials before extruding the adhesive backing material onto the back surface of the primary backing material. A preferred scrubbing or washing method includes passing the raw fabric through a bath containing an aqueous detergent solution of about 64 ° C to about 70 ° C (for example, 67 ° C). Suitable detergents include, but are not limited to, STA that is available in American Emulsions. After the washing processing step with detergent, the raw fabric is dried or preheated. The drying can be carried out at a temperature from about 108 ° C to about 112 ° C (for example, 110 ° C), from about 1.8 to about 2.2 minutes (for example, 2 minutes). Another preferred scrubbing or washing method includes using a wet vacuum system that initially doses water at room temperature or heated water (optionally containing a detergent or cleaning solution (on the side of the primary backing material of the raw fabric, and then the water and the retained quantities of processing materials are sucked in sequence, the wet suction system is suitably adapted with a rod and dosing head and vacuum, in such a way that the entire width of the raw material can be sucked out of moisture at least once in a continuous extrusion coating line.After the moisture aspiration processing step, the raw material is suitably dried and / or preheated.Detergent detergents, cleaning solutions, or cleaning concentrates for use in a method of Moisture aspiration include, but are not limited to, aqueous alkaline solutions, for example They consist of tetrasodium salt of ethylenediaminetetraacetic acid. A suitable moisture extraction system is the carpet cleaning system Rinsevac, and a suitable cleaning concentrate is the Rinsevac Professional Carpet Cleaner, both supplied by Blue Luster Products, Inc., Indianapolis, In. Other suitable methods of the present invention for scrubbing or washing processing materials, adaptable to an extrusion coating line, such as, for example, that illustrated in Figure 2, include steam cleaning, evaporation at elevated temperatures and / or vacuum, and chemical washing with solvent of the raw material. It is also contemplated that the use of polyolefin waxes (as opposed to conventional organic and mineral oils) as processing materials would allow for a better performance of the adhesive backing material by itself, or at least less demanding scrubbing or washing requirements. . However, practitioners will find that the scrubbing or washing requirements may vary with the amount and specific type of processing material present. That is, higher amounts of process materials, and / or higher molecular processing materials may require more stringent scrubbing and washing techniques, such as, for example, multiple washing and drying steps using concentrated wash solutions. based on softened or deionized water. Practitioners will also recognize that the scrubbing and washing requirements to effectively remove or displace the processing materials. may be more extensive than ordinary washing or other cleaning procedures performed for cosmetic or decorative purposes, or made to simply remove loose fibers, primary backing material, or other debris ordinarily resulting from the operations of cushioning, drilling with needle, and / or cut. In another aspect of the present invention, the raw fabric is coated with an aqueous precoat material, either as a final backing, or preferably before the adhesive backing material is extruded thereon. The particles of this dispersion can be made from different polyolefin materials, such as ethylene-acrylic acid (EAA), ethylene-vinyl acetate (EVA), polypropylene or polyethylene (e.g., low density polyethylene (LDPE), linear polyethylene low density (LLDPE), or substantially linear ethylene polymer, or mixtures thereof). At present, polyethylene particles are preferred. More preferably, the polyethylene particles are those sold by Quantum USI Division under the designation "Microthene FN500". Preferably, the polyolefin particles are present in an amount between about 10 and 75 weight percent of the dispersion, more preferably between about 20 and about 50 percent, and most preferably between about 25 and about 33 percent. The particle size of the polyolefin particles is important, both to ensure that good dispersion is achieved, and also to ensure that the polyolefin particles penetrate the yarn and primary backing to provide good abrasion resistance. Preferably, the average particle size of the polyolefin particles is between about 1 and about 1,000 microns, and more preferably between about 5 and 40 microns. The most preferred polyethylene particles referred to above have an average particle size of about 18 to about 22 microns (e.g., 20 microns). Preferably, the polyolefin particles have a Vicat softening point (measured according to ASTM D1525) of between about 50 ° C and about 100 ° C, and more preferably between about 75 ° C and 100 ° C. The most preferred polyethylene particles referred to above have a softening point of about 80 ° C to about 85 ° C (for example, 83 ° C). When polypropylene particles are used, they preferably have a melt flow (ASTM D-1238 Condition 210 / 2.16) of between about 1 and about 80, more preferably between about 60 and about 80. When using polyethylene particles, preferential They have a melt index I2 (ASTM D-1238 Condition 190 / 2.16) of between about 1 and about 100 grams / 10 minutes, and more preferably between about 20 and about 25 grams / 10 minutes. The most preferred polyethylene particles referred to above have a melt index I2 of 22 grams / 10 minutes. Ethylene-acrylic acid (EAA) can be used for the polyolefin particles, preferably in combination with the polyethylene or polypropylene particles. It has been found that ethylene-acrylic acid can increase the adhesion of the previous coating to the yarn and the primary backing, as well as to an extruded thermoplastic sheet thereon. The aqueous dispersion preferably contains other ingredients. For example, a surfactant is preferably included to help keep the polyolefin particles dispersed. Suitable surfactants are nonionic, anionic, cationic, and fluorotensive. Preferably, the surfactant is present in an amount of between about 0.01 and about 1 weight percent, based on the total weight of the dispersion. More preferably, the surfactant is anionic. Most preferably, the surfactant is one sold by Ciba Geigy under the designation "Igepal C0430", and is present at 0.1 weight percent, based on the total weight of the dispersion.

A thickener is also preferably included to provide a suitable viscosity to the dispersion. Preferably, the thickener is one selected from the group consisting of sodium or ammonium salts of polyacrylic acids, and is present in an amount of between about 0.1 and about 2 weight percent, based on the total weight of the dispersion. More preferably, the thickener is a salt of a polyacrylic acid, such as that sold by Sun Chem Internatio-nal, under the designation "Print Gum 600", and is present at about 0.8 weight percent, based on the total weight of the dispersion. Preferably, the viscosity of the dispersion measured on a Brookfield RVT viscometer is between about 3,000 cP (centipoise) at 20 rpm with a No. 5 spindle, and about 50,000 cP at 2.5 rpm with a No. 5 spindle, measured at 23 ° C. More preferably, the viscosity of the dispersion is between about 10,000 and 20,000 cP at 2.5 rpm with a spindle No. 5. In addition, the dispersion preferably includes a defoaming agent. Preferably, the defoaming agent is a defoaming agent that is not silicone, and is present in an amount between about 0.01 and about 1.0 weight percent, based on the total weight of the dispersion. More preferably, the defoamer is one such as sold by LENMAR Chemical Corporation under the designation "MARFOAM N-24A", and is present at approximately 0.1 weight percent, based on the total weight of the dispersion. Preferably, the aqueous dispersion further includes a dispersion improver, such as vaporized silica, which has been found to act as a compatibilizer for the dispersion, thus allowing the use of larger polyolefin particles. Preferably, the vaporized silica is present between about 0.1 and about 0.2 weight percent, based on the total weight of the dispersion. More preferably, the vaporized silica is one such as that sold by DeGussa under the designation "Aerosil 300". The aqueous dispersion of polyolefin particles can be done in different ways. Preferably, the ingredients are added to the water in the following order: surfactant, defoamer, polyolefin, thickener. The mixture is then stirred in a homogeneous mixer, preferably with high shear mixing, until all lumps have dispersed, usually for about 8 to about 12 minutes (eg, 10 minutes). The dispersion can be applied to the carpet in different ways. For example, the dispersion can be applied directly, such as with a roller on an application. roller, or a blade. Alternatively, the dispersion can be applied in an indirect manner, such as with a tray applicator. Preferably, a roller-on-roller applicator is used, the upper roller rotating from about 22 to about 27 percent of the line speed (e.g., 25 percent of the line speed). The amount of dispersion applied and the concentration of the particles can be varied depending on the desired processing and product parameters. Preferably, the amount of dispersion applied and the concentration of the particles are selected to apply between about 4 and about 12 ounces per square yard (OSY) (between about 141.5 and about 424.4 cubic centimeters / square meter) of carpet. More preferably, this is achieved by using a dispersion containing about 50 weight percent polyolefin particles (based on the total weight of the dispersion), and applying between about 8 and about 10 OSY (between about 283 and approximately 353.7 cubic centimeters / square meter) of the dispersion. After application of the dispersion, heat is applied to the back side of the primary backing, to dry the dispersion, and to at least partially fuse the particles. As a result, the loops of thread are fixed at primary backup. Preferably, heat is applied by passing the product through an oven. This furnace is preferably set at a temperature between about 100 ° C and about 150 ° C, and the product passes between about 2 and about 5 minutes through the furnace. Also, because the object is to at least partially fuse the particles, the oven temperature is set between about 5 ° C and about 75 ° C above the Vicat softening point of the polyolefin particles. After treatment with the dispersion of polyolefin particles, the carpet can be used as is, or more preferably, an additional backing can be applied to it. Additional backings can be applied by different methods, with the preferred method, as described above, involving the use of an extruded sheet of a thermoplastic material, preferably the homogeneously branched ethylene polymer described above, on which a conventional secondary backing is laminated. . In particular, preferably a molten thermoplastic material is extruded through a die, to make a sheet that is as wide as the carpet. The molten extruded sheet is applied to the back side of the primary carpet backing. Because the sheet is fused, the sheet will conform to the shape of the loops of thread, and will also serve to fix the loops on the primary backing.

The extrusion coating configurations include a monolayer T-type die, single-lip die extrusion coating, two-lip die extrusion coating, and multistage extrusion coating. Preferably, the extrusion coating equipment is configured to apply a total coating weight of between about 4 and about 30 ounces / square yard (OSY) (from about 141.5 to about 1061.1 cubic centimeters / square meter), with more preferred between approximately 18 OSY (approximately 636.7 cubic centimeters / square meter) and approximately 22 OSY (approximately 778.1 cubic centimeters / square meter), for example, 20 OSY, (707.4 cubic centimeters / square meter). Otherwise measured, the thickness of an unexpanded, collapsed, extruded, adhesive backed backing material is in the range of about 6 to about 80 mils (from about 0.152 millimeters to about 2032 millimeters), preferably about 10 mils. to about 60 thousandths (from about 0.25 to about 1.52 millimeters), more preferably from about 15 to about 50 thousandths (from about 0.38 to about 1.27 millimeters), and most preferably from about 20 to about 40 mils (from about 0.51 to about 1.02 millimeters).

The line speed of the extrusion process will depend on factors such as the particular polymer that is being extruded, the exact equipment that is being used, and the weight of the polymer being applied. Preferably, the line speed is between about 18 and about 250 feet / minute (between about 5.5 and about 76.2 meters / minute), more preferably between about 80 and about 220 feet / minute (between about 24.4 and about 67.1 meters / minute), and most preferably between about 100 and about 200 feet / minute (from about 30.5 to about 61 meters / minute). The melting temperature of the extrusion coating depends mainly on the particular polymer that is being extruded. When the most preferred substantially linear polyethylene described above is used, the melting temperature of the extrusion coating is greater than about 450 ° F (232 ° C), preferably greater than, or equal to, about 500 ° F (about 260 ° C). C), or is between about 450 ° F (about 232 ° C), and about 650 ° F (about 343 ° C), more preferably between about 475 ° F (about 246 ° C) and about 600 ° F (about 316 ° C) ° C), and most preferably between about 500 ° F and about 550 ° F (between about 260 ° C and about 288 ° C).

Preferably, two resin layers are extruded, each layer comprising a different resin, the layer being applied directly on the back side of the primary backing material (first layer), which has a higher melt index than the second layer, which It is applied on the back side of the first layer. Because it is the first layer on which it rests to encapsulate and penetrate the yarn, this layer must have a sufficiently high melt index (sufficiently low melt viscosity) to promote encapsulation and thread penetration. The second layer, which is not generally on which it rests to encapsulate and penetrate the yarn, can be used either as the lower surface of the carpet, or to facilitate the application of an optional secondary backup material. For both uses, it is preferred to have a lower melt index to provide a higher strength after cooling. In addition, because it is not on which it rests to encapsulate or penetrate the fiber bundles, a lower quality resin and / or less closely controlled properties can be used in the second layer. In a preferred embodiment, the second layer is a recycled feed supply. Also, the first and second layers may consist of different chemistries or polymer compositions. For example, the first layer may be comprised of an adhesive polymer (as an additive or as the composition of all the layer), such as, but not limited to, an ethylene-vinyl acetate copolymer, an ethylene-acrylic acid copolymer, or a maleic anhydride / ethylene graft polymer (preferably, an ethylene polymer extrusion graft) substantially linear / maleic anhydride, or a high density polyethylene / maleic anhydride extrusion graft), and the second layer may be comprised of a non-polar polymer, such as a homogeneously branched ethylene polymer, a low density polyethylene, or an ultra-low density polyethylene. Alternatively, the first layer may be comprised of a non-polar polymer, and the second layer may be comprised of an adhesive polymer. Preferably, the first layer has a melt index 12 of between about 30 and about 175 grams / 10 minutes, and the second layer has a melt index I2 of between about 1 and about 70 grams / 10 minutes. More preferably, the first layer has a melt index I2 of between about 30 and about 70 grams / 10 minutes, and the second layer has a melt index I2 of between about 10 and about 30 grams / 10 minutes. It is also preferred to extrude two layers of a single polymer composition, to have greater control over the thickness or weight of the resin applied to the carpet. In the alternative modalities, 3 or more layers of the resin on the back surface of the primary backing material, to achieve still higher coating weights, and / or to obtain a more gradual transition between the applied first and last layer. Preferably, a double-lip die is used to apply two layers. Alternatively, two or more extrusion stations, or a single-lip coextrusion die, can be used to apply these two or more layers. Another aspect of the present invention is the use of modified homogeneously branched ethylene polymers. In particular, in certain aspects of the invention, the at least one homogeneously branched ethylene polymer that is employed as the adhesive backing material, the primary backing material, or the wire, preferably as the adhesive backing material, is modified by the addition of at least one adhesive polymeric additive. Suitable adhesive polymeric additives include polymeric products comprised of: (1) one or more ethylenically unsaturated carboxylic acids, anhydrides, alkyl esters, and half-esters, for example acrylic acid, methacrylic acid, maleic acid, maleic anhydride, itaconic acid, acid fumaric, crotonic acid, and citraconic acid, citraconic anhydride, succinic acid, succinic anhydride, methyl acid maleate, ethyl acid maleate; esters of ethylenically unsaturated carboxylic acids, for example ethyl acrylate, methacrylate of methyl, ethyl methacrylate, methyl acrylate, isobutyl acrylate, and methyl fumarate; unsaturated esters of carboxylic acids, for example vinyl acetate, vinyl propionate, and vinyl benzoate; and ethylenically unsaturated amides and nitriles, for example acrylamide, acrylonitrile, methacrylonitrile, and fumaronitrile; and (2) one or more ethylenically unsaturated hydrocarbon monomers, such as aliphatic alpha-olefin monomers, for example ethylene, propylene, butene-1, and isobutene; conjugated dienes, for example butadiene and isoprene; monovinylidene-aromatic carbocyclic monomers, for example styrene, alpha-methylstyrene, toluene, and tertiary butyl-styrene. Suitable adhesive polymeric additives can be conveniently prepared by known techniques, such as, for example, interpolymerization, or by a polymerization process followed by a chemical grafting or extrusion process. Suitable grafting techniques are described in U.S. Patent Nos. 4,762,890; 4,927,888; 4,230,830; 3,873,643; and 3,882,194. The preferred adhesive polymeric additives for use in the present invention are maleic anhydride grafts, wherein the maleic anhydride is grafted onto an ethylene polymer in a concentration of about 0.1 to about 5.0 weight percent, preferably about 0.5 to about 1.5 percent in weight. The use of ethylene / maleic anhydride polymer grafts as adhesive polymeric additives in the present invention significantly improves the performance and operating window of homogeneously branched ethylene polymers coated by extrusion as the adhesive backing material, especially for the polar polymer, such as, for example, but not limited to, carpet with nylon spider and polyester. The improvement pertains to a substantially higher abrasion resistance and binding strength of comparatives. The improvement was surprising, because it is generally known that graft adhesives require prolonged molten or semi-fused contact times for better performance and function as interlayer adhesives for films and coatings where there is a continuous substrate, as opposed to the interface discontinuous in the construction of carpets. Preferred ethylene polymers for use as the graft host polymer include low density polyethylene (LDPE), high density polyethylene (HDPE), heterogeneously branched linear low density polyethylene.

(LLDPE), homogenously branched linear ethylene polymers, and substantially linear ethylene polymers. The preferred host ethylene polymers have a polymer density greater than, or equal to, 0.915 grams / cubic centimeter, and more preferably greater than, or equal to 0.92 grams / centimeter. cubic tro. Substantially linear ethylene polymers, and high density polyethylene, are the preferred ethylene host polymers. In this aspect of the present invention, the adhesive polymeric additive is added to the homogeneously branched ethylene polymer at a level in the range of about 0.5 to about 30 weight percent, preferably about 1 to about 20 weight percent. percent by weight, more preferably from about 5 to about 15 weight percent, based on the total weight of the polymer. For the preferred ethylene-maleic anhydride polymer grafts, the additions should provide a final concentration of maleic anhydride in the range from about 0.01 to about 0.5 weight percent, preferably from about 0.05 to about 0.2 percent by weight, based on the total weight of the polymer. Auxiliary equipment, such as a preheater, can be used. In particular, a heater, such as a convection oven or infrared panels, can be used to heat the back of the raw fabric before the adhesive backing material is extruded thereon. By doing so, it has been found that the encapsulation and penetration of the yarn bundles can be improved. Preferably, the preheater is an infrared unit established between about 200 ° C and about 1,500 ° C, and the raw fabric is exposed to this heating for between about 3 and about 30 seconds. More preferably, the heater is set to about 1,000 ° C, and the raw fabric is exposed to this heating for about 5 to about 7 seconds (eg, 6 seconds). In addition to, or as an alternative to, the preheating, the process of the invention may also employ a soaking process step after heating, to lengthen the melting time for the adhesive backing material, in order to improve this. the encapsulation and penetration of the yarn or fiber bundles by the adhesive backing material. Preferably, after the adhesive backing material is applied to the raw fabric, it is heated by a convection oven or infrared radiation, at a temperature between about 200 ° C and about 1,500 ° C, for between about 3 and 30 seconds. , more preferably at 1,000 ° C for about 5 to about 7 seconds (for example 6 seconds). As another piece of auxiliary or optional equipment, a vacuum clamping roller can be used to direct the extrusion of adhesive backing material (ie, semi-melted or melted polymeric fabric) onto the raw fabric. In an appropriately configured extrusion coating operation, the hair face of the raw fabric is placed towards the vacuum tightening roller, and the polymeric fabric is lowered onto the back surface of the primary backing material of the raw fabric. The vacuum tightening roller 24 (illustrated in Figure 2, and available from Black Clawson Corporation) is suitable for vacuum stripping the fabric of adhesive backing material. The vacuum tightening roller 24 can be adapted from a conventional tightening roller, wherein a portion of the internal hollow part of the roller is divided, engaged, and coupled to an external vacuum pump 27, for the purpose to provide a vacuum surface. The surface of the vacuum portion is drilled, but machined flush and continuously with the remaining surface of the roller. Suitable vacuum tightening rollers can have a complete vacuum surface of 360 °; however, a vacuum surface of about 10 to about 180 °, more preferably about 60 °, is preferred. In order to effectively remove the fabric from adhesive backing material on the raw fabric, and maximize the penetration of the wire or fiber bundles, the vacuum is set to more than 15 inches of H20 (3.7 Pa), preferably more than, or equal to, 25 inches of H20 (6.1 Pa), and more preferably more than, or equal to, 40 inches of H20 (9.8 Pa), or between about 15 and about 50 inches of H20 (from about 3.7 to about 12.3 Pa). ), preferably between about 20 and about 45 inches of H20 (from about 4.9 to about 11.1 Pa). The time that is actually subjected to the vacuum raw material will depend primarily on the speed of the extrusion coating line, and the degree of extraction on the adhesive backing fabric will largely depend on the level of vacuum and the porosity of the material. raw gender. As such, higher vacuum levels will be required for higher extrusion coating line speeds and / or denser raw fabrics, to effectively extract the adhesive backing material. In addition to, or as an alternative to, a vacuum tightening roller, a positive high-pressure air device, such as a knife or air knife, can also be used to force the fabric of adhesive backing material onto the back surface of the primary backup material. Preferably, the positive air pressure device is set to provide an air pressure greater than 20 psi (0.14 MPa), preferably greater than, or equal to, 40 psi (0.27 MPa), more preferably greater than, or equal to, at 60 psi (0.41 MPa), or between about 20 and about 120 psi (between about 0.14 and about 0.82 MPa), and most preferably between about 30 and about 80 psi (between about 0.20 and about 0.54 MPa). Preferably, the positive air pressure device is placed in the extrusion coating tightening, it extends across the full width of the polymeric fabric, and is placed behind the polymeric fabric towards the cooling roller, to force the polymeric fabric onto the raw fabric, and to press the polymeric fabric into the fabric. the thread or in the fiber bundles. The extruded polymers can be used clean, or one or more additives can be included. A preferred additive is an inorganic filler, more preferably an inorganic filler with a high heat content. Examples of these fillers include, but are not limited to, calcium carbonate, aluminum trihydrate, talc, barite. It is believed that fillers with a high heat content are suitable in the invention, because these fillers allow the extrudate to remain at elevated temperatures longer, with the beneficial result of providing better encapsulation and penetration. That is, fillers are usually added to carpet backing materials to merely add volume (ie, as extenders), or to impart sound insulation and sound deadening characteristics. However, we have found that inorganic mineral fillers that have high heat contents, surprisingly improve the encapsulation and penetration of the yarn, which in turn improves the performance of the abrasion resistance and the binding strength of quilting. carpet samples Coated by extrusion. Preferably, a high heat content filler is added at a level between about 1 and about 75 weight percent of the total extrudate, more preferably between about 15 and about 60 weight percent, and very preferably between about 20 weight percent and 50 weight percent. These fillings will have a specific heat content greater than, or equal to, 0.4 cal-cc / ° C (1.8 Joules-cc / ° C), preferably greater than, or equal to 0.5 cal-cc / ° C ( 2 Joules-cm / ° C), more preferably greater than, or equal to, 0.6 cal-cc / ° C (2.5 • _) Joules-cm / ° C), and most preferably greater than, or equal to, approximately 0.7 cal-cc / ° C (2.9 Joules-cm3 / ° C). Representative examples of high-heat content fillers for use in the present invention include, but are not limited to, limestone (primarily CaCO3), marble, quartz, silica, and barite (primarily BaSO4). The high heat content fillers must be milled or precipitated to a size that can be conveniently incorporated into an extrusion coating melt stream. Suitable particle sizes are from about 1 to about 50 microns. If a foamed backing is desired on the carpet, a blowing agent can be added to the adhesive backing material, and / or to the optional secondary backing material. Yes is used, blowing agents are preferably conventional heat-activated blowing agents, such as azodicarbonamide, toluenesulfonylsemicarbazide, and oxybis (benzenesulfonyl) hydrazide. The amount of blowing agent added depends on the degree of foaming sought. A typical level of blowing agent is between about 0.1 and about 1.0 weight percent. The implosion in the present invention is performed by restricting the expansion of the adhesive backing material in the direction opposite to the primary backing material during the activation of the implosion agent, such that the molten polymer is forced inwardly and into the free space. of the thread or bundles of fibers. An impregnated adhesive backing material will have an unexpanded, collapsed matrix (relative to a foamed backing), and will be essentially of the same thickness (measured from the plane of the back surface of the primary backing material) as would be the case without the use of the implosion agent. That is, the layer of adhesive backing material would be characterized by not expanding by the implosion agent. The implosion agent is selected and formulated in the adhesive backing material, and the extrusion conditions are set in such a way that the activation of the implosion agent is present at the time of tightening, while the adhesive backing material is still semifused or melted. With the improved penetration of the yarn made with the use of an implosion agent, the carpet will exhibit a comparatively improved abrasion resistance. Accordingly, the use of an implosion agent can allow the use of polymeric compositions having lower molecular weights, in order to provide a better possibility of extrusion coating, and still maintain a higher abrasion resistance (i.e. , comparable to adhesive backing materials based on polymeric compositions of higher molecular weight). An effective amount of implosing agent would be between about 0.1 and about 1.0 weight percent, based on the weight of the adhesive backing material. Conventional blowing agents, or any material that ordinarily functions as a blowing agent, such as an implosion agent in the present invention, which provides expansion of the adhesive backing material matrix, which is suitably restricted or confined when used, can be used. the material is activated, such that the molten polymer is forced into and out of the free space of the yarn or fiber bundles, and there is no substantial expansion of the adhesive backing material as a result of having used the agent of implosion. However, preferably, an imploded adhesive backing material will be characterized as having a closed cell structure that it can be conveniently identified by photomicrographs at a 50x magnification. Other additives may also be included in the adhesive backing material, to the extent that they do not interfere with the improved properties discovered by the applicants. For example, antioxidants may be used, such as spherically hindered phenols, sterically hindered amines, and phosphites. Suitable antioxidants include Irganox 1010 from Ciba Geigy, which is a hindered phenol, and Irgafos 168 from Ciba Geigy, which is a phosphite. Other possible additives include anti-blocking additives, pigments and dyes, antistatic agents, antimicrobial agents (such as quaternary ammonium salts), and quench roller release additives (such as fatty acid amides). As noted above, and as shown in Figure 2, the carpet of the invention preferably also includes a secondary backing material. Preferably, the secondary backing material is directly laminated to the extruded layer, while the extrudate is still molten after the extrusion coating. It has been found that this technique can improve the penetration of the extrusion coating on the primary backing. Alternatively, the secondary backup material can be laminated in a later step, by reheating and / or remelting at least the outermost portion of the extruded layer, or by a coextrusion coating technique, using at least two dedicated extruders. Also, the secondary backing material can be laminated through some other means, such as by interposing a layer of a polymeric adhesive material between the adhesive backing material and the secondary backing material. Suitable polymeric adhesive materials include, but are not limited to, ethylene-acrylic acid (EAA) copolymers, ionomers, and maleic anhydride grafted polyethylene compositions. The material for the secondary backing material can be a conventional material, such as the spun polypropylene fabric sold by AMOCO under the designation -Action Bac. This material is a woolen yarn with polypropylene monofilaments running in one direction, and polypropylene yarn running in the other. More preferably, the secondary backing material used with the present invention is a spun polypropylene fabric with monofilaments running in both directions. A suitable example of this material is sold by Amoco under the designation Style 3878. This material has a basis weight of 2 OSY (70.7 cubic centimeters / square meter). This material with monofilaments running in both directions has been found beneficial to provide improved dimensional stability to the carpet. In an alternately preferred embodiment, the secondary backup material is a material known as fiber insurance yarn or "FLW". The FLW is a fabric that includes needle-punched fibers. Sometimes, the FLW is used as a primary backing material on a carpet with a low pile weight. In this mat, the fibers protrude over the hair side, to help prevent the primary backing material from showing through the hair. However, in this alternately preferred embodiment, the FLW is used as the secondary backing material, the needle-punched fibers projecting away from the carpet. It has been found that doing so improves the adhesion of the carpet when installed with a adhesive that adheres directly. In particular, the surface area for contacting the surface adhering adhesive increases, and the protruding fibers help anchor the under carpet to the adhesive that adheres directly. In an alternative way, the secondary backing material may be a non-spun fabric. There are several types available, including, but not limited to, spun bonding, spreading in a wet, blown, and entangled with air. As noted above, it is preferred that the secondary backup be made of a polyolefin to facilitate the I recycle In an alternately preferred embodiment, the non-spunbond fabric is spin-linked polypropylene fabric, such as that available from Don & Low Non-wovens under the name "Daltex". Normally, the yarn bonded fabric is made of extruded and extruded polymer filaments, which are spread together and then bonded together by stitches, for example by a heated calender roll. The basis weight of this spin-linked secondary backing may vary, preferably between 35 and 80 grams / square meter (gsm), more preferably between 60 and 80 grams / square meter. More preferably, the basis weight is 77-83 grams / square meter (eg, 80 grams / square meter). One factor favoring a higher basis weight for the yarn bonded fabric is that the higher base weight fabric is less likely to melt when placed in contact with the molten extruded backing. It has been found that a centrifugally bonded non-spun fabric is suitable for use as a secondary backing in the present invention, because the porous nature of the fabric increases the surface area of the carpet to adhere the carpet to the floor. In yet another alternately preferred embodiment, the secondary backing is a spun polypropylene fabric, such as Amoco's Action Bac that has been improved by having 2 OSY (70.7 cubic centimeters / square meter) of polypropylene fibers pierced with needle on one side of it. This needle-punched fabric is laminated to have the polypropylene fibers embedded within the adhesive backing layer. As a result, the strands of the spun polypropylene fabric are exposed. It has been shown that this embodiment has better adhesion properties, compared to a modality without needle-punched fibers, because, without needle-punched fibers, the threads of the spun polypropylene fabric are embedded at least partially in the layer adhesive backing. As such, the surface area for adhesion is reduced. It is also observed that the back of the carpet made in this modality was much less abrasive than those found with the traditional latex backing carpet. The carpet is also more flexible than the traditional latex backing carpet. Accordingly, this mode is preferred to make area mats and the like. Other materials can still be used for secondary backup. For example, if an integral cushion is desired, a polyurethane foam or other cushion material can be laminated to the back side of the carpet. These backs can be used for wide carpet, as well as for carpet mosaic. The construction of the carpet backed by Extrusion and the methods described herein, are particularly suitable for manufacturing carpet mosaic. Figure 6 shows a cross section of a carpet mosaic 100 made in accordance with the present invention. A yarn 103, preferably made of polypropylene, is cushioned on a primary backing 101, which is also preferably made of polypropylene, to leave a carpet hair face 104 on top of the primary backing 101, and backward stitching 105 under the primary backup. An adhesive layer 107 is applied to the back of the primary backing 101 and to the backward stitching 105. Preferably, this adhesive layer is made of a polyolefin. More preferably, the adhesive layer is made of ethylene polymers described in detail above. More preferably, this adhesive layer 107 is made of a substantially linear ethylene polymer, with the additives described in Example 194 below. In a preferred embodiment of carpet mosaic, the carpet included from about 5 to about 200 OSY (from about 176.8 to about 7,074 cubic centimeters / square meter) of extruded adhesive backing. More preferably, the mosaic carpet includes from about 30 to about 80 OSY (from about 1,061 to about 2,830 cubic centimeters / square meter) of extruded backing, more preferably 50 OSY (1,768 centimeter). cubic units / square meter). Preferably, the carpet mosaic carpet receives its extruded backing in two passes, that is, two layers of extruded backing are applied. The first pass applies layer 107 of Figure 6. Preferably, this layer 107 of between about 2.5 and about 100 OSY (from about 88.4 to about 3.537 cubic centimeters / square meter of the extruded polymer, more preferably between about 15 and about 40 OSY (between about 530.5 and about 1.415 cubic centimeters / square meter), and most preferably 25 OSY (884 cubic centimeters / square meter) The second pass adds layer 111. Preferably, second layer 111 is about 2.5 and about 100 OSY (between about 88.4 and about 3.537 cubic centimeters / square meter), more preferably between about 15 and 40 OSY (between about 530.5 and about 1.415 cubic centimeters / square meter), and most preferably 25 OSY (884 cubic centimeters / square meter) The application of the extruded backing in two passes s allows having the opportunity to apply first and second layers that have different physical and / or chemical properties. As noted above, it is sometimes preferable to apply a polymer with a higher melt index adjacent to the primary backing, and a polymer with a lower melt index below it. In addition, it may also be preferable to use an extrudate with a lower filler content in the layer next to the primary backing, and an extrudate with a higher filler content in the layer below it. In a preferred embodiment, the layer following the primary backing includes a filler load of 30 weight percent, and the layer below it includes a filler load of 60 weight percent. It is believed that the lower filler content provides better penetration of the primary backing and of the backward stitches in the carpet by the extrudate. When making the carpet mosaic, it is preferable to embed a layer of reinforcement material 109 between the first and second extruded backing layers. An important property of the carpet mosaic is the dimensional stability, that is, the ability of the mosaic to maintain its size and flatness over time. It has been found that the inclusion of this layer of reinforcement material improves the dimensional stability of the carpet mosaic made in accordance with this preferred embodiment. Suitable reinforcing materials include dimensionally and thermally stable fabrics, such as non-spun or wet-spread glass fiber canvases, as well as spun and non-spun thermoplastic fabrics (e.g., polypropylene, nylon, and polyester). In a more preferable, the reinforcement layer is a non-woven polypropylene fabric sold by Reemay as "Typar", with a basis weight of 3.5 OSY (124 cubic centimeters / square meter). Alternatively, a preferred reinforcing layer is a fiberglass canvas sold by ELK Corp. as "Ultra-Mat": with a basis weight of 1.4 OSY (49.5 cubic centimeters / square meter). a secondary backing fabric 113 under the second extruded backing layer 111. Suitable materials for the secondary backing fabric include those described above, however, it is currently not preferred to include a secondary backing fabric over the carpet backing. Figure 7 schematically shows a preferred line 120 for making the carpet mosaic in accordance with the present invention, unrolling a section of raw fabric 121, ie, quilted yarn in a primary backing, from the roll 123. The raw fabric 121 passes on the rollers 125 and 127, with the primary backrest towards the roller 123. Between the rollers 125 and 127 there is a preheater 129, as described above. nter an extruder 131, to extrude a sheet 135 of the polymeric backing through the die 133, on the back of the raw fabric, at a point between the roller 127 and the pinch roller 141. The exact location in which the sheet 135 contacting the raw fabric may be varied depending on the line speed and the desired time for the molten polymer to rest on the raw fabric before passing between the tightening roller 141 and the cooling roller 143. At present, it is preferred that the sheet 135 contacts the raw fabric to remain on the raw fabric for between about 0.5 and about 2 seconds, more preferably about 1 second, before passing between the tightening roller 141 and the roller. cooling 143. In this preferred illustrated embodiment, a non-spun polypropylene web 139 is fed from the roll 137, to contact the cooling roller 143 at a point just before the tightening roller 141. As a result, the canvas 139, which will act as a reinforcing fabric in the finished carpet mosaic, is laminated in the raw fabric through the polymer. The pressure between the tightening roller 141 and the cooling roller 143 can be varied depending on the force desired to push the extruded sheet. More preferably, there is an air pressure of 60 psi (0.41 MPa) pushing the rollers together. Also, as described in connection with Figure 2, it may be desirable to include a vacuum groove in the pinch roller. In addition, you can also use a pressurized air jet to push the sheet Extruded to the shallow carpet. The size of the cooling roller 143, and the length of time that the carpet rotates against it, can be varied depending on the level of cooling desired in the process. Preferably, the cooling roller 143 is cooled simply by passing ambient water therethrough. After passing over the cooling roller 143, the carpet is carried over the rollers 145 and 147, with the hair of the carpet towards the rollers. A second extruder 149 extrudes a polymer sheet 153 through its die 151 on the back of the canvas 139. Again, the point at which the extruded sheet 153 contacts the canvas 139 can be varied as described above. At this point, if a secondary backing fabric is desired for the carpet tile, that fabric can be introduced from a roll similar to that shown at 137, to contact and laminate to the carpet through the extruded sheet 153 as passes between the tightening roller 155 and the cooling roller 153. This secondary backing fabric is currently not preferred for the construction of carpet tiles. The carpet passes between the tightening roller 155 and the cooling roller 157. Again, the applied pressure between the two rollers 155 and 157 can be varied. At present, 60 psi (0.41 MPa) of air pressure against the tightening roller 155. After passing around the cooling roller 157, the carpet passes around the roller 159, and is preferably passed over an enhancement roller (not shown) to print a desired pattern on the part back of the carpet. Although the apparatus shown in Figure 7 is preferred for making a carpet tile with two layers of extruded backing and a reinforcing fabric therebetween, the same construction can be made with a single extrusion die, pinch roller, and roller Cooling. In particular, the first extruded backing layer and the reinforcing fabric can be applied in a first pass through the line, after which the carpet is wound. The second layer of extruded backing can be applied on top of the reinforcement fabric in a second pass through the same line, after which the carpet is ready to be cut into carpet tiles. The carpet mosaic is usually made by producing a piece of backed carpet, and then the carpet is cut into squares of the appropriate size. In the United States, the most common size is 18 inches (45.7 centimeters) per side. In the rest of the world, the most common size is 50 centimeters per side. In yet another alternative modality, a pressure sensitive adhesive to the underside of the backed carpet, and a release sheet is included. In this way, a "separate and paste" carpet is produced. This is particularly beneficial when the carpet is going to be cut in mosaics. Examples of suitable pressure sensitive adhesives include ethylene-vinyl acetate copolymers, and substantially linear ethylene polymers formulated with polymeric viscosifiers and waxes. The release sheet can be made of conventional polymers and / or paper products. Preferably, the release sheet makes a polyester / wax formulation. It has been determined that the pressure sensitive adhesive is best applied directly to the adhesive backing material, while the adhesive backing material is still at an elevated temperature from the extrusion coating process. A preferred technique is to laminate by extrusion the pressure sensitive adhesive with the adhesive backing material; that is, apply the pressure sensitive adhesive when tightening. Alternatively, the adhesive backing material may be reheated before the pressure sensitive adhesive is applied. Another preferred embodiment of the present invention, excluding an optional secondary backup material, involves the combination of the different steps of the process described herein, together with the use of at least one substantially linear ethylene polymer with an effective amount of an implosion agent formulated therein in the first layer of a two-layer adhesive backing material. The preferred combination of process steps includes at least precoating with an aqueous polyolefin system; remove the processing materials by washing or scrubbing the raw fabric with an aqueous detergent solution heated to at least 67 ° C; drying and preheating the raw fabric, subjecting it to infrared radiation set at approximately 1,000 ° C for about 1 to about 6 seconds; extrusion coating the adhesive backing material on the back surface of the preheated washed primary backing material, using extrusion melt temperatures greater than or equal to 615 ° F (324 ° C); subjecting the fabric of semi-cast or melted adhesive backing material to a vacuum greater than 40 inches H20 (9.8 Pa) while in the extrusion coating tightening; subjecting the semi-cast or melted adhesive backing material to a positive air pressure device set at more than about 60 psi (0.41 MPa) in the extrusion coating tightening; activate an implosion agent while in the extrusion coating tightening; and soaking the carpet with heat, and soaking the carpet with heat by subjecting it to infrared radiation set at approximately 1,000 ° C for about 1 to about 6 seconds.

Different modalities of the present invention were evaluated, and in specific cases, they were compared with the modalities of the prior art. However, the examples shown should in no way limit the scope of the present invention to these examples.

Examples The primary performance criteria determined for the different examples included: padding link, abrasion resistance, sailboat evaluation, flexibility, and rolling force. The padding bond test was conducted in accordance with ASTM D-1335-67. Modules for the ethylene polymers used in the present invention were measured in accordance with ASTM-790. The abrasion resistance was based on a qualitative test of Velero eraser. In this test, a roll of 2 inches (5.1 centimeters) in diameter and 2 pounds (0.91 kilograms) coated with the side of standard Sailboat loops was passed, 10 times on the face side of coated carpet samples. The eraser on the abraded carpet was then compared to a set of carpet standards, and evaluated on a scale of 1 to 10, where an evaluation of 10 denoted zero erasing. The flexibility assessment was also based on a quantitative evaluation. The rolling force was based on a qualitative manual evaluation, where a good delamination evaluation was given if the different layers of a carpet sample could not be manually separated (i.e., separation of the adhesive backing material from the primary backing material), while a poor evaluation if the layers were delaminated. An Aachen test is used to determine the dimensional stability of the carpet mosaic. The Aachen test used here is the ISO 2551 Test Method. Briefly described, carpet mosaics are first measured in the dimensions of the machine and across the machine, and then exposed to heat (140 ° F (60 ° C) for 2 hours) and humidity (submerged in water for 2 hours). The carpet tiles are dried for 16 hours in a drying oven. The mosaics are then placed in a conditioning room for 48 hours, after which each tile is measured in the machine direction and across the machine. The results are given in terms of a percentage of change from the original dimensions.

Table 1 lists the different ethylene polymers used to prepare the different examples.

Table 1 SLEP denotes a substantially linear ethylene / 1-octene copolymer available from The Dow Chemical Company. HBLEP denotes a homogenously branched linear ethylene polymer such as Exact ™ R resin, available from Exxon Corporation. LLDPE denotes a linear low density ethylene / l-octene copolymer, such as a Dowle resin available from The Dow Chemical Company. ULDPE denotes an ultra-low density / l-octene linear ethylene copolymer, such as an ATTANEMR resin available from The Dow Chemical Company. LDPE denotes a high pressure ethylene homopolymer, such as is available with different polymer manufacturers. HDPE denotes a high density polyethylene resin, as is available with different polymer manufacturers. denotes that the aforementioned polymer is not suitable for use in certain aspetas of the present invention. ND denotes that the value was not determined.

Table 2 summarizes the polymers, extrusion conditions, and performance results of the carpet sample for Examples of Invention 1-8 and Comparative Tests 9-12. The extrusion coating equipment consisted of a Black Extruder co-extrusion line of two extruders equipped with a 3-1 / 2 inch (8.9 cm) diameter primary extruder, with an L / D of 30: 1, and a secondary extruder of 2-1 / 2 inches (6.4 centimeters) in diameter, with an L / D of 24: 1. For these examples, only the large extruder was operated at 90 rpm (113.4 kilograms per hour). A 76-centimeter slot die was attached to the extruder, and edged at 69 centimeters with a 20-mil (0.51-millimeter) die gap, and a 6-inch (15.2 centimeter) air gap / extrac- tion. The pressure of the tightening roller was set at 85 psi (0.58 MPa), and the cooling roller controlled at 60 ° F (15.6 ° C). The target extrusion temperatures, line speed, and coating thicknesses are listed in Table 2. Patches of raw polypropylene fabric were cut. (26 OSY (919.6 cubic centimeters / square meter), quilted, loop pile, with straight stitch raw material available from Shaw Industries under the designation of Volunteer), and laminated on brown paper for each example, and resins candidates were coated by extrusion on the side later of the crude genera. Secondary backing material (2.8 OSY (99 cubic centimeters / square meter), spun polypropylene fabric known as Action BacR available from Amoco Chemical Company, Fabrics and Fibers Division), was added to the back side of the raw fabric after disposal of the Extruded in the die, and before the pressure rollers tighten, to form a laminated structure. Figure 2 shows the extrusion coating method and the application sequence of an adhesive backing material coated by extrusion, followed by the application of an optional secondary backup material. In some cases, the raw-gender patches were first preheated in a convection oven at 200 ° F (93 ° C) for 30 minutes. After the coated samples were aged for 24 hours at room temperature, and with 70 percent relative humidity, the mulch bond, abrasion resistance, and delamination were determined.

Table 2 * denotes example of comparative test; the example is not an example of the present invention. ND denotes that the value was not determined. Examples of the Invention 1 to 8 show that the homogeneously branched ethylene polymers result in carpet samples with good flexibility and good cohesion of the carpet components, and that the binding of the carpet and the abrasion resistance depend on the processing conditions. Two low density, high pressure polyethylenes, a heterogeneously branched linear low density polyethylene, and an extrusion coating of heterogeneously branched ultra-low density polyethylene (Comparative Tests 9 to 12) resulted in relatively stiff carpet samples, and a cohesiveness of the components of the relatively poor carpet.

An indication of the poor component cohesiveness was the relatively low adhesiveness of the backing material to the primary backing material. Another indication was the relatively low penetration of the yarn or fiber bundles with the extrusion coating resins of low density polyethylene, linear low density polyethylene, and ultra-low density polyethylene. Table 3 summarizes the polymers, extrusion conditions, and performance results of the carpet for Examples 13 to 22. These examples used the same extrusion equipment, extrusion conditions, and crude fabrics mentioned for the examples. 1 to 12. Table 3 Examples of Invention 13 to 22 show the effect of the coating thickness and the extrusion temperature on the performance of the underlayer. In certain aspects of the present invention, coating thicknesses greater than 7 thousandths (0.18 millimeters), preferably greater than, or equal to, 11 thousandths (0.27 millimeters), more preferably greater than, or equal to, approximately 15 thousandths (0.38 millimeters), and most preferably greater than, or equal to, 22 mils (0.56 millimeters), are preferred for extrusion melting temperatures greater than 550 ° F (288 ° C), preferably greater than, or equal to, 575 ° F (302 ° C), more preferably greater than, or equal to, 600 ° F (316 ° C), and most preferably greater than, or equal to, 615 ° F (324 ° C). Practitioners will appreciate that the melt temperature of the extrusion and the line speed of the extrusion are inversely related. That is, lower extrusion temperatures will generally require slower extrusion line speeds to achieve good yarn penetration. Practitioners will also appreciate that, at elevated temperatures, thermal stabilization additives, such as Irgano < 1010 and Irgafos "R 168 (both supplied by Ciba-Geigy) to achieve the full benefit of the present invention, such as, for example, a penetration of the adhesive backing material into the yarn or fiber bundles greater than 40 per cent. Practitioners also they will appreciate that an excessive chemical stabilization can adversely affect the extraction performance, and therefore, the selection of the additive and its concentration must be balanced against the extraction requirements and the penetration requirements. However, in general, higher additive concentrations will be required at higher extrusion melting temperatures. Table 4 summarizes the polymers, extrusion conditions, and performance results of the carpet for Examples 23 to 54. In this evaluation, the extrusion coating equipment consisted of a Black Clawson model 435 extruder of 3-1 / 2 inches (8.9 centimeters) in diameter, equipped with a 30: 1 L / D screw, an Electro Flight impulse system of 150 horsepower (311 Joules / hr), a 3-layer Cloreren feed block, and a given Coating Hanger Black Clawson model 300 XLHL 30"externally beard up to 24 inches (61 centimeters), using a die hole of 20 thousandths (0.51 millimeters), and an air gap / extraction of 6 inches (15.2 centimeters). Extrusion temperatures, screw speed, line speed, and target coating thicknesses are listed in Table 4. Polypropylene raw material samples were used (26 OSY (920 cubic centimeters / square meter), ge Cushioned raw, loop hair, stitch straight supplied by Shaw Industries under the designation of Volunteer). The candidate ethylene polymers were extrusion coated on the back side of raw fabrics which were continuously passed through the coater by extrusion, instead of being slickly laminated as patches of individual raw fabrics. Gas-fired electric and infrared heaters were installed before the coating station to pre-heat the raw goods. A vacuum vacuum pressure roller with a vacuum section of 45 ° was installed and joined to a variable vacuum pump. The vacuum section was placed at the contact point of the extrudate and the raw fabrics. The pressure of the tightening roller was set at 80 psi (5.6 kg / cm), and the cooling roller was controlled at 120 ° F (49 ° C). A secondary backing material (2.8 OSY (99 cmJ /) of polypropylene-Yarn or Action Bac available from Amoco Chemical Company, Fabrics and Fibers Division) was added to the back side of the carpet samples after the extrusion arrangement in the die, and before the clamping pressure rollers, to form a laminated structure. After the coated samples were aged for 24 hours at room temperature and with 70 percent relative humidity, the mulch bond, the abrasion resistance, and the delamination resistance were determined.

Table 4 15 fifteen Denotes the Comparative Test Example; the example is not an example of the preferred embodiment of the present invention. ND = the value was not determined.

These examples show that homogenously branched ethylene polymers result in carpet samples with good flexibility and good cohesion of the carpet components, and that the binding strength of the padding and the abrasion resistance depend on the processing conditions. . These examples also show that the improvement in shallow carpet performance can be obtained by utilizing a step of preheating the carpet, an optimized coating thickness, and / or a vacuum pressing pressure process step. The high pressure low density polyethylene extrusion coating resin resulted in a rigid carpet with poor component cohesiveness. Table 5 summarizes the polymers, extrusion conditions, and performance results of the carpet for Examples 55 to 77. These examples employed the same type of extrusion and extrusion conditions mentioned for Examples 23 to 54, with the except that raw nylon fabrics (26 OSY (920 cubic centimeters / square meter), raw quilted, straight-laced, straight-stitch fabrics available from Shaw Industries under the designation of Vocation) were used instead of raw fabrics of polypropylene.

Table 5 15 ND denotes that the value was not determined.

Examples of the Invention 55 to 77 also show that the homogeneously branched ethylene polymers result in carpet samples with good flexibility and good cohesion of the carpet components, and that the binding strength of the carpet and the resistance to The abrasion depends on the processing conditions. As Examples 23 to 53, these examples also show that improvements in shallow carpet performance can be obtained by employing a preheating process step, an optimum coating thickness, and / or a pressing pressure process step of empty. Table 6 summarizes the polymers, extrusion conditions, and performance results of the carpet for Examples 78 to 86. These examples used the same extrusion equipment and extrusion conditions mentioned for Examples 1 to 12, with the Except that raw cross-stitched polypropylene fabrics (20 OSY (707 cubic centimeters / square meter), loop pile padding, available from Shaw Industries under the "Proton" style) were used, instead of the genres of straight stitch.

Table 6 Denotes the Comparative Test Example; the example is not an example of the present invention. ND denotes that the value was not determined Examples of Invention 78 to 83 show that homogeneously branched ethylene polymers result in cross stitch carpet samples with good flexibility and good cohesion of the carpet components. The linear low density polyethylene extrusion coating resin used for Comparative Tests 84 to 86 resulted in rigid cross stitch carpet samples. Table 7 summarizes the polymers, extrusion conditions, and performance results of the carpet for Examples 87 to 90. These examples used the same extrusion equipment and extrusion conditions mentioned for Examples 23 to 54, except that raw polypropylene fabrics were used, ie a 2.750 denier quilted polypropylene yarn at 16 OSY (566 cubic centimeters / square meter) in straight stitch lacing hair, and available from Shaw Industries , under the name of style "Quadratic", instead of the raw polypropylene fabrics. In addition, for Examples 88 to 90, the crude fabrics were coated with an olefinic suspension or emulsion, known as a precoat, prior to extrusion coating. In particular, an aqueous dispersion of polyethylene particles was prepared by weighing 200 parts of water. Next, 0.4 parts of a Ciba surfactant were dispersed Geigy under the designation "Igepal CO-430" in the water, using a high speed homogenizer, at low speed. Then 100 parts of "FN500" from Quantum Chemical were added to the mixture, using medium to high mixing rates for about 5 minutes. After the FN500 was shaken, 0.4 parts of a Lenmar defoamer under the designation "Marfoam" was added to reduce foaming of the mixture. Finally, 2.4 parts of a thickener sold by Sun Chemical International under the designation "Printgum 600M" to the mixture were added. It took a minimum of 10 minutes of mixing after adding this thickener. This dispersion was applied to the back of the primary backrest by conventional elements. In particular, 38 OSY (1,344 cubic centimeters / square meter) were applied, based on the wet dispersion, to the hairless side of the primary backing by a roll-on-roller applicator locking at 10 feet per minute (3.05 meters per minute) . After the dispersion was applied, the carpet was passed directly to the conventional high-speed drying oven. The total residence time in the oven was 5 minutes, and the carpet reached a final temperature of approximately 290 ° F (143 ° C). The observations made before the previous coating was applied, but before the application of an extruded adhesive backing material, showed that the carpet thus produced had a good penetration of bundles and wrap. The measurements showed that 4 and 8 OSY (283 cubic centimeters / square meter) of the FN500, based on dry weight, were added to the carpet backing. Prior to the application of an extruded adhesive backing, the carpet of Examples 88 to 90 was also tested in accordance with the ASTM D-1335 test method, to measure the binding strength of carpet padding (See, 1991, nnnual Book of ASTM Standards, volume 07.01). This test measures the force required to pull one or both legs of a loop on a loop pile mat without the backing. The carpet made in Examples 88 to 90 showed an average quilting bond strength of 9.0 pounds (4.1 kilograms) before the application of the extruded adhesive backing. Example 87 included a previous coating of Adcote 50T4990, a dispersion of ethylene-acrylic acid copolymer available from Morton International, Woodstock, 111., applied at 4 OSY (141.5 cubic centimeters / square meter). No vacuum was applied for these examples.

Table 7 Examples of the Invention 87 to 90 show that homogeneously branched ethylene polymers result in carpet samples with good flexibility and good cohesion of the carpet components, and that the performance of the carpet can be improved by the application of a previous coating. Table 8 summarizes the polymers, the extrusion conditions, and the results for Examples 91 to 96. These examples used the same extrusion equipment and extrusion conditions that are mentioned for Examples 23 to 54, with the exception that They used raw nylon fabrics, that is, a nylon 6 of 3050 denier, quilted at 20 OSY (707 cubic centimeters / square meter), in a loop pile, of straight stitches, and available from Shaw Industries under the name of style " Vanguard ", instead of the straight stitch raw fabrics, and the raw fabrics were coated with an olefinic suspension or emulsion (ie, a precoat) prior to the extrusion coating step. No vacuum was applied for these examples. Previous coatings evaluated included Adcote 50T4990, a dispersion of ethylene-acrylic acid copolymer available from Morton International, Woodstock, 111., and a suspension of low density polyethylene, where, for the latter, previously coated raw fabrics were available. in Shaw Indus-tries under the Vanguard designation. These previous coatings were applied in weights of 4 OSY (141.5 cubic centimeters / square meter) and 8 OSY (283 cubic centimeters / square meter).

Table 8 These Examples show that the homogeneously branched ethylene polymers result in carpet samples with good flexibility and good cohesion of the carpet components, and that the performance of the carpet can be improved by the application of an aqueous precoat. These examples used the same extrusion equipment, extrusion conditions and crude fabrics mentioned for Examples 1 to 12, with the exception that a double-lip or two-station extrusion coating technique was evaluated. In this evaluation, the raw fabrics were first coated by extrusion with one layer at once on the back side of the carpet. This layer was identified as the bottom layer. Once coated, the samples were then coated by extrusion again with another layer, identified as the top layer. Table 9 ND denotes that the value was not determined. Examples of the invention 97 to 109 show that the extrusion in two stations of the homogeneously branched ethylene polymers, results in carpet samples with a good flexibility and a good cohesion of the components of the carpet. The top layer can also contain the components of the carpet. The top layer can also contain fillers or recycled polymer materials to modify the properties or to save costs. Table 10 summarizes the polymers, extrusion conditions, and performance results of the carpet for Examples 110 to 117. These examples used the same extrusion equipment, raw fabrics, and extrusion conditions mentioned for the examples. 1 to 12, with the exception that a one-die coextrusion technique was used. Different candidate ethylene polymers were introduced into both extruders, respectively. Then the ethylene polymers were fed simultaneously into a single die, and coextruded on the back side of the raw genera. The layer extruded on the back side of the carpet (i.e., adjacent to the primary backing material) was identified as the bottom layer, while the outer layer was identified as the top layer. Different thicknesses were evaluated, and different melting temperatures were used.

Table 10 Examples of the invention 110 to 117 show that co-extrusion with a single die of the homogeneously branched ethylene polymers results in carpet samples with good flexibility and cohesion of the carpet components. The top layer may also contain fillers or recycled polymer material to modify the properties or to provide cost savings. As a simulation of extrusion coating, a compression molding method was developed to fuse candidate resin plates on the back side of the raw fabrics. This method employs a programmable press. The following lists the procedure. Granules or ethylene polymer powder were pressed into plates weighing approximately 16 grams, and having a thickness of 0.025 inches (0.64 millimeters). The press used was a Tetrahedron pneumatic programmable press. The granules or the polymer powder were placed between Mylar brand polyester film in the desired plate mold, and preheated for 30 seconds at 374 ° F (190 ° C) (this was done by inserting the samples into the preheated press, and closing the plates enough to allow the heating of the polymer sample without compressing it). After 30 seconds, the plates closed completely, and the Tetrahedron program was started. The program provided two tons (1,814 kilograms) of compression at 374 ° F (190 ° C) for 1.5 minutes, and 50 tons (4.5 x 10 kg) of compression at 100 ° F (38 ° C), cooling for 5 minutes. Once the program was finished, the sample was removed and cooled further. The samples were then stored for later use in a compression lamination step with raw-gender squares. The crude fabrics were cut into squares (slightly larger than the size used to mold the ethylene polymer samples as described above), and compacted onto an insulation board. Then the sample boxes were preheated for 15 minutes in a Hot Pack oven set at 110 ° C. The ethylene polymer plates, as prepared above, were placed on Mylar brand polyester film, and set in the preheated press (374 ° F) (190 ° C) for 5 minutes. The platens of the press were closed enough to preheat the plates without compressing them. The raw-cloth boxes, which had previously been heated for about 5 minutes to about 374 ° F (190 ° C), were then removed from the Hot Pack furnace, and introduced into the press (ie, inverted on the polymer plates). preheated). At the time when the polymer plates and the raw material frames were coupled, approximately 0.1 ton (90.7 kilograms) of force was applied, and then the press was immediately opened. Then he they removed the laminated samples from the press, and allowed them to cool to room temperature. The amount of time required to laminate the raw material and polymer plates by compression was approximately 3 a and seconds. Table 12 gives the molding conditions and performance results for different homogeneously branched substantially linear ethylene polymers.

Table 12 To measure the adhesion of the candidate ethylene polymers to the raw fabric frames, the compression lamination method described for Examples 118 to 122 was used. The separation force was then measured using an Instron set at a head speed crossed by 25 millimeters per minute.

Table 13 gives the adhesion results for different homogeneously branched ethylene polymers, low density and high pressure polyethylene, heterogeneously branched ultra-low density polyethylene, heterogeneously branched linear low density polyethylene, and checkered laminated high density polyethylene. Made from crude polypropylene carpet fabrics.

Table 13 Denotes the Example of the Comparative Test; the example is not an example of the preferred embodiment of the present invention.

These examples show that the homogeneously branched substantially linear ethylene polymers and homogeneously branched linear ethylene polymers provide superior adhesion relative to ordinary polyolefin resins, and as such, result in better performance when used as a material adhesive backing. The interface of the cross section of the carpet sample was captured in photomicrographs using an electron scanning microscope to evaluate the adhesive interaction between different carpet components. Figure 3 is a photomicrograph of the interface cross section of Example 18 at 20x and 50x amplifications. Figure 4 is a photomicrograph of the interface cross section of Example 22 at 20x and 50x amplifications. Although it was found that Example 18 possesses only regular carpet performance, it was found that Example 22 possesses relatively good carpet performance. The best performance of Example 22 is attributed to the best intimate contact between the adhesive backing material and the primary backing material, and to the substantial encapsulation of the fiber bundles due to the better penetration of the beam. The best beam penetration of Example 22 in relation to Example 18 is clearly evident when comparing Figure 3 and Figure 4.

To quantify beam penetration, digital image analysis was performed using a Quantimet 570 imager available from Leica Inc. Deerfield, 111., and running the QUIC Version 2.0 software. The digital images were obtained from an electron scanning microscope through a Sanyo VDC 3860 CCD video camera equipped with a 12.5-75 millimeter Javelin zoom lens. The total cross-sectional area of some fibers was defined by plotting on the digital image, using the binary editing feature of the QUIC software. The empty cross-sectional area (ie, the area without penetration of the backing material) of the beam was determined in the same manner as for the total cross-sectional area. Then the penetration of the beam was calculated as one minus the ratio of the empty areas to the beams. Figure 5 shows the relationship between beam penetration and padding bond strength for nylon and polypropylene carpets. Beam penetrations are required by the extrusion-coated ethylene polymer greater than 40 percent, preferably greater than, or equal to, 60 percent, more preferably greater than, or equal to, 80 percent, and most preferably greater than, or equal to, 90 percent, for good performance of the carpet. Also, Figure 5 indicates that more are required low penetration levels of the fiber bundle for the nylon carpet in order to achieve the same level of abrasion resistance as for the polypropylene carpet. Here, nylon carpet has two important differences in relation to polypropylene carpet. For one, the nylon carpet was washed with a light aqueous detergent solution as part of the dyeing operation. Secondly, the fibers of the nylon carpet are polar, while the fibers of the polypropylene carpet are non-polar. However, the result of Figure 5 of a lower fiber bundle penetration requirement for the nylon carpet is unexpected and surprising, because, although a non-polar adhesive backing material is employed, it appears that a performance of high abrasion more easily with a washed or scrubbed fleece mat (ie, nylon) in relation to the non-fleece mat (ie, polypropylene). Ordinarily, one skilled in the art would expect similar materials to be better attracted to each other, and thus, would require less penetration of the adhesive backing material into the fiber bundles for a given level of abrasion resistance. This result is also surprising, because the homogeneously branched ethylene polymers of U.S. Patent Number 5,395,471 have been shown to exhibit better adhesion to polypropylene substrates, and nevertheless, better results are obtained here for the polypropylene substrates. fibers nylon on polypropylene fibers. These results indicated that the selection of the adhesive backing material for the mechanical bond, and a scrubbing or washing step, can compensate for the lack, or, reduced chemical interactions between the different components of the carpet. To indicate the relative ability of the candidate ethylene polymers to penetrate the yarn or fiber bundles of the carpet at reasonable processing temperatures, and thus provide good performance of the carpet, the temperature test was carried out. solidification. In this test, the candidate ethylene polymers were tested in the Temperature Sweep mode on a Rheometrics 800E Mechanical Spectrometer (S / N 035-014) adapted with a cone / cylinder fitting. The dimensions of the accessory were 52 millimeters (internal diameter of the cup) by 50 millimeters (external diameter of the head) by 17 millimeters (height of the head) by 0.04 millimeters (cone angle).

The gap between the head and the cup was calibrated at 50 microns + 2 microns at room temperature, and with a gap of 0 to 220 ° C. Samples were loaded into the cup, and heated to melt. The gap was set at 50 micras Hh 2 micras as soon as it was pushed into the head. Any excessive amount of samples or overflow was cleaned. The solidification measurement was started when the tool temperature reached 220 ° C. The cup was oscillated at one Hz and with a dynamic tension of 20 percent. The experiment proceeded at a first slow cooling rate from 220 ° C to 110 ° C at a step of 10 ° C. The samples were treated at a second slow cooling rate of 5 ° C / step from 110 ° C to 40 ° C. To prevent any contraction of the fitting, self-tension was applied to maintain normal force slightly above zero. Self-tension was established as: 5 grams (pre-tension), sensitivity of 1 gram, and low limit of 100 dynes / square centimeter (1.02 kilogram-mos / square meter). When the samples solidified, a high torque was suddenly generated. Self-tension was applied to prevent the transducer from being overloaded before the sample solidified completely. Self-tension was established as: maximum applied stress of 100 percent, maximum allowed torque of 100 g-cm, minimum allowed torque of 10 g-cm, and tension adjustment of 50 percent. The entire experiment was conducted in a dry nitrogen environment to minimize sample degradation. Table 14 gives the solidification temperatures for homogeneously branched ethylene polymers and an extrusion coating resin of low density and high pressure polyethylene.

Table 14 Denotes low density polyethylene resin These examples show that the homogeneously branched ethylene polymers have relatively low solidification temperatures, and as such, a better ability to penetrate into the yarns or bundles of carpet fibers, compared to ordinary low density polyethylenes. It is thought that olefin polymers suitable for use in the present invention have solidification temperatures of less than 100 ° C, preferably less than, or equal to, 90 ° C, more preferably less than, or equal to, 85 ° C, and most preferably less than, or equal to, 80 ° C. In certain embodiments of the present invention, the temperature of solidification of the olefin extrusion coating resin, where homogeneously branched ethylene polymers are preferred, ranges from about 65 ° C to about 100 ° C, preferably from about 70 ° C to about 90 ° C C, and more preferably from about 70 ° C to about 85 ° C. In another evaluation, a wet vacuum scrubbing and scrubbing technique was investigated to determine its effect on the performance of the adhesive backing materials of the present invention. The evaluation consisted of two different methods of moisture aspiration. The first moisture aspiration procedure (denoted as Vac # 1 in the table below) consisted of cleaning the back side of the raw genus samples (ie, the side of the primary backing material, oppositely to the side of the fiber face), using a commercial carpet moisture vacuum equipped with a dosing / filling tank, Carpet Cleaning System Rinsevac supplied by Blue Luster Products, Inc., Indianapolis , IN, filled to dose tap water at room temperature as the cleaning solution. When the first moisture aspiration method was used, the raw-gender samples were subjected to two separate moisture-aspiration cleanings, and were completely air-dried after each cleaning. He The second moisture aspiration procedure (denoted as Vac # 2 in the Table below) consisted of cleaning the back side of the raw material samples, using the Carpent Cleaning System Rinsenvac filling to dose a hot aqueous solution (90 °). C) of Professional Carpet Cleaner Rinsenvac diluted as the cleaning solution mixture. The concentration of the cleaning solution for the second moisture aspiration procedure was 10 parts of tap water for one part of Rinsenvac detergent. When the second moisture aspiration method was used, the raw-gender samples were subjected to vacuum cleaning followed by complete air drying, a rinse using water at room temperature, and then a final air-drying step. For each washing procedure, 0.5 gallons (1.9 liters) of cleaning solution was dosed for 5 square yards (4.2 square meters) of raw fabrics. In this evaluation, raw, unwashed (control samples) washed samples were extrusion coated using a single-layer die configuration, although co-extrusion of a single die and double co-extrusion can also be used. lip. Auxiliary equipment included: preheating and heat soaking ovens. The extrusion coating equipment consisted of a Black Clawson coextrusion line of 2 extruders, with a primary extrusion of 3-1 / 2 inches (8.9 centimeters) in diameter, with a L / D of 30: 1, and a secondary extruder of 2-1 / 2 inches ( 6.4 centimeters) in diameter with an L / D of 24: 1. For these examples, only the large extruder was operated at variable speeds. A slot die of 76 centimeters is attached, and it is bearded up to 69 centimeters with a die hole of 20 thousandths (0.51 millimeters), and an air gap / extraction of 6 inches (15.2 centimeters). The pressure of the tightening roller was set at 30 psi (0.2 MPa), and the temperature of the cooling roller was varied. Raw fabrics were Volunteer carpet patches supplied by Shaw Industries. The Volunteer carpet consists of polypropylene fibers at 26 ounces / square yardage (920 cubic centimeters / square meter), and is characterized as a cushioned carpet of single-stitch laces. Both the unwashed and washed raw control gender samples were laminated on to parchment paper during the extrusion coating to apply the adhesive backing material. Both the unwashed control samples and the washed samples were first heated first in a convection oven, before applying the extrusion-coated adhesive backing material. A substantially linear ethylene polymer, designated as XU-59100.00, was used as supplied by The Dow Chemical Company, as the adhesive backing material in this evaluation. The XU-59100.00 is characterized by having a melt index of 30 grams / 10 minutes, and a polymer density of 0.900 grams / cubic centimeter. The measured preheat temperature was set to 160 ° F (71 ° C), the melting temperature of the extrusion coating was set to 500 ° F (260 ° C), the temperature of the quench roll was set to 80 ° F ( 27 ° C), and the line speed of the extrusion coating was set at 85 feet / minute (26 meters / minute). After the extrusion-coated samples were allowed to age for at least 24 hours at room temperature, the mulch bond, the abrasion resistance, and the delamination performance were measured. The padding bond test was conducted in accordance with ASTM D-1335-67. Abrasion resistance results were obtained using a Sailboat test procedure, where a roll of 2 inches (51 millimeters) in diameter, and 2 pounds (0.91 kilograms) was passed, coated with the side of the loops Standard sailboat, 10 times on the side of the coated carpet samples. The lint was then compared on the abraded carpet with a set of carpet standards, and evaluated on a scale of 1 to 10 (denoting 10 zero lint). The abrasion resistance was also quantified using the Insurance Test of Fiber, which is described later in this. In general, if the Sailboat Number was below 6, or the abrasion resistance of the carpet sample was judged poor, the padding links were not measured. The following Table 15 summarizes the results of this evaluation.

Table 15 The results of Table 15 show that, in coating weights of equivalent adhesive backing material, the use of a moisture aspiration process step before the application of the adhesive backing material, can improve in a significant way the performance of the carpet in relation to the samples not washed. The improvement is so dramatic that substantially reduced adhesive backing material coating weights can be used, while maintaining excellent quilting bond and abrasion resistance. In another evaluation, the cushioned raw-gender samples were extrusion coated to evaluate the effect of calcium carbonate as a high-heat-content filler, and a conventional blowing agent (ie, azodicarbonamide), when used as a implosion agent. Calcium carbonate and azodicarbonamide were dry blended with a substantially linear ethylene polymer according to the percentage by weight shown in the Table immediately below. The substantially linear ethylene polymer had a melt index of 30 grams / 10 minutes, and a density of 0.885 grams / cubic centimeter, and was supplied by The Dow Chemical Company under the designation XU-59400.00. The azodicarbonamide implosion agent was Epicell # 301 which was supplied as a 30 weight percent concentrate in low density polyethylene, by EPI Chemical Company. Calcium carbonate, which had a specific heat capacity of approximately 0.548 cal-cc / ° C (2.3 Joules-cm / ° C), was supplied as a 75 percent by weight concentrate in low density polyethylene by Heritage Bag Company. In this evaluation, the raw Volunteer fabrics supplied by Shaw Industries were used. The raw fabrics were polypropylene fibers, carpet patches of 26 ounces / square yard (920 cubic centimeters / square meter), quilted, with laces hair, with a single stitch, which were cut and laminated on brown paper for each sample, such that each exemplary adhesive backing material was extrusion coated on the back side of the carpet (i.e., on the primary backing material of the carpet patches). For each sample, prior to extrusion coating on the adhesive backing material, the raw fabrics were first preheated in a convection oven. In this evaluation, the extrusion coating die configuration was single layer, and the auxiliary equipment included pre-heaters and heat-soaked ovens. Specifically, the extrusion coating equipment consisted of a Black Clawson coextrusion line of two extruders, with a primary extrusion of 3-1 / 2 inches (8.9 centimeters) in diameter, with an L / D of 30: 1, and a secondary extruder 2-1 / 2 inches (6.4 centimeters) in diameter with an L / D of 24: 1. However, in this evaluation, only the large extruder was operated at variable speeds. A 76-centimeter slot die was attached to the extruder, and Bearded up to 69 centimeters with a die hole of 20 thousandths (0.51 millimeters), and an air gap / extraction of 6 inches (15.2 centimeters). The pressure of the tightening roller was set to 30 psi (0.2 MPa), and the temperature of the cooling roller was varied. The preheat temperature of the raw goods was set at 160 ° F (71 ° C), the melting temperature of the extrusion was set at 550 ° F (288 ° C), and the line speed was 75 feet / minute (23 meters / minute). The temperature of the cooling roller was set to 100 ° F (38 ° C) for the sample that did not contain implosion agent, and was established at 70 ° F (21 ° C), for the samples containing the implosion agent. After the extrusion-coated samples were aged for at least 24 hours, they were tested for bonding, abrasion resistance, Velero evaluation, lint evaluation, flexibility, and delamination resistance. The padding bond test was conducted using ASTM D-1335-67. The abrasion resistance and the Sailboat test were based on qualitative tests, where a roll of two inches (51 millimeters) in diameter, and 2 pounds (0.91 kilograms), was coated 10 times, covered with the side of Velero loops standard, on the face side of each of the samples coated by extrusion, to abrade the sample. Then the lint was compared on the abraded folder with a set of standards, and evaluated on a scale of 1 to 10 (denoting 10 zero fluff). To provide quantitative abrasion results, a Fiber Insurance Test was used. In this test, the abrasion resistance value is taken as the "Fiber Insurance Fluff Number". The test involves cutting the abraded fibers with a pair of Fiskars 6"spring loaded scissors, and comparing the sample weights before and after removing the abraded fibers, Specifically, the Fiber Insurance Lint test is performed by providing samples coated by extrusion of 8 inches (203 millimeters) in the transverse direction by 10 inches (254 millimeters) in the direction of the machine, holding the samples in such a way that they remain flat during double lamination, doubly rolling the samples in the direction of the machine 15 times at a constant speed, and at an angle of about 45 °, using the Sailboat roll discussed earlier in this evaluation, using a 2-inch by 2-inch (51-millimeter by 51-millimeter) sample cutter attached to a press perforator certified by National Analytical Equipment Federation (NAEF), to provide two test samples for each sample weighing and recording the sample weights for each sample up to 0.1 milligrams, using a calibrated AE200 scale; carefully removing all the abraded fiber using a pair of scissors loaded with Fiskars 6"spring, while avoiding cutting any part of a fiber loop, reweighing and recording the two test samples, and taking the difference in weight before and after removing the abraded fiber such as the Insurance Fluff Number of Fiber (FLFN) Note that the fiber insurance fluff numbers are inversely related to the Sailboat numbers, that is, although higher Sailboat numbers are desirable as indicative of better abrasion resistance, lower fluff numbers indicate better abrasion resistance Table 16 provides the weight percentage of the additive and the performance results of the carpet.

All examples of this evaluation exhibited good flexibility, and examples with a Sailboat number of at least 6 all exhibited good delamination resistance. Examples where the implosion agent was used had all cells closed and a matrix of collapsed adhesive backing material, i.e. the thickness of the layer of adhesive backing material was approximately equal with and without the implosion agent. Table 16 shows that the use of an implosion agent and a high-heat fill, either separately or in combination, significantly improves both the cushion bond and the abrasion resistance of the carpet covered by extrusion, comparing with a weight of the resin equivalent coating without these additives. Also, Table 16 indicates in a surprising manner that the use of these additives allows to have an improved performance with reduced weights of the coating of the adhesive backing material. In another evaluation, a sample of unmodified control adhesive backing material, and two samples of adhesive backing material modified by the addition of ethylene polymer grafted with maleic anhydride, onto an unpadded raw material, were coated by extrusion, using a single-layer die configuration, although a coextrusion of a single die and a double-lip coextrusion can also be used. The auxiliary equipment included: preheaters and ovens soaked in heat. The extrusion coating equipment consisted of a Black Clawson coextrusion line of two extruders, with a primary extrusion of 3-1 / 2 inches (8.9 centimeters) in diameter, with an L / D of 30: 1, and a secondary extruder 2-1 / 2 inches (6.4 centimeters) in diameter, with an L / D of 24: 1. For these examples, only the large extruder was operated at variable speeds. A slot die of 76 centimeters was added, and it was bearded up to 69 centimeters, with a hole of the die of 20 thousandths (0.51 millimeters), and an air gap / extraction of 6 inches (15.2 centimeters). The pressure of the tightening roller was set at 30 psi (2.1 kg / cm), the temperature of the cooling roller was set at 75 ° F-80 ° F (24 ° C-27 ° C), and the speed of the line of extrusion was 75 feet / minute (23 meters / minute). Prior to the application of the adhesive backing material, the raw fabrics were preheated to approximately 210 ° F (99 ° C) in a convection oven, and the melt temperature of the extrusion was 595 ° F-610 ° F ( 313 ° C-321 ° C). The unmodified control adhesive backing material was a substantially linear ethylene polymer having a melt index of 30 grams / 10 minutes, and a density of 0.885 grams / cubic centimeter, as supplied by The Dow Chemical Company under the designation XU-59400.00. To prepare two adhesive backing materials modified, the XU 59400.00 was mixed dry with 10 weight percent of two different grafts of maleic anhydride / ethylene polymer, each containing 1.0 weight percent maleic anhydride, to give a final concentration of 0.1 per cent. weight percent maleic anhydride for the two mixtures. The grafts themselves were prepared following the procedures described in U.S. Patent No. 4,762,890. A graft designated as MAH-1 in Table 17, used a high density polyethylene as the host ethylene polymer. The other graft, designated as MAH-2 in Table 17 used a substantially linear ethylene polymer as the host ethylene polymer. The raw genera were Vocation 26 carpet patches supplied by Shaw Industries. The Vocation 26 carpet consists of nylon fibers of 26 ounces / square yard (907 cubic centimeters / square meter), and is characterized as a cushioned, loop-like, single-stitch carpet. The raw-gender samples were laminated to brown paper during the extrusion coating to apply the control adhesive backing material and the two modified adhesive backing materials. No secondary backup material was added to the back side of the samples after the application of the adhesive backing materials, although it can also be used.

After the extrusion coated samples were allowed to age for at least 24 hours at room temperature, the mulch bond, the abrasion resistance, and the delamination performance were measured. The padding bond test was conducted in accordance with ASTM D-1335-67. Abrasion resistance results were obtained using the Sailboat test procedure described above, where a roll of 2 inches (51 millimeters) in diameter, and 2 pounds (0.91 kilograms) coated with the side of loops was passed 10 times. of the standard sailboat, on the face side of the covered carpet samples. The lint on the abraded carpet was then compared to a set of carpet standards, and evaluated on a scale of 1 to 10 (denoting 10 zero lint). Abrasion resistance was also quantified using the Fiber Insurance Test described above. In general, if the Sailboat number was below 6, or the abrasion resistance of the carpet sample was judged poor, the padding links were not measured. The following Table 17 summarizes the results of this evaluation.

Table 17 The results of Table 17 show that the incorporation of maleic anhydride-ethylene polymer grafts, where a high density polyethylene (HDPE) is used, or a substantially linear ethylene polymer, such as the host resin, allow Significant improvements in padding bond strength and in comparative abrasion resistance. An advantage of these improvements is that now practitioners can employ reduced weights of the thermoplastic adhesive backing material coating for the purposes of saving costs and still maintaining the desired high performance levels. Example 176 was the same as Example 88 above, except that there was no extruded adhesive backing on the carpet. The carpet thus produced had a good penetration of the beam, and wrapping. The measurements showed that approximately 12 OSY (424 cubic centimeters / square meter) of the FN500, based on dry weight, was added to the carpet backing. The carpet was also tested according to the ASTM D-1335 test method, to measure the binding strength of carpet padding (see, 1991 Jnnual Book of ASTM Standards, volume 07.01). This test measures the force required to pull one or both legs of a loop on a loop pile mat without the backing. The carpet made in Example 176 showed an average quilting bond strength of 9.0 pounds (4.1 kilograms). Example 177 was the same as Example 176, except for the following changes. First, a defoamer was not used in the dispersion. Second, Aerosil A300 from Degussa was added to the dispersion in 0.5 parts. Third, a high density polyethylene from Dow Chemical Co. under the designation DOW 12065 HDPE was used in place of the FN500. Fourth, a surfactant was used under the designation DA-6 of Sun Chemical International instead of CO-430. Finally, the carpet was dried in a Blue M forced air convection oven at 270 ° F (132 ° C) for 30 minutes. The addition for high density polyethylene was 8.6 OSY (304 cubic centimeters / square meter). The average padding bond strength was measured at 4.0 pounds (1.8 kilograms).

Example 178 was the same as Example 177, except that the Aerosil A-300 was removed, and that, instead of the high density polyethylene, an ethylene-vinyl acetate (EVA) polymer was used from Quantum, under the designation FE -532. The addition for the EVA was 10 OSY (354 cubic centimeters / square meter). The average padding bond strength for the resulting carpet was measured at 8.2 pounds (3.7 kilograms). Example 179 was the same as Example 178, except that, instead of the EVA, a Quantum polyethylene was used under the designation MRL-0414. The addition for polyethylene was 3 OSY (106 cubic centimeters / square meter), and the average padding bond strength was measured at 2.3 pounds (1.04 kilograms). Example 180 was the same as Example 177, except that the addition for the FN500 was 5.4 OSY (191 cubic centimeters / square meter). The quilting bond strength was measured at 5.2 pounds (2.4 kilograms). Examples 181 was the same as Example 180, except that, instead of Igepal CO-430, a surfactant was used under the designation OT-75 of Sun Chemical International. The addition for the FN500 was 10.5 OSY (371 cubic centimeters / square meter), and the average padding bond strength of 4.3 pounds (1.95 kilograms). Examples 182-193 were made to demonstrate different secondary backings applied to the carpet made in Example 176. In Example 182, a piece of carpet made in Example 176 received a secondary backing by placing a coextruded ethylene-vinyl acetate / polyethylene sheet from Quantum Chemical Co. under the designation NA202 UE635 on the side. that is not carpet hair. The previously extruded sheet was 23 thousandths (0.58 millimeters) thick. The mat was then placed in a gravity convection oven set at 300 ° F (149 ° C) for 30 minutes, to cause the sheet to melt and bond to the back of the previously coated carpet. Then the carpet was allowed to cool to room temperature. Examples 183-185 were performed as in Example 182, with the exception that the Quantum sheet NA202 UE635 was 35, 37, and 50 thousandths (0.89, 0.94, and 1.3 millimeters) thick, respectively. Example 186 was made by taking the carpet of Example 176, and applying a VAE latex filled with calcium carbonate on the back of the carpet. The mat was then placed in a convection oven by gravity at 300 ° F (149 ° C) for 30 minutes to dry the VAE. The coating weight was about 25 OSY (884 cubic centimeters / square meter), based on dry weight. Example 187 was carried out as in Example 186, except that the latex was a non-filled VAE latex. In In particular, this latex was purchased from Reichold Chemical Co. under the designation Elvace 97808. Example 188 was carried out in the same way as Example 186, except that latex of Styrene-Butadiene rubber (SBR) filled with calcium carbonate was used. , instead of VAE latex. The SBR latex was applied to a coating weight of approximately 25 OSY (884 cubic centimeters / square meter). Example 189 was performed by taking the carpet of Example 176, and spreading an EVA powder over the back of the carpet. In particular, the EVA powder was from DuPont under the designation Elvax 410, and was applied to 10 OSY (354 cubic centimeters / square meter). Example 190 was performed as in Example 189, with the exception that the powder was a polyolefin wax supplied by Hercules under the designation Polywax 2000. Example 191 was made by taking the carpet of Example 176, and applying a melt adhesive in hot compound to the back of the carpet. In particular, the hot melt consisted of filled EVA and Piccovar CB-20 from Hercules, Inc, and was applied to the carpet at 30 OSY (1,061 cubic centimeters / square meter), and at a temperature of approximately 300 ° F (149 ° C). C). Example 192 was performed in the same way as Example 191, with the exception that a urethane foam cushion was laminated backing the carpet through hot melt. In particular, a cushion of polyurethane foam, available from Shaw Industries under the designation Duratech 100, was laminated with hot melt. Example 193 was performed according to the preferred embodiment of the aqueous precoat aspect of the present invention. To a carpet sample of Example 176, a sheet of a polymer was directly extruded on the backside. The polymer used was the polyethylene elastomer provided, designated "G" in Table 1 above. The density of this particular polymer was approximately 0.90 grams / cubic centimeter. The melt index was 75. An ignited infrared heater with Marsden propane was used to preheat the substrate. The heater was set at temperatures between approximately 200 ° F (93 ° C) and approximately 230 ° F (110 ° C). The temperature of the carpet was measured at approximately 145 ° F (63 ° C) at the point just before receiving the extruded sheet. The polymer was extruded to a thickness of 7 mils (0.18 millimeters) using a typical extrusion coating facility used for paper coating. In particular, a typical polyethylene type extruder was used with temperatures of 350 ° F (177 ° C) for the first barrel, 375 ° F (191 ° C) for the second barrel, and 400 ° F (204 ° C) for the remaining barrels, the nozzle, and the extrusion die. The die was a type of slot that extruded a hot polymer curtain over the back of the carpet. Then the carpet was placed around a cooling roller, with the rear parts against the cooling roller, and with a temperature of 120 ° F (49 ° C). The line speed was set at 23 feet per minute (7 meters per minute). The carpet was compressed on the cooling roller with a clamping pressure of 45 psi (0.31 MPa). Although not made in this specifi c example, a fabric can be laminated, such as a polypropylene secondary backing fabric typical of Amoco Fabrics. __ Fibers , p as "ActionBac", through the extruded sheet, just before, or on this cooling roller. Examples 194 to 197 were conducted to make carpet mosaic in accordance with the present invention. Example 194 was made according to the most preferred method for the manufacture of carpet mosaic. A raw cloth 6 feet (1.8 meters) wide on a roll was provided. The raw fabric comprised cushioned polypropylene yarn on a primary non-spun backing obtained at Akzo under the name "Colback" (a mixture of polyamide and polyester polymers) with cut pile, at a face yarn weight of about 45 OSY (1,592 cubic centimeters / square meter). This crude fabric was passed under the extruder at 17 feet per minute (5.2 meters per minute). The extruder contained a molten polymer blend having the following composition: by weight Substantially linear ethylene polymer (Dow XU-59400.00) 24 Polyethylene grafted with maleic anhydride (Dow XU-60769.07) Filled with calcium carbonate (Georgia Marble # 9 59 Viscosante (Hercatac 1148 Hercules) 12 Concentrate black 1 100 The temperature in the die was approximately 500 ° F (260 ° C) Approximately 25 OSY (884 cubic centimeters / square meter) was applied in a first pass, after which A sheet of a reinforcing fabric was spread on top of this first polymer layer The reinforcement fabric in this example was a sheet of 3.5 OSY (124 cubic centimeters / square meter) of Typar (a non-spun polypropylene fabric available from Reemay as "3351") After passing over a cooling roller, the carpet was wound up for a subsequent pass through the line in order to apply a second layer. through the same line, it applied a second layer of the same extrudate on top of the reinforcing sheet. The total addition, not including the Typar was 49.2 OSY (1,740 cubic centimeters / square meter). After cooling, the carpet was cut into 18-inch (45.7 centimeter) mosaics per side, and tested to determine the quilting bond, and the Aachen dimensional stability. The results are shown in the following Table 18. Example 195 was carried out in the same way as Example 194, except that a nylon thread of loops was used for the yarn facing 20 OSY (707 cubic centimeters / square meter), with a straight stitch, and the total addition was 54. 0 OSY (1,910 cubic centimeters / square meter). Example 196 was performed as in Example 195, except that the nylon cord of laces was cushioned to OSY (1,061 cubic centimeters / square meter), with a changed stitch, and the total addition was 52.6 OSY (1,860 cubic centimeters / square meter.) Example 197 was performed as in Example 196, except that the primary backup used was a non-spun polyester fabric sold by Freudenberg as "Lutradur." The total addition was 52.3 OSY (1,850 cubic centimeters / square meter).

TABLE 18 * The thread broke in the padding link test Examples 198 to 208 were conducted to make carpet mosaic with different aggregate weights for the second pass. In addition, two different reinforcement materials were tested. Example 198 was performed as in Example 194 above, with the exception that the extrudate applied in the first pass had the following composition: % by weight Substantially linear ethylene polymer (Dow XU-59400.00) 69 Calcium carbonate filler (Georgia Marble # 9) 30 Black concentrate 1 100 11 OSY (389 cubic centimeters / square meter) of this extrudate were applied to the part posterior of a raw fabric consisting of a polypropylene yarn cushioned a polypropylene primary backing spun at approximately 26 OSY (920 cubic centimeters / square meter) in a pattern of loops. In Examples 198 to 203, a 3.5 OSY Typar fabric (124 cubic centimeters / square meter) was embedded between the first layer of the extrudate and the second. In Examples 204 to 208, a 1.4 OSY (49.5 cubic centimeters / square meter) fiberglass cloth from ELK Corp. was used as the reinforcement layer. In all of Examples 198 to 208, the second extrudate layer, which was placed on top of a second pass through the same line, had the following composition:% by weight Substantially linear ethylene polymer (Dow XU-59400.00) 24 Polyethylene grafted with maleic anhydride (XU-60769.07 from Dow) 4 Calcium carbonate filler (Georgia Marble # 9 59 Viscosante (Hercatac 114876 from Hercules) 12 Black concentrate 1 100 The added weight of the second pass was varied as shown below in Table 19. The carpet was cut in mosaics and underwent the Aachen dimensional stability test with the results noted below. Although the particularly preferred and alternative embodiments have been described herein, it should be noted that other different embodiments and modifications may be made without departing from the scope of the invention described herein. It is the appended claims that define the scope of the patent arising from the present application. Table 19

Claims

1. A carpet comprising a primary backing material having a face and a back side, a plurality of fibers attached to the primary backing material, and extending from the face of the primary backing material, and exposed to the back side of the backing material primary, an adhesive backing material, and an optional secondary backing material adjacent to the adhesive backing material, wherein at least one of the primary backing material, the adhesive backing material, or the optional secondary backing material is comprised of when minus a homogeneously branched ethylene polymer characterized by having a short chain branching distribution index (SCBDI) greater than, or equal to, 50 percent.

2. The carpet of claim 1, wherein the adhesive backing material is comprised of at least one homogeneously branched ethylene polymer.

The carpet of claim 1, wherein the homogeneously branched ethylene polymer comprises ethylene and at least one c-olefin of 3 to 20 carbon atoms.

4. The carpet of claim 3, wherein the homogeneously branched ethylene polymer is a copolymer of ethylene and an α-olefin of 3 to 20 carbon atoms.

5. The carpet of claim 4, wherein the α-olefin of 3 to 20 carbon atoms is selected from the group consisting of propylene, 1-butene, 1-isobutylene, 1-pentene, 1-hexene, 4-methyl -1-pentene, 1-heptene, and 1-octene.

6. The carpet of claim 5, wherein the c-olefin of 3 to 20 carbon atoms is 1-octene.

A method for manufacturing a carpet, the carpet comprising a primary backing material having a face and a back side, a plurality of fibers attached to the primary backing material, and extending from the face of the primary backing material, and exposed on the back side of the primary backing material, an adhesive backing material disposed on the back side of the primary backing material, and an optional secondary backing material adjacent to the backing adhesive material, the method comprising the step of extrusion coating a adhesive backing material or optional secondary backing material on the back surface of the primary backing material, wherein the extrusion-coated adhesive backing material or the optional secondary backing material is comprised of at least one homogeneously branched ethylene polymer, characterized by having a branching distribution index short chain (SCBDI) greater than, or equal to, 50 percent.

8. The method of claim 7, wherein Extrusion coating an adhesive backing material on the back side of the primary backing material.

The carpet of claim 1, wherein the at least one homogeneously branched ethylene polymer is further characterized by having a single differential scanning calorimetry melting peak, DSC, of between -30 ° C and 150 ° C.

10. The carpet of claim 9, wherein the at least one homogeneously branched ethylene polymer is a substantially linear ethylene polymer characterized by having: (a) a melt flow ratio I? O / I2 - 5- ^ 3 , (b) a molecular weight distribution Mw / Mn, determined by gel permeation chromatography, and defined by the equation: (Mw / Mn) < (I10 / I2) = 4.63, and (c) a gas extrusion rheology such that the critical tear rate at the establishment of the surface melt fracture for the substantially linear ethylene polymer is at least 50 percent greater that the critical tear rate upon establishment of the 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 polymer from substantially linear ethylene and the linear ethylene polymer are simultaneously ethylene homopolymers or interpolymers, and at least one α-olefin of 3 to 20 carbon atoms, and have the same I2 and Mw / Mn, and where the critical tear rates of the substantially linear ethylene polymer and the linear ethylene polymer are measured at the same melting temperature, using a gas extrusion rheometer. The carpet of claim 1, wherein at least one homogeneously branched ethylene polymer is a homogeneously branched linear ethylene polymer. The method of claim 7, wherein the at least one homogeneously branched ethylene polymer is further characterized by having a single melting peak of differential scanning calorimetry, DSC, of between -30 ° C and 150 ° C. The method of claim 12, wherein the at least one homogeneously branched ethylene polymer is a substantially linear ethylene polymer characterized by having: (a) a melt flow ratio IJLO I2 - 5.63, (b) a distribution of molecular weight Mw / Mn, determined by gel permeation chromatography, and defined by the equation: (Mw / Mn) < (I10 / I2) = 4.63, and (c) a gas extrusion rheology such that the critical tear rate at the setting of the surface melt fracture for the substantially linear ethylene polymer is at least 50 percent greater that the critical tear rate upon establishment of the 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 polymer substantially linear ethylene and the linear ethylene polymer are simultaneously homopolymers or interpolymers of ethylene, and at least one α-olefin of 3 to 20 carbon atoms, and have the same I2 and Mw / Mn, and wherein the respective critical tear of the substantially linear ethylene polymer and the linear ethylene polymer are measured at the same melting temperature, using a rheometry or gas extrusion. The method of claim 7, wherein the at least one homogeneously branched ethylene polymer is a homogenously branched linear ethylene polymer.