CA1305805C - Composite flooring felt for vinyl flooring containing latexes and an activator and a process for preparing the same - Google Patents
Composite flooring felt for vinyl flooring containing latexes and an activator and a process for preparing the sameInfo
- Publication number
- CA1305805C CA1305805C CA000587860A CA587860A CA1305805C CA 1305805 C CA1305805 C CA 1305805C CA 000587860 A CA000587860 A CA 000587860A CA 587860 A CA587860 A CA 587860A CA 1305805 C CA1305805 C CA 1305805C
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Classifications
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
- D21H17/20—Macromolecular organic compounds
- D21H17/33—Synthetic macromolecular compounds
- D21H17/34—Synthetic macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
- D21H17/41—Synthetic macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds containing ionic groups
- D21H17/44—Synthetic macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds containing ionic groups cationic
- D21H17/45—Nitrogen-containing groups
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
- D04H1/64—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
- D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
- D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
- D06M15/21—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
- D06M15/227—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds of hydrocarbons, or reaction products thereof, e.g. afterhalogenated or sulfochlorinated
- D06M15/233—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds of hydrocarbons, or reaction products thereof, e.g. afterhalogenated or sulfochlorinated aromatic, e.g. styrene
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
- D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
- D06N7/0071—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing
- D06N7/0073—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing the back coating or pre-coat being applied as an aqueous dispersion or latex
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
- D21H17/20—Macromolecular organic compounds
- D21H17/33—Synthetic macromolecular compounds
- D21H17/34—Synthetic macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
- D21H17/37—Polymers of unsaturated acids or derivatives thereof, e.g. polyacrylates
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H23/00—Processes or apparatus for adding material to the pulp or to the paper
- D21H23/02—Processes or apparatus for adding material to the pulp or to the paper characterised by the manner in which substances are added
- D21H23/04—Addition to the pulp; After-treatment of added substances in the pulp
- D21H23/06—Controlling the addition
- D21H23/08—Controlling the addition by measuring pulp properties, e.g. zeta potential, pH
- D21H23/10—Controlling the addition by measuring pulp properties, e.g. zeta potential, pH at least two kinds of compounds being added
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H23/00—Processes or apparatus for adding material to the pulp or to the paper
- D21H23/76—Processes or apparatus for adding material to the pulp or to the paper characterised by choice of auxiliary compounds which are added separately from at least one other compound, e.g. to improve the incorporation of the latter or to obtain an enhanced combined effect
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N2203/00—Macromolecular materials of the coating layers
- D06N2203/04—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
- D06N2203/045—Vinyl (co)polymers
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N2211/00—Specially adapted uses
- D06N2211/06—Building materials
- D06N2211/066—Floor coverings
Landscapes
- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Dispersion Chemistry (AREA)
- General Chemical & Material Sciences (AREA)
- Paper (AREA)
Abstract
The present invention is a composite flooring felt for vinyl flooring containing a blend of latexes and an activator. Also included is a process for preparing the flooring felt composite. The process can additionally contain a wet strength resin and a flocculant. The activator is a poly(dimethyl diallyl ammonium chloride). This composite flooring felt has significantly improved properties over those which do not contain the activator. 35,0$7-F
Description
~30s~3r; ~i , A COMPOSITE FLOORING FELT FOR VINYL
FLOORING CONTAINING LATEXES AND AN
ACTIVATOR AND A PROCESS FOR PREPARING THE SAME
Vinyl flooring has two parts, a vinyl portion and a flooring felt portion (made from fiber, filler and a latex binder). The vinyl contains a plasticizer such as dioctyl phthalate or butyl benzyl phthalate which is necessary to soften the vinyl during processing. The vinyl and plasticizer ara called the plastisol. The consequence i5 the plasticizer weakens the latex in the felt composite when the plastisol is combined with the felt composite.
The plasticizer also weakens the felt composite itself. The hot tensile property (strength of felt composite at high temperatures) is affected by the presence of the plasticizer. The felt composite provides the integrity for the plastisol and, therefore, must remain strong and not stretch during the process of fusion of the vinyl. Fusion occurs when the plastisol which has been contacted with the felt composite is heated at high temperatures. During fusion, the plasticizer penetrates into the vinyl to give the vinyl integrity. The plasticizer also penetrates into the felt composite and increases the flexibility of the felt composite causing undesirable 35,067-F _1_ l30ssas wrinkling and stretching (plasticized elongation) resulting in distorted patterns (misregistration) on the resultant vinyl flooring.
The retention properties and drainage properties of the aqueous dispersion used to make the felt composite must also be within a range to optimize the runnability of the felt composite on common paper-making equipment.
Preparing a felt composite having plasticizer stiffness and reduced elongation as well as improved retention and drainage properties for processing would therefore, be desirable.
According to one aspect of the present invention there is provided a felt composite useful for flooring felt having improved properties for vinyl flooring which comprises:
(a) a first latex polymer selected from the group con-sisting of: an acrylate copolymer; a copolymer of a monovinylidene monomer and an acyclic conjugated diene; and a copolymer of a monovinylidene monomer and an ~,~-ethylenically unsaturated carboxylic acid ester;
(b) a second latex polymer comprising ~,~ -ethylenically unsaturated carboxylic acid monomers and nonionic vinyl monomers wherein the ~,~-ethylenically unsaturated carboxylic acid monomers are present in an amount of from 10 to 50 weight percent based on total monomers of the second latex polymer said first and second latex being present in an amount of at least about 7% bv weight based on the total dry weight of the composite, said first latex ~D
FLOORING CONTAINING LATEXES AND AN
ACTIVATOR AND A PROCESS FOR PREPARING THE SAME
Vinyl flooring has two parts, a vinyl portion and a flooring felt portion (made from fiber, filler and a latex binder). The vinyl contains a plasticizer such as dioctyl phthalate or butyl benzyl phthalate which is necessary to soften the vinyl during processing. The vinyl and plasticizer ara called the plastisol. The consequence i5 the plasticizer weakens the latex in the felt composite when the plastisol is combined with the felt composite.
The plasticizer also weakens the felt composite itself. The hot tensile property (strength of felt composite at high temperatures) is affected by the presence of the plasticizer. The felt composite provides the integrity for the plastisol and, therefore, must remain strong and not stretch during the process of fusion of the vinyl. Fusion occurs when the plastisol which has been contacted with the felt composite is heated at high temperatures. During fusion, the plasticizer penetrates into the vinyl to give the vinyl integrity. The plasticizer also penetrates into the felt composite and increases the flexibility of the felt composite causing undesirable 35,067-F _1_ l30ssas wrinkling and stretching (plasticized elongation) resulting in distorted patterns (misregistration) on the resultant vinyl flooring.
The retention properties and drainage properties of the aqueous dispersion used to make the felt composite must also be within a range to optimize the runnability of the felt composite on common paper-making equipment.
Preparing a felt composite having plasticizer stiffness and reduced elongation as well as improved retention and drainage properties for processing would therefore, be desirable.
According to one aspect of the present invention there is provided a felt composite useful for flooring felt having improved properties for vinyl flooring which comprises:
(a) a first latex polymer selected from the group con-sisting of: an acrylate copolymer; a copolymer of a monovinylidene monomer and an acyclic conjugated diene; and a copolymer of a monovinylidene monomer and an ~,~-ethylenically unsaturated carboxylic acid ester;
(b) a second latex polymer comprising ~,~ -ethylenically unsaturated carboxylic acid monomers and nonionic vinyl monomers wherein the ~,~-ethylenically unsaturated carboxylic acid monomers are present in an amount of from 10 to 50 weight percent based on total monomers of the second latex polymer said first and second latex being present in an amount of at least about 7% bv weight based on the total dry weight of the composite, said first latex ~D
- 2 -~305~3~5 being present in an amount of about 50% to about 90% by weight based on the total weiaht of the first and second latexes; and (c) a poly(dimethyl diallyl ammonium chloride) activating agent of the formula:
~S
N ~ Cl wherein n = 600 - 3500, in an amount sufficient to render improved plasticizer stiffness and elongation to the flooring felt composite, (d) a filler in an amount of at least about 10% by weight based on the total dry weight of composite; and (e) a fiber or fibers in an amount of at lea~t about 5%
by weight based on the total dry weight of composite.
According to a further aspect of the present invention there is provided a process for preparing flooring felt which comprises:
(a) preparing a slurry comprising:
(i) fibers in an amount of from 5 to 75weight percent based on the dry weight of the felt composite;
(ii) a filler in an amount of from 1.0 to 85 weight percent based on the total dry weight of the felt composite;
(iii) a wet strength resin in an amount of from 0 to 1 weight percent of total composite based on dry weight of l~s~r~
6~693-4332 composite; and (iv) an activating agent, poly(dimethyl diallyl ammonium chloride) in an amount sufficient to render improved plasticizer stiffness and elongation to the flooring felt~ said activating agent having the formula:
CH2 ~ C 2 Cl / \
wherein n = 600-3500 (b) adjusting the pH of the slurry to from 6 to 12;
(c) contacting the slurry to form an aqueous dispersion with a blend of a first latex polymer selected from: an acrylate copolymer; a copolymer of a monovinylidene monomer and an acyclic conjugated diene; or a copolymer of a monovinylidene monomer and an ~,~-ethylenically unsaturated carboxylic acid ester; and a second latex polymer comprising ~,~-ethylenically unsaturated carboxylic acid monomers and nonionic vinyl monomers wherein the ~,~-ethylenically unsaturated carboxylic acid monomers are present in an amount of from 10 to 50 weight percent based on total monomers of the second latex polymer, wherein the first and second latexes are present in an amount of from 7 to 25 weight percent of the felt composite, based on the dry weight of the total felt composite said first latex bein~ present in an amount of about 50%
to about 90% by weight based on the total weight of the first and D
~3US~C~5 second latexes;
(d) distributinq and draining the aqueous dispersion on a porous substrate to form a wet web: and (e) drying the web.
According to another aspect of the present invention there is provided a process for preparing flooring felt which comprises:
(a) preparing a slurry comprising:
(i) fibers in an amount of from 5 to75 weight percent based on the dry weight of the felt composlte;
(ii) a filler in an amount of from 10 to 85 weight percent based on the total dry weight of the felt composite;
(iii) a wet strength resin in an amount of from 0 to 1 weight percent of total composite based on dry weight of composite;
(iv) an activating agent, poly(dimethyl diallyl ammonium chloride) in an amount sufficient to render improved plasticizer stiffness and elongation to the flooring felt composite, said activating agent having the formula:
~ C~2 ~ C~2 N Cl / \
wherein n = 600 - 3500 B - 5_ ~S8~5 64693-4332 (b! adjusting the pH of the slurry from about 6 to 12;
(c) contacting the slurry to form an aqueous dispersion, with a blend of latex having (i) a first portion of a first latex polymer selected from: an acrylate copolymer; a copolymer of a mono-vinylidene monomer and an acyclic conjugated diene; or a copolymer of a monovinylidene monomer and an ~,~-ethylenically unsaturated carboxylic acid ester;
(ii) a second latex polymer comprising ~,~-ethylenically unsaturated carboxylic acid monomers and nonionic vinyl monomers wherein the ~,~-ethylenically unsaturated carboxylic acid monomers are present in an amount of from 10 to 50 weight percent based on total monomers of the second ~atex polymer; and (iii) a flocculant in an amount of from 0.5 lbs/ton (0.25 g/kg) solids to 6 lbs/ton (3 g/kg) solids based on the dry weight of the total felt composite;
~d) contacting the resultant aqueous dispersion with a second portion of the first latex polymer in an amount of from 6 to 70 weight percent of the total amount of first latex added, wherein the tota~ amount of latex present in the felt composite is in an amount of from 7 to 25 weight percent of the felt composite, based on the dry weight of the total felt composite and said ; first latex being present in an amount of about 50% to about 90%
by weight based on the total weight of the first and second latexes;
.
~3~5~5 ~ e~ distributing and draining the aqueous dispersion on a porous substrate to form a wet web; and (f) drying the web.
Yet another aspect of the present invention is the further addition of a flocculant to the aqueous dispersion to colloidally destabilize the resultant mixture to form a fibrous agglomerate in aqueous suspension which improves processing properties such as retention and drainage.
Still another aspect of the present invention is the order of latex addition to the felt composite slurry. The preferred order of addition results in improved retention proper-ties and drainage properties of the wet web used to make the felt composite whiGh optimizes the runnability of the wet web on common paper-making equipment.
A. The Filler The flooring felt of the present invention will con-tain conventional fillers known to one skilled in the art.
Typical~y such fillers are finely-divided essentially water-insoluble inorganic materials. Such materials include, for example, talc, calcium carbonate, clay, titanium dioxide, amorphous silica, zinc oxide, barium sulfate, calcium sulfate, aluminum silicate, magnesium silicate, diatomaceous earth, aluminum trihydrate, magnesium carbonate, partially calcined dolomitic limestone, magnesium hydroxide and mixtures of two or more of such materials.
The filler is added in an amount of from 10 to - 85 weight percent based on the total dry weight of the . ~
`:
13Q'~S
felt composite. Preferably, the filler is added in an amount of from 60 to 75 weight percent based on the total dry weight of the felt composite.
B. The Fiber The fiber is any water-insoluble, natural or synthetic water-dispersible fiber or blend of such fibers. Usually water-dispersibility is provided by a small amount of ionic or hydrophilic groups or charges which are of insufficient magnitude to provide water-solubility. Either long or short fibers, or mixtures thereof, are useful, but short fibers are preferred. Many of the fibers from natural materials are anionic, e.g.S wood pulp. Some of the synthetic fibers are treated to make them slightly ionic, i.e., anionic or cationic. Glass fibers, chopped glass, blown glass, reclaimed waste papers~ cellulose from cotton and linen rags, mineral wool, synthetic wood pulp such as is made from polyethylene, polypropylene, straws, ceramic fiber, nylon fiber, polyester fiber, and similar materials are useful.
Particularly useful fibers are the cellulosic and lignocellulosic fibers commonly known as wood pulp of the various kinds from hardwood and softwood such as stone ground wood, steam-heated mechanical pulp, chemomechanical pulp, semichemical pulp and chemical pulp. Specific examples are unbleached sulfite pulp, bleached sulfite pulp, unbleached sulfate pulp and
~S
N ~ Cl wherein n = 600 - 3500, in an amount sufficient to render improved plasticizer stiffness and elongation to the flooring felt composite, (d) a filler in an amount of at least about 10% by weight based on the total dry weight of composite; and (e) a fiber or fibers in an amount of at lea~t about 5%
by weight based on the total dry weight of composite.
According to a further aspect of the present invention there is provided a process for preparing flooring felt which comprises:
(a) preparing a slurry comprising:
(i) fibers in an amount of from 5 to 75weight percent based on the dry weight of the felt composite;
(ii) a filler in an amount of from 1.0 to 85 weight percent based on the total dry weight of the felt composite;
(iii) a wet strength resin in an amount of from 0 to 1 weight percent of total composite based on dry weight of l~s~r~
6~693-4332 composite; and (iv) an activating agent, poly(dimethyl diallyl ammonium chloride) in an amount sufficient to render improved plasticizer stiffness and elongation to the flooring felt~ said activating agent having the formula:
CH2 ~ C 2 Cl / \
wherein n = 600-3500 (b) adjusting the pH of the slurry to from 6 to 12;
(c) contacting the slurry to form an aqueous dispersion with a blend of a first latex polymer selected from: an acrylate copolymer; a copolymer of a monovinylidene monomer and an acyclic conjugated diene; or a copolymer of a monovinylidene monomer and an ~,~-ethylenically unsaturated carboxylic acid ester; and a second latex polymer comprising ~,~-ethylenically unsaturated carboxylic acid monomers and nonionic vinyl monomers wherein the ~,~-ethylenically unsaturated carboxylic acid monomers are present in an amount of from 10 to 50 weight percent based on total monomers of the second latex polymer, wherein the first and second latexes are present in an amount of from 7 to 25 weight percent of the felt composite, based on the dry weight of the total felt composite said first latex bein~ present in an amount of about 50%
to about 90% by weight based on the total weight of the first and D
~3US~C~5 second latexes;
(d) distributinq and draining the aqueous dispersion on a porous substrate to form a wet web: and (e) drying the web.
According to another aspect of the present invention there is provided a process for preparing flooring felt which comprises:
(a) preparing a slurry comprising:
(i) fibers in an amount of from 5 to75 weight percent based on the dry weight of the felt composlte;
(ii) a filler in an amount of from 10 to 85 weight percent based on the total dry weight of the felt composite;
(iii) a wet strength resin in an amount of from 0 to 1 weight percent of total composite based on dry weight of composite;
(iv) an activating agent, poly(dimethyl diallyl ammonium chloride) in an amount sufficient to render improved plasticizer stiffness and elongation to the flooring felt composite, said activating agent having the formula:
~ C~2 ~ C~2 N Cl / \
wherein n = 600 - 3500 B - 5_ ~S8~5 64693-4332 (b! adjusting the pH of the slurry from about 6 to 12;
(c) contacting the slurry to form an aqueous dispersion, with a blend of latex having (i) a first portion of a first latex polymer selected from: an acrylate copolymer; a copolymer of a mono-vinylidene monomer and an acyclic conjugated diene; or a copolymer of a monovinylidene monomer and an ~,~-ethylenically unsaturated carboxylic acid ester;
(ii) a second latex polymer comprising ~,~-ethylenically unsaturated carboxylic acid monomers and nonionic vinyl monomers wherein the ~,~-ethylenically unsaturated carboxylic acid monomers are present in an amount of from 10 to 50 weight percent based on total monomers of the second ~atex polymer; and (iii) a flocculant in an amount of from 0.5 lbs/ton (0.25 g/kg) solids to 6 lbs/ton (3 g/kg) solids based on the dry weight of the total felt composite;
~d) contacting the resultant aqueous dispersion with a second portion of the first latex polymer in an amount of from 6 to 70 weight percent of the total amount of first latex added, wherein the tota~ amount of latex present in the felt composite is in an amount of from 7 to 25 weight percent of the felt composite, based on the dry weight of the total felt composite and said ; first latex being present in an amount of about 50% to about 90%
by weight based on the total weight of the first and second latexes;
.
~3~5~5 ~ e~ distributing and draining the aqueous dispersion on a porous substrate to form a wet web; and (f) drying the web.
Yet another aspect of the present invention is the further addition of a flocculant to the aqueous dispersion to colloidally destabilize the resultant mixture to form a fibrous agglomerate in aqueous suspension which improves processing properties such as retention and drainage.
Still another aspect of the present invention is the order of latex addition to the felt composite slurry. The preferred order of addition results in improved retention proper-ties and drainage properties of the wet web used to make the felt composite whiGh optimizes the runnability of the wet web on common paper-making equipment.
A. The Filler The flooring felt of the present invention will con-tain conventional fillers known to one skilled in the art.
Typical~y such fillers are finely-divided essentially water-insoluble inorganic materials. Such materials include, for example, talc, calcium carbonate, clay, titanium dioxide, amorphous silica, zinc oxide, barium sulfate, calcium sulfate, aluminum silicate, magnesium silicate, diatomaceous earth, aluminum trihydrate, magnesium carbonate, partially calcined dolomitic limestone, magnesium hydroxide and mixtures of two or more of such materials.
The filler is added in an amount of from 10 to - 85 weight percent based on the total dry weight of the . ~
`:
13Q'~S
felt composite. Preferably, the filler is added in an amount of from 60 to 75 weight percent based on the total dry weight of the felt composite.
B. The Fiber The fiber is any water-insoluble, natural or synthetic water-dispersible fiber or blend of such fibers. Usually water-dispersibility is provided by a small amount of ionic or hydrophilic groups or charges which are of insufficient magnitude to provide water-solubility. Either long or short fibers, or mixtures thereof, are useful, but short fibers are preferred. Many of the fibers from natural materials are anionic, e.g.S wood pulp. Some of the synthetic fibers are treated to make them slightly ionic, i.e., anionic or cationic. Glass fibers, chopped glass, blown glass, reclaimed waste papers~ cellulose from cotton and linen rags, mineral wool, synthetic wood pulp such as is made from polyethylene, polypropylene, straws, ceramic fiber, nylon fiber, polyester fiber, and similar materials are useful.
Particularly useful fibers are the cellulosic and lignocellulosic fibers commonly known as wood pulp of the various kinds from hardwood and softwood such as stone ground wood, steam-heated mechanical pulp, chemomechanical pulp, semichemical pulp and chemical pulp. Specific examples are unbleached sulfite pulp, bleached sulfite pulp, unbleached sulfate pulp and
3 bleached sulfate pulp.
Cellulose, fiberglass, polyester, polyethylene and polypropylene are preferred fibers included in the felt composite. The fibers are typically included in 35,067-F -8-13n~
an amount o~ from 5 to 75 weight percent based on the dry weight of the felt composite.
C. The First Latex Polymer (i) The First Latex Polymer comPrisin~ a Monovinylidene Monomer and an Acyclic Aliphatic Conju~ated Diene Monomer The Monovinylidene Monomer The term "monovinylidene monomer" is intended to include those monomers wherein a radical of the formula:
R
CH2=C-(wherein R is hydrogen or a lower alkyl such as an alkyl having from 1 to 4 carbon atoms) is attached directly to an aromatic nucleus containing from 6 to 10 carbon atoms, including those wherein the aromatic nucleus is substituted with alkyl or halogen substituents. Typical of these monomers are styrene, ~-methylstyrene, ortho-, meta- and para-methylstyrer.e;
ortho-, meta- and para-ethylstyrene;
o,p-dimethylstyrene; o,p-diethylstyrene;
isopropylstyrene; o-methyl-p-isopropylstyrene;
p-chlorostyrene; p-bromostyrene; o,p-dichlorostyrene;
o,p-dibromostyrene; vinylnaphthalene; diverse vinyl (alkylnaphthalenes) and vinyl (halonaphthalenes) and 3 comonomeric mixtures thereof.
The monovinylidene monomer can be present in an amount of from 20 to 80 weight percent based on the weight of the first latex copolymer. Preferably, monovinylidene monomer is present in an amount of from 35,067-F -9-13CtS~3~5 40 to 60 weight percent based on the weight of the first latex copolymer.
The Acyclic Aliphatic_Coniu~ated Diene Monomer "Acyclic aliphatic conjugated dienes" usefully employed herein include typically those compounds which have from 4 to 9 carbon atoms~ for example, 1,3-butadiene, 2-methyl-1,3-butadiene; 2,3-dimethyl--1,3-butadiene; pentadiene; 2-neopentyl-1,3-butadiene and other hydrocarbon analogs of 2,3-butadienes, such as 2-chloro-1,3-butadiene; 2-cyano-1,3-butadiene, the substituted straight chain conjugated pentadienes, the straight chain and branched chain conjugated hexadienes, other straight and branched chain conjugated dienes having from 4 to 9 carbon atoms, and comonomeric mixtures thereof. The 1,3-butadiene hydrocarbon monomers, such as those mentioned hereinbefore, provide interpolymers having particularly desirable properties and are therefore preferred. The co~t, ready availability and the excellent properties of interpolymers produced therefrom makes 1,3-butadiene the most preferred acyclic aliphatic conjugated diene.
The conjugated diene can be present in an amount of from 80 to 20 weight percent based on the weight of the first latex copolymer. Preferably the conjugated diene is present in an amount of from 40 to 50 weight percent based on the weight of the first latex copolymer.
An ~ ethylenically unsaturated carboxylic acid may also be incorporated. Such ~,~-ethylenically unsaturated carboxylic acid~ include compositions of the formula:
35,067-F -10-13t~
RCH-C-COOH
wherein R is H and R' i3 H, C1-C4 alkyl, or -CH2COOX;
~ is -COOX and R' is H or -CH2COOX; or~
R is CH3 and R' is H; and X is H or C1-C4 alkyl.
Suitable ~9~-ethylenically unsaturated aliphatic carboxylic acids are monoethylenically unsaturated monocarboxylic, dicarboxylic and tricarboxylic acids having the ethylenic unsaturation alpha-beta to at least one of the carboxyl groups and similar monomers having a higher number of carboxyl groups. It is understood that the carboxyl groups may be present in the acid or salt form (-COOM in which M
represents hydrogen or a metal, such as for example, sodium or potassium) and are readily interconvertible by well known simple procedures.
Specific examples of the ~,~-ethylenically unsaturated aliphatic carboxylic acids are acrylic acid, methacrylic acid, fumaric acid, itaconic acid, maleic acid, aconitic acid, various ~-substituted acrylic acids such as ~-ethacrylic acid, ~-propyl acrylic acid and ~-butyl acrylic acid.
The latex polymer comprising a monovinylidene 3 monomer and an acyclic conjugated diene can be present in an amount of from 60 to 90 weight percent based on the weight of the total latex present in the felt composite and preferably is present in an amount of 70 weight percent based on total latex present in the felt composite.
, 35,067-F -11-13~80~i (ii) The First Latex Polymer Comprisin~ a Monovin~lidene and an Ester of an a,~-Ethylenically Unsaturated CarboxYlic Acid The first latex polymer can also suitably comprise a copolymer of a monovinylidene as defined herein above and an ester of an ~ ethylenically unsaturated carboxylic acid as defined herein below.
An ~ ethylenically unsaturated carboxylic acid termonomer can also be incorporated into the latex 0 copolymer.
(iii) The First Latex Polvmer Comprisin~ Acrylates The first latex polymer can also be selected from acrylates which includes monomers of the acrylate or methacrylate type. Additionally, the acrylates can include acids, esters, amides, and substituted derivatives thereof. Generally, the preferred acrylates are C1 -C8 alkyl acrylates or methacrylates.
Examples of such acrylates include butyl acrylate,
Cellulose, fiberglass, polyester, polyethylene and polypropylene are preferred fibers included in the felt composite. The fibers are typically included in 35,067-F -8-13n~
an amount o~ from 5 to 75 weight percent based on the dry weight of the felt composite.
C. The First Latex Polymer (i) The First Latex Polymer comPrisin~ a Monovinylidene Monomer and an Acyclic Aliphatic Conju~ated Diene Monomer The Monovinylidene Monomer The term "monovinylidene monomer" is intended to include those monomers wherein a radical of the formula:
R
CH2=C-(wherein R is hydrogen or a lower alkyl such as an alkyl having from 1 to 4 carbon atoms) is attached directly to an aromatic nucleus containing from 6 to 10 carbon atoms, including those wherein the aromatic nucleus is substituted with alkyl or halogen substituents. Typical of these monomers are styrene, ~-methylstyrene, ortho-, meta- and para-methylstyrer.e;
ortho-, meta- and para-ethylstyrene;
o,p-dimethylstyrene; o,p-diethylstyrene;
isopropylstyrene; o-methyl-p-isopropylstyrene;
p-chlorostyrene; p-bromostyrene; o,p-dichlorostyrene;
o,p-dibromostyrene; vinylnaphthalene; diverse vinyl (alkylnaphthalenes) and vinyl (halonaphthalenes) and 3 comonomeric mixtures thereof.
The monovinylidene monomer can be present in an amount of from 20 to 80 weight percent based on the weight of the first latex copolymer. Preferably, monovinylidene monomer is present in an amount of from 35,067-F -9-13CtS~3~5 40 to 60 weight percent based on the weight of the first latex copolymer.
The Acyclic Aliphatic_Coniu~ated Diene Monomer "Acyclic aliphatic conjugated dienes" usefully employed herein include typically those compounds which have from 4 to 9 carbon atoms~ for example, 1,3-butadiene, 2-methyl-1,3-butadiene; 2,3-dimethyl--1,3-butadiene; pentadiene; 2-neopentyl-1,3-butadiene and other hydrocarbon analogs of 2,3-butadienes, such as 2-chloro-1,3-butadiene; 2-cyano-1,3-butadiene, the substituted straight chain conjugated pentadienes, the straight chain and branched chain conjugated hexadienes, other straight and branched chain conjugated dienes having from 4 to 9 carbon atoms, and comonomeric mixtures thereof. The 1,3-butadiene hydrocarbon monomers, such as those mentioned hereinbefore, provide interpolymers having particularly desirable properties and are therefore preferred. The co~t, ready availability and the excellent properties of interpolymers produced therefrom makes 1,3-butadiene the most preferred acyclic aliphatic conjugated diene.
The conjugated diene can be present in an amount of from 80 to 20 weight percent based on the weight of the first latex copolymer. Preferably the conjugated diene is present in an amount of from 40 to 50 weight percent based on the weight of the first latex copolymer.
An ~ ethylenically unsaturated carboxylic acid may also be incorporated. Such ~,~-ethylenically unsaturated carboxylic acid~ include compositions of the formula:
35,067-F -10-13t~
RCH-C-COOH
wherein R is H and R' i3 H, C1-C4 alkyl, or -CH2COOX;
~ is -COOX and R' is H or -CH2COOX; or~
R is CH3 and R' is H; and X is H or C1-C4 alkyl.
Suitable ~9~-ethylenically unsaturated aliphatic carboxylic acids are monoethylenically unsaturated monocarboxylic, dicarboxylic and tricarboxylic acids having the ethylenic unsaturation alpha-beta to at least one of the carboxyl groups and similar monomers having a higher number of carboxyl groups. It is understood that the carboxyl groups may be present in the acid or salt form (-COOM in which M
represents hydrogen or a metal, such as for example, sodium or potassium) and are readily interconvertible by well known simple procedures.
Specific examples of the ~,~-ethylenically unsaturated aliphatic carboxylic acids are acrylic acid, methacrylic acid, fumaric acid, itaconic acid, maleic acid, aconitic acid, various ~-substituted acrylic acids such as ~-ethacrylic acid, ~-propyl acrylic acid and ~-butyl acrylic acid.
The latex polymer comprising a monovinylidene 3 monomer and an acyclic conjugated diene can be present in an amount of from 60 to 90 weight percent based on the weight of the total latex present in the felt composite and preferably is present in an amount of 70 weight percent based on total latex present in the felt composite.
, 35,067-F -11-13~80~i (ii) The First Latex Polymer Comprisin~ a Monovin~lidene and an Ester of an a,~-Ethylenically Unsaturated CarboxYlic Acid The first latex polymer can also suitably comprise a copolymer of a monovinylidene as defined herein above and an ester of an ~ ethylenically unsaturated carboxylic acid as defined herein below.
An ~ ethylenically unsaturated carboxylic acid termonomer can also be incorporated into the latex 0 copolymer.
(iii) The First Latex Polvmer Comprisin~ Acrylates The first latex polymer can also be selected from acrylates which includes monomers of the acrylate or methacrylate type. Additionally, the acrylates can include acids, esters, amides, and substituted derivatives thereof. Generally, the preferred acrylates are C1 -C8 alkyl acrylates or methacrylates.
Examples of such acrylates include butyl acrylate,
4-biphenyl acrylate, hexyl acrylate, tertbutyl acrylate, methylmethacrylate, butylmethacrylate 5 lauryl methacrylate, hexylmethacrylate, isobutylmethyacrylate, and isopropylmethacrylate. The preferred acrylates are butyl acrylate and methylmethacrylate.
D. The Second Latex Polymer Comprisin~ an ~,~-ethylenicallY unsaturated carboxylic acid and suitable nonionic vinyl monomers (i) Carboxylic Acid Monomer The carboxylic acid monomer is typically comprised of a carboxyl containing acrylate which is water-swellable at a pH of at least 6. Representative carboxylic acid monomers is a 10 to 50 weight percent, based on total monomers of the second latex polymer, of 35,067-F -12-13(~S~OS
a C3-Cg ~ ethylenically unsaturated carboxylic acid monomer of the formula:
RCH=C-COOH
wherein R is H and R1 is H, C1-C4 alkyl, or -CH2COOX; R is -COOX and R1 is H or -CH2COOX; or R is CH3 and R1 is H;
and X is H or C1-C4 alkyl.
Acrylic or methacrylic acid or a mixture thereof with itaconic or fumaric acid are preferred, but crotonic and aconitic acid and half esters of these and other polycarboxylic acids, such as maleic acid with C1-C4 alkanols, are also suitable, particularly if used in minor amount in combination with acrylic or methacrylic acid. For most purposes, it is preferable to have at least 10 weight percent, more preferrably 20 weight percent carboxylic acid monomer based on the weight of the second latex copolymer.
(ii) Nonionic Vin~l Monomer To provide the extended polymer backbone for the second latex polymer requires from 50 to 90 weight percent of at least one copolymerizable nonionic C2-C12 ~,~-ethylenically unsaturated monomer selected from the group con~isting of the formula CH2=CYZ
wherein Y is H and Z is -COOR, -C6H4R', CN, Cl, or -CH=CH2;
Y is CH3 and Z is -COOR, -C6H4R', CN or -CH-CH2; or 35,067-F -13-13~
Y and Z are Cl; and R is C1-Cg alkyl or C2-Cg hydroxyalkyl;
R' is H, Cl, Br, or C1-C4 alkyl; and R" is C1-Cg alkyl.
Typical of such monomers are the C1-C8 alkyl and C2-C8 hydroxyalkyl ester of acrylic and methacrylic acid including, for example, ethyl acrylate, ethyl methacrylate, methyl methacrylate, 2-ethylhexyl acrylate, butyl acrylate, butyl methacrylate, 2-hydroxyethyl acrylate, 2-hydroxybutyl methacrylate;
styrene, vinyltoluene, t-butylstyrene, isopropylstyrene, and p-chlorostyrene; vinyl acetate, vinyl butyrate, vinyl caprolate; acrylonitrile~
methacrylonitrile, butadiene, isoprene, vinyl chloride and vinylidene chloride. In practice, a monovinyl ester such as ethyl acrylate or a mixture thereof with styrene,hydroxyethyl acrylate, acrylonitrile 9 vinyl chlroide or vinyl acetate is preferred.
These monomers, of course, must be copolymerizable with the carboxylic acid. Normally from 50 to 90 weight percent, and preferably from 80 weight percent of nonionic vinyl monomer, based on total weight of monomers, is used in preparing the copolymer.
The second latex polymer can comprise from 10 to 50 weight p~rcent based on the weight of the total latex present in the felt composite and preferably comprises from 30 to 40 weight percent based on total latex present in the felt composite. Most preferably the amount of the second latex polymer is 30 weight 35,067-F -14_ ~3t?S~
percent based on the weight of the total latex present in the felt composite.
The amount of total latex present in the felt composite can typically vary from 7 to 25 weight percent of the felt composite, based on the dry weight of the total felt composite. Preferably the amount of total latex present in the felt composite is from 11 to 17 weight percent of the felt composite, based on the dry weight of the total felt composite.
In the preparation of many of the latexes of different compositions useful in the invention, it is advantageous to use a chain transfer agent of known kinds such as, but not restricted to, the various long chain mercaptans, bromoform, and carbon tetrachloride.
E. The Activator The activator is a polydiallyldimethylammon um chloride which is represented by the following formula.
\ S
N Cle wherein n=600-3500. The viscosity at 25C of the activator can be from 100 to 200 CPS (0.1 to 0.2 Pa-s) ; and more preferably the viscosity can be from 600 to 900 CPS (6 to 0.9 Pa-s).
35,067-F -15-The activator is present in the felt composite in an amount sufficient to render improved plasticizer stiffness and elongation to the flooring felt composite. Typically such an amount is from 25 to 60 weight percent based on the weight of the second latex polymer. Preferably, the activator is present in the felt composite in an amount of from 35 to 40 weight percent based on the weight of the second latex polymer. Mo~t preferably, the activator is present in the felt composite in an amount of 37 weight percent based on the weight of the second latex polymer.
F. The PH of the Felt Composite Slurr~
The pH of the felt composite slurry will typically be greater than the swelling point of the second latex polymer. Such a pH will typically be from 6 to 12. Preferably the pH will be from 8 to lO to maximize the plasticized tensile and minimize the plasticized elongation, imparting a strong flooring felt which resists wrinkling and breakage during the process of making the vinyl felt composite flooring.
The pH can be increased by adding an alkaline additive such a~ caustic or sodium carbonate. Sodium carbonate is the preferred additive due to safer handling during production.
G. The Wet-Stren~th Resin To improve the processing properties, a wet-strength resin can be added to the felt composite formulation. Such a wet-strength resin can be any of the conventional wet-strength resins utilized in latex formulation~ such as adipic acid-diethylene triamine-epichlorohydrin.
35,067-F -16-130S8~?5 The wet-strength resin is typically added in an amount of from 0 to 1 weight percent of total composite based on dry weight of composite. More preferably, the wet-strength resin is present in the felt composite in an amount of from 0.05 to 0.5 weight percent of total composite based on dry weight of composite. Most preferably, the wet-strength resin is present in the felt composite in an amount of 0.25 weight percent of total composite based on dry weight of composite.
H. The Flocculant To improve the processing properties a flocculant can be added to the felt composite formulation. Such a flocculant can be any of the conventional flocculants utilized in latex formulations. Representative examples would include:
alum, cationic wet strength resins such as adipic acid--diethylene triamine-epichlorohydrin, or cationic polyacrylamide. Preferably, the flocculant is a cationic polyacrylamide made by reacting acrylamide monomer in an amount of from 75 to 98 weight percent based on total weight of the polymer with a cationic amine or quaternary ammonium compound such as the methyl chloride quaternary compound of dimethyl aminoethyl acrylate or methacrylate.
Typically, the flocculant is added to the felt composite formulation in an amount of from 0.5 lbs/ton (0.25 g/kg) solids to 6 lbs/ton (3 g/kg) solids based on the dry weight of the total felt composite.
Preferably, the amount of flocculant added to the felt composite formulation is 1.5 lbs/ton (0.75 g/kg) solids based on the weight of the total felt composite.
35,067-F -17-13~i8~5 Preparin~ the felt composite The felt composite formulation is typically prepared by making a slurry of the fibers, the fillers, the wet strength resin and the activating agent. The
D. The Second Latex Polymer Comprisin~ an ~,~-ethylenicallY unsaturated carboxylic acid and suitable nonionic vinyl monomers (i) Carboxylic Acid Monomer The carboxylic acid monomer is typically comprised of a carboxyl containing acrylate which is water-swellable at a pH of at least 6. Representative carboxylic acid monomers is a 10 to 50 weight percent, based on total monomers of the second latex polymer, of 35,067-F -12-13(~S~OS
a C3-Cg ~ ethylenically unsaturated carboxylic acid monomer of the formula:
RCH=C-COOH
wherein R is H and R1 is H, C1-C4 alkyl, or -CH2COOX; R is -COOX and R1 is H or -CH2COOX; or R is CH3 and R1 is H;
and X is H or C1-C4 alkyl.
Acrylic or methacrylic acid or a mixture thereof with itaconic or fumaric acid are preferred, but crotonic and aconitic acid and half esters of these and other polycarboxylic acids, such as maleic acid with C1-C4 alkanols, are also suitable, particularly if used in minor amount in combination with acrylic or methacrylic acid. For most purposes, it is preferable to have at least 10 weight percent, more preferrably 20 weight percent carboxylic acid monomer based on the weight of the second latex copolymer.
(ii) Nonionic Vin~l Monomer To provide the extended polymer backbone for the second latex polymer requires from 50 to 90 weight percent of at least one copolymerizable nonionic C2-C12 ~,~-ethylenically unsaturated monomer selected from the group con~isting of the formula CH2=CYZ
wherein Y is H and Z is -COOR, -C6H4R', CN, Cl, or -CH=CH2;
Y is CH3 and Z is -COOR, -C6H4R', CN or -CH-CH2; or 35,067-F -13-13~
Y and Z are Cl; and R is C1-Cg alkyl or C2-Cg hydroxyalkyl;
R' is H, Cl, Br, or C1-C4 alkyl; and R" is C1-Cg alkyl.
Typical of such monomers are the C1-C8 alkyl and C2-C8 hydroxyalkyl ester of acrylic and methacrylic acid including, for example, ethyl acrylate, ethyl methacrylate, methyl methacrylate, 2-ethylhexyl acrylate, butyl acrylate, butyl methacrylate, 2-hydroxyethyl acrylate, 2-hydroxybutyl methacrylate;
styrene, vinyltoluene, t-butylstyrene, isopropylstyrene, and p-chlorostyrene; vinyl acetate, vinyl butyrate, vinyl caprolate; acrylonitrile~
methacrylonitrile, butadiene, isoprene, vinyl chloride and vinylidene chloride. In practice, a monovinyl ester such as ethyl acrylate or a mixture thereof with styrene,hydroxyethyl acrylate, acrylonitrile 9 vinyl chlroide or vinyl acetate is preferred.
These monomers, of course, must be copolymerizable with the carboxylic acid. Normally from 50 to 90 weight percent, and preferably from 80 weight percent of nonionic vinyl monomer, based on total weight of monomers, is used in preparing the copolymer.
The second latex polymer can comprise from 10 to 50 weight p~rcent based on the weight of the total latex present in the felt composite and preferably comprises from 30 to 40 weight percent based on total latex present in the felt composite. Most preferably the amount of the second latex polymer is 30 weight 35,067-F -14_ ~3t?S~
percent based on the weight of the total latex present in the felt composite.
The amount of total latex present in the felt composite can typically vary from 7 to 25 weight percent of the felt composite, based on the dry weight of the total felt composite. Preferably the amount of total latex present in the felt composite is from 11 to 17 weight percent of the felt composite, based on the dry weight of the total felt composite.
In the preparation of many of the latexes of different compositions useful in the invention, it is advantageous to use a chain transfer agent of known kinds such as, but not restricted to, the various long chain mercaptans, bromoform, and carbon tetrachloride.
E. The Activator The activator is a polydiallyldimethylammon um chloride which is represented by the following formula.
\ S
N Cle wherein n=600-3500. The viscosity at 25C of the activator can be from 100 to 200 CPS (0.1 to 0.2 Pa-s) ; and more preferably the viscosity can be from 600 to 900 CPS (6 to 0.9 Pa-s).
35,067-F -15-The activator is present in the felt composite in an amount sufficient to render improved plasticizer stiffness and elongation to the flooring felt composite. Typically such an amount is from 25 to 60 weight percent based on the weight of the second latex polymer. Preferably, the activator is present in the felt composite in an amount of from 35 to 40 weight percent based on the weight of the second latex polymer. Mo~t preferably, the activator is present in the felt composite in an amount of 37 weight percent based on the weight of the second latex polymer.
F. The PH of the Felt Composite Slurr~
The pH of the felt composite slurry will typically be greater than the swelling point of the second latex polymer. Such a pH will typically be from 6 to 12. Preferably the pH will be from 8 to lO to maximize the plasticized tensile and minimize the plasticized elongation, imparting a strong flooring felt which resists wrinkling and breakage during the process of making the vinyl felt composite flooring.
The pH can be increased by adding an alkaline additive such a~ caustic or sodium carbonate. Sodium carbonate is the preferred additive due to safer handling during production.
G. The Wet-Stren~th Resin To improve the processing properties, a wet-strength resin can be added to the felt composite formulation. Such a wet-strength resin can be any of the conventional wet-strength resins utilized in latex formulation~ such as adipic acid-diethylene triamine-epichlorohydrin.
35,067-F -16-130S8~?5 The wet-strength resin is typically added in an amount of from 0 to 1 weight percent of total composite based on dry weight of composite. More preferably, the wet-strength resin is present in the felt composite in an amount of from 0.05 to 0.5 weight percent of total composite based on dry weight of composite. Most preferably, the wet-strength resin is present in the felt composite in an amount of 0.25 weight percent of total composite based on dry weight of composite.
H. The Flocculant To improve the processing properties a flocculant can be added to the felt composite formulation. Such a flocculant can be any of the conventional flocculants utilized in latex formulations. Representative examples would include:
alum, cationic wet strength resins such as adipic acid--diethylene triamine-epichlorohydrin, or cationic polyacrylamide. Preferably, the flocculant is a cationic polyacrylamide made by reacting acrylamide monomer in an amount of from 75 to 98 weight percent based on total weight of the polymer with a cationic amine or quaternary ammonium compound such as the methyl chloride quaternary compound of dimethyl aminoethyl acrylate or methacrylate.
Typically, the flocculant is added to the felt composite formulation in an amount of from 0.5 lbs/ton (0.25 g/kg) solids to 6 lbs/ton (3 g/kg) solids based on the dry weight of the total felt composite.
Preferably, the amount of flocculant added to the felt composite formulation is 1.5 lbs/ton (0.75 g/kg) solids based on the weight of the total felt composite.
35,067-F -17-13~i8~5 Preparin~ the felt composite The felt composite formulation is typically prepared by making a slurry of the fibers, the fillers, the wet strength resin and the activating agent. The
5 pH of the slurry is adjusted to from 6 to 12. The first and second latexes are then combined and added to the slurry to form an aqueous dispersion. The flocculant can then be added to the resultant aqueous dispersion. The aqueous dispersion is then distributed 0 and drained on a porous substrate such as a wire to form a wet web and the web is dried.
Ordinarily, the filler, the water and the latex are added (usually but not necessarily in that order) to the slurry with agitation. At least some required colloidal destabilization can occur simultaneously with the mixing of the fiber, filler and latex either through interaction of the required components or through the concurrent addition of other optional wet-end additives such as those mentioned below. The mechanical shear caused by mixing and by transfer of the materials through the equipment used can cause, or assist in, the destabilization~ An effective and preferred method of carrying out (or completing the carrying out) of the destabilization is the mixing with the other components of a flocculating agent, as described herein above. When used, a flocculant is added so that the destabilization can take place before 3 the distributing and draining step.
The temperature of the process through the step of forming the wet web usually is in the range of from 40F (4.4C) to 130F (54C) although temperatures outside those ranges can be used provided that they are above the freezing point of the aqueous dispersion and 35,067-F -18-_19_ are below the temperature at which the latex polymer being used would soften unduly. Sometimes temperatures above ambient conditions promote ~aster drainage.
A preferred method of preparing the felt composite to optimize the drainage and retention properties of the aqueous dispersion comprises preparing the slurry with the fibers, the fillers, and the wet strength resin; adding the activating agent;
adjusting the pH of the slurry to from 6 to 12; adding from 30 to 94 weight percent of the first latex polymer to the total amount of the second latex polymer to form a blend and adding the blend to the slurry to form an aqueous dispersion; adding the remaining portion of the first latex polymer in an amount of from 6 to 70 weight percent of the total amount of first latex added;
adding a flocculating agent; distributing and draining the aquesous dispersion on a porous substrate such as a wire to form a wet web; and then drying the web.
Also useful in the practice of this invention are small amounts of various other wet-end additives of the types commonly used in paper-making. Such materials include antioxidants, various hydrocarbon and natural waxes, particuarly in the form of anionic or cationic emulsions; cellulose derivatives such as carboxymethylcellulose and hydroxyethyl cellulose;
water-soluble organic dyestuffs, water-insoluble but water-dispersible coloring pigments such as carbon black~ vat colors and sulfur colors; starch, natural gums such as guar gum and locust bean gum, particularly their anionic and cationic derivatives; non-ionic acrylamide polymers; strength improving resins such as melamine-formaldehyde resins, urea-formaldehyde resins and curing agents of various types such as the 3s,067-F _19-~3(~S~3~S
sulfur-containing vulcanizing agents and accessory compounds. Further quantities and/or kinds of anionic or cationic surfactants may also be added in sma]l amounts at various points in the process if desired.
Non-ionic surfactants should be used sparingly, if at all.
Optionally, either internal or external sizing can be employed together with the required features of this invention.
The flooring felt of the present invention is typically prepared by conventional methods such as on a handsheet-forming apparatus or common9 continuous paper-making equipment such as a Fourdrinier machine, a cylinder machine, suction machines such as a Rotaformer, or on millboard equipment. Also suitable for use in the practice of this invention are other well-known modifications of such equipment, for example, a Fourdrinier machine with secondary headboxes or multicylinder machines in which, if desired, different furnishes can be used in the different cylinders to vary the composition and the properties of one or more of the several plies which can comprise a finished board. For further details, reference is made to the general summary of paper and paper making as found in Kirk-Othmer, Encyclopedia of Chemical Technolo~y, Interscience Publishers, Inc., New York, 14 (1967 pages 494-510, with the sheet forming aspect and appropriate equipment therefor being described on pages 505-508.
The densities of the products obtained from the above-described process cover a wide range, such as from 30 pounds per cubic foot to 85 pounds per cubic 35,067-F -20-~3~?S8~
foot (480 to 1400 kg/m3). Since the filler constitutes such a high proportion of the weight of the products, the kind of filler selected for a particular product has considerable effect on the density and other properties of the product.
The thickness of the felt composite which is produced can vary from 15 mils to 60 mils (0.4 to 1.5 mm), the preferred value depending somewhat upon the proposed use. However, the thickness generally is from 20 mils to 35 mils (0.5 to 0.9 mm).
DescriDtion of Test Methods:
Draina~e Rate The Drainage Rate is the time in seconds for the slurry diluted with 15,000 ml of water to drain from a 10 x 12 inch (254 x 304.8 mm) Williams handsheet mold through an 80 mesh (180 ~m) screen.
Room temPerature, tensile and elon~ation Room temperature, tensile and elongation of the felt composite are determined on an Instron using a
Ordinarily, the filler, the water and the latex are added (usually but not necessarily in that order) to the slurry with agitation. At least some required colloidal destabilization can occur simultaneously with the mixing of the fiber, filler and latex either through interaction of the required components or through the concurrent addition of other optional wet-end additives such as those mentioned below. The mechanical shear caused by mixing and by transfer of the materials through the equipment used can cause, or assist in, the destabilization~ An effective and preferred method of carrying out (or completing the carrying out) of the destabilization is the mixing with the other components of a flocculating agent, as described herein above. When used, a flocculant is added so that the destabilization can take place before 3 the distributing and draining step.
The temperature of the process through the step of forming the wet web usually is in the range of from 40F (4.4C) to 130F (54C) although temperatures outside those ranges can be used provided that they are above the freezing point of the aqueous dispersion and 35,067-F -18-_19_ are below the temperature at which the latex polymer being used would soften unduly. Sometimes temperatures above ambient conditions promote ~aster drainage.
A preferred method of preparing the felt composite to optimize the drainage and retention properties of the aqueous dispersion comprises preparing the slurry with the fibers, the fillers, and the wet strength resin; adding the activating agent;
adjusting the pH of the slurry to from 6 to 12; adding from 30 to 94 weight percent of the first latex polymer to the total amount of the second latex polymer to form a blend and adding the blend to the slurry to form an aqueous dispersion; adding the remaining portion of the first latex polymer in an amount of from 6 to 70 weight percent of the total amount of first latex added;
adding a flocculating agent; distributing and draining the aquesous dispersion on a porous substrate such as a wire to form a wet web; and then drying the web.
Also useful in the practice of this invention are small amounts of various other wet-end additives of the types commonly used in paper-making. Such materials include antioxidants, various hydrocarbon and natural waxes, particuarly in the form of anionic or cationic emulsions; cellulose derivatives such as carboxymethylcellulose and hydroxyethyl cellulose;
water-soluble organic dyestuffs, water-insoluble but water-dispersible coloring pigments such as carbon black~ vat colors and sulfur colors; starch, natural gums such as guar gum and locust bean gum, particularly their anionic and cationic derivatives; non-ionic acrylamide polymers; strength improving resins such as melamine-formaldehyde resins, urea-formaldehyde resins and curing agents of various types such as the 3s,067-F _19-~3(~S~3~S
sulfur-containing vulcanizing agents and accessory compounds. Further quantities and/or kinds of anionic or cationic surfactants may also be added in sma]l amounts at various points in the process if desired.
Non-ionic surfactants should be used sparingly, if at all.
Optionally, either internal or external sizing can be employed together with the required features of this invention.
The flooring felt of the present invention is typically prepared by conventional methods such as on a handsheet-forming apparatus or common9 continuous paper-making equipment such as a Fourdrinier machine, a cylinder machine, suction machines such as a Rotaformer, or on millboard equipment. Also suitable for use in the practice of this invention are other well-known modifications of such equipment, for example, a Fourdrinier machine with secondary headboxes or multicylinder machines in which, if desired, different furnishes can be used in the different cylinders to vary the composition and the properties of one or more of the several plies which can comprise a finished board. For further details, reference is made to the general summary of paper and paper making as found in Kirk-Othmer, Encyclopedia of Chemical Technolo~y, Interscience Publishers, Inc., New York, 14 (1967 pages 494-510, with the sheet forming aspect and appropriate equipment therefor being described on pages 505-508.
The densities of the products obtained from the above-described process cover a wide range, such as from 30 pounds per cubic foot to 85 pounds per cubic 35,067-F -20-~3~?S8~
foot (480 to 1400 kg/m3). Since the filler constitutes such a high proportion of the weight of the products, the kind of filler selected for a particular product has considerable effect on the density and other properties of the product.
The thickness of the felt composite which is produced can vary from 15 mils to 60 mils (0.4 to 1.5 mm), the preferred value depending somewhat upon the proposed use. However, the thickness generally is from 20 mils to 35 mils (0.5 to 0.9 mm).
DescriDtion of Test Methods:
Draina~e Rate The Drainage Rate is the time in seconds for the slurry diluted with 15,000 ml of water to drain from a 10 x 12 inch (254 x 304.8 mm) Williams handsheet mold through an 80 mesh (180 ~m) screen.
Room temPerature, tensile and elon~ation Room temperature, tensile and elongation of the felt composite are determined on an Instron using a
6 inch jaw gap (152.4 mm~, crosshead speed of 5 inches/1 minute (1~7 mm/1 minute).
350F (177C) Tensile 350F (177C) Tensile of the felt composite is determined by placing a 30 mil (0.76 mm) thick 1 inch x 9 (25.4 mm x 228.6 mm) inch piece of felt 3 composite into a 350F (177C) heated chamber placed between the jaws of an Instron. After one minute at 350F (177C) the felt composite sample is tested.
Plasticized tensile and elon~ation Plasticized tensile and elongation is determined by soaking 1 inch (25.4 mm) wide strips of 35,067-F -21-13U~ 5 the felt composite in butyl benzyl phthalate for 18 to 24 hours and testing on an Instron.
Plasticized stiffness Plasticized stiffness is determined by soaking 1 1/2 x 2 3/4 inch (38.1 mm x 69.9 mm)samples of the felt composite in butyl benzyl phthalate for 18-24 hours and testing on a Taber stiffness tester.
Retention, percent The materials for the felt composite are added in amounts sufficient to provide felt weighing 45-67g.
Thus, the dry weight of the product also represents the percent retention of solids in the felt.
The invention is further illustrated but is not limited by the following examples wherein all parts and percentages are by weight unless otherwise specified.
ExamPles of Floorin~ felt to be Used in ~inyl Floorin~
Example 1 Into a 2500 ml beaker, was placed 380 cc of 1.2 percent bleached Kraft D~mtar pulp beaten to approximately 500 ml Canadian Standard Freeness (C.S.F.) Then 1000 cc of water at 85F (29.4G) was added. While stirring, the following materials were added- 0.162 grams (5 pounds/ton (2.5 g/kg)) of total solids) Kymene~ 557-H (polyamide epichlorohydrin wet strength resin available from Hercules (wet strength resin); 50 g talc and 2 g of 1/8 inch (3.2 mm) polyester fiber. To this mixture was added 0.75 g (22 pounds/ton (11 g/kg) of total solids)) Age-floc~ WT-40, a poly(dimethyl diallyl ammonium chloride) activator available from CPS Chemical, followed by 0.7 g Na2C03 to adjust the pH of the slurry to 10Ø To this was 35,067-F -22-i3~ 30S
added 1.95 g of a 20/24/56 methacrylic acid/ethyl acrylate/methyl-methacrylate latex and 7.8 g of a 49/50/1 styrene~butadiene/itaconic acid latex. The mixture was stirred for one minute at moderate agitation and a (flocculant) cationic polyacrylamide was added at 0.2 percent concentration until the latex had been completely flocculated (water clear). A 10 inch by 12 inch (254 mm by 304.8 mm) handsheet of this mixture was made using a Williams handsheet mold and dried on a Williams dryer for 20 minutes.
Comparative ExamDle Into a 2500 ml beaker, was placed 380 cc (cm3) of 1.2 percent bleached Kraft domtar pulp beaten to appro,ximately 500 ml C.S.F. and 1000 cc of water at 85F
was added. While stirring, 0.162 g (5 pounds/ton (2.5 g/kg) of total solids)) Kymene3 557-H a polyamide epichlorohydrin wet strength resin available from Hercule ; 0.162 g Alum; 50 g talc and 2 g 1/8 inch (3.2 mm) polyester fiber were added. To this was added 9.75 g of a 70 percent/30 percent blend of 54/45/1 styrene/butadiene/fumaric acid and 79/20/1 styrene/butadiene/fumaric acid. This was mixed for one minute under moderate agitation and then a cationic polyacrylamide flocculant at 0.2 percent concentration was added until the latex had been completely flocculated (water clear). A 10 inch x 12 inch (254 mm x 304.8 mm) handsheet of this mixture was made using a 3 Williams Handsheet mold and dried on a Williams dryer for 20 minutes.
35,067-F -23-'~
13~ 5 --24~
~ ll~r o ~ In ~
o ~ _ ~ ~ ~ _~
~ ~ S ~ C~d ~ Ln C~O C o ~ E~ l o~ ~D
~ ~1 o~c~ C ~ ~
C~d ~ J V~
1~ ~
___ c ~r~ 'a~
~ bO ~ X a) ~ ~d a o. . ~ ~ ~ ~ ~ o ~ ~ ~ o~ ~ E3 ~
:~ 1~ F ~1 CL X X O
O ~ ~
35, 067-F -24-13~
-25~
The data in the Table of Results indicates that the felt composite of the Example having the activator demonstrated significantly improved properties over the felt composite of the Comparative Example made without the activator.
Example 2 (order of addition) A lighter weight (lower caliper) flooring felt was made as in Example 1. Into a 2500 ml beaker was placed 254 ml of a 1.2 percent bleached Kraft domtar pulp beaten to approximately 500 C.S.F~ Then 1000 cc of water was added at 85F (30C). While stirring, 0.11 g (5 lbs/ton of total (2.5 g/kg) solids)) of Kymene~ 557-H, 33.5 g talc and 1.3 g of 1/8 inch (3.2 mm) polyester fibers were added. To this mixture were added 0.46 g (20 lbs/ton of total solids) Age-Floc WT-40, followed by 0.3 g of Na2C03. To the resulting mixture was added 5.5 g of a blend of 40 percent of 20/24/56 methacrylic acid/ethyl acrylate~methyl methacrylate and 60 percent of the 49/50/1 styrene/butadiene/itaconic acid latex. The dispersion was mixed for one minute at 1500 rpm on a Cole Palmer Servodyne electric mixer. Then 1.4 lbs/ton (0.7 g/kg) of total solids of the cationic polyacrylamide was added and the dispersion was mixed for 30 seconds at 1500 rpm. Then 1.1 Grams of the styrene/butadiene/itaconic acid latex was added and the dispersion was mixed for an additional minute at 1500 rpm to simulate the shear encountered in pumping stock on a fourdrinier machine. The percent retention and the drainage rate were then tested.
The percent retention of this Example 2 flooring felt was 93.3 percent and the drainage rate 35,067-F -25-~v~
was 24 seconds. The percent retention was improved over the Example l and comparative Example because the Example 2 sample was mixed at 1500 rpm to simulate the shear encountered in pumping stock on a fourdrinier machine subsequent to percent retention and drainage rate testing. Such shear will cause the percent retention and drainage rate to degrade. Therefore, although the Example 1 and comparative Example retention values from the Table of Results were greater than 97 percent, those values were based on percent retention without shear. The Example 2 retention was 93.3 percent with shear.
3o 35,067-F -26-
350F (177C) Tensile 350F (177C) Tensile of the felt composite is determined by placing a 30 mil (0.76 mm) thick 1 inch x 9 (25.4 mm x 228.6 mm) inch piece of felt 3 composite into a 350F (177C) heated chamber placed between the jaws of an Instron. After one minute at 350F (177C) the felt composite sample is tested.
Plasticized tensile and elon~ation Plasticized tensile and elongation is determined by soaking 1 inch (25.4 mm) wide strips of 35,067-F -21-13U~ 5 the felt composite in butyl benzyl phthalate for 18 to 24 hours and testing on an Instron.
Plasticized stiffness Plasticized stiffness is determined by soaking 1 1/2 x 2 3/4 inch (38.1 mm x 69.9 mm)samples of the felt composite in butyl benzyl phthalate for 18-24 hours and testing on a Taber stiffness tester.
Retention, percent The materials for the felt composite are added in amounts sufficient to provide felt weighing 45-67g.
Thus, the dry weight of the product also represents the percent retention of solids in the felt.
The invention is further illustrated but is not limited by the following examples wherein all parts and percentages are by weight unless otherwise specified.
ExamPles of Floorin~ felt to be Used in ~inyl Floorin~
Example 1 Into a 2500 ml beaker, was placed 380 cc of 1.2 percent bleached Kraft D~mtar pulp beaten to approximately 500 ml Canadian Standard Freeness (C.S.F.) Then 1000 cc of water at 85F (29.4G) was added. While stirring, the following materials were added- 0.162 grams (5 pounds/ton (2.5 g/kg)) of total solids) Kymene~ 557-H (polyamide epichlorohydrin wet strength resin available from Hercules (wet strength resin); 50 g talc and 2 g of 1/8 inch (3.2 mm) polyester fiber. To this mixture was added 0.75 g (22 pounds/ton (11 g/kg) of total solids)) Age-floc~ WT-40, a poly(dimethyl diallyl ammonium chloride) activator available from CPS Chemical, followed by 0.7 g Na2C03 to adjust the pH of the slurry to 10Ø To this was 35,067-F -22-i3~ 30S
added 1.95 g of a 20/24/56 methacrylic acid/ethyl acrylate/methyl-methacrylate latex and 7.8 g of a 49/50/1 styrene~butadiene/itaconic acid latex. The mixture was stirred for one minute at moderate agitation and a (flocculant) cationic polyacrylamide was added at 0.2 percent concentration until the latex had been completely flocculated (water clear). A 10 inch by 12 inch (254 mm by 304.8 mm) handsheet of this mixture was made using a Williams handsheet mold and dried on a Williams dryer for 20 minutes.
Comparative ExamDle Into a 2500 ml beaker, was placed 380 cc (cm3) of 1.2 percent bleached Kraft domtar pulp beaten to appro,ximately 500 ml C.S.F. and 1000 cc of water at 85F
was added. While stirring, 0.162 g (5 pounds/ton (2.5 g/kg) of total solids)) Kymene3 557-H a polyamide epichlorohydrin wet strength resin available from Hercule ; 0.162 g Alum; 50 g talc and 2 g 1/8 inch (3.2 mm) polyester fiber were added. To this was added 9.75 g of a 70 percent/30 percent blend of 54/45/1 styrene/butadiene/fumaric acid and 79/20/1 styrene/butadiene/fumaric acid. This was mixed for one minute under moderate agitation and then a cationic polyacrylamide flocculant at 0.2 percent concentration was added until the latex had been completely flocculated (water clear). A 10 inch x 12 inch (254 mm x 304.8 mm) handsheet of this mixture was made using a 3 Williams Handsheet mold and dried on a Williams dryer for 20 minutes.
35,067-F -23-'~
13~ 5 --24~
~ ll~r o ~ In ~
o ~ _ ~ ~ ~ _~
~ ~ S ~ C~d ~ Ln C~O C o ~ E~ l o~ ~D
~ ~1 o~c~ C ~ ~
C~d ~ J V~
1~ ~
___ c ~r~ 'a~
~ bO ~ X a) ~ ~d a o. . ~ ~ ~ ~ ~ o ~ ~ ~ o~ ~ E3 ~
:~ 1~ F ~1 CL X X O
O ~ ~
35, 067-F -24-13~
-25~
The data in the Table of Results indicates that the felt composite of the Example having the activator demonstrated significantly improved properties over the felt composite of the Comparative Example made without the activator.
Example 2 (order of addition) A lighter weight (lower caliper) flooring felt was made as in Example 1. Into a 2500 ml beaker was placed 254 ml of a 1.2 percent bleached Kraft domtar pulp beaten to approximately 500 C.S.F~ Then 1000 cc of water was added at 85F (30C). While stirring, 0.11 g (5 lbs/ton of total (2.5 g/kg) solids)) of Kymene~ 557-H, 33.5 g talc and 1.3 g of 1/8 inch (3.2 mm) polyester fibers were added. To this mixture were added 0.46 g (20 lbs/ton of total solids) Age-Floc WT-40, followed by 0.3 g of Na2C03. To the resulting mixture was added 5.5 g of a blend of 40 percent of 20/24/56 methacrylic acid/ethyl acrylate~methyl methacrylate and 60 percent of the 49/50/1 styrene/butadiene/itaconic acid latex. The dispersion was mixed for one minute at 1500 rpm on a Cole Palmer Servodyne electric mixer. Then 1.4 lbs/ton (0.7 g/kg) of total solids of the cationic polyacrylamide was added and the dispersion was mixed for 30 seconds at 1500 rpm. Then 1.1 Grams of the styrene/butadiene/itaconic acid latex was added and the dispersion was mixed for an additional minute at 1500 rpm to simulate the shear encountered in pumping stock on a fourdrinier machine. The percent retention and the drainage rate were then tested.
The percent retention of this Example 2 flooring felt was 93.3 percent and the drainage rate 35,067-F -25-~v~
was 24 seconds. The percent retention was improved over the Example l and comparative Example because the Example 2 sample was mixed at 1500 rpm to simulate the shear encountered in pumping stock on a fourdrinier machine subsequent to percent retention and drainage rate testing. Such shear will cause the percent retention and drainage rate to degrade. Therefore, although the Example 1 and comparative Example retention values from the Table of Results were greater than 97 percent, those values were based on percent retention without shear. The Example 2 retention was 93.3 percent with shear.
3o 35,067-F -26-
Claims (8)
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A felt composite useful for flooring felt having improved properties for vinyl flooring which comprises:
(a) a first latex polymer selected from the group consisting of: an acrylate copolymer; a copolymer of a monovinylidene monomer and an acyclic conjugated diene; and a copolymer of a monovinylidene monomer and an .alpha.,.beta.-ethylenically unsaturated carboxylic acid ester;
(b) a second latex polymer comprising .alpha.,.beta.-ethylenically unsaturated carboxylic acid monomers and nonionic vinyl monomers wherein the .alpha.,.beta.-ethylenically unsaturated carboxylic acid monomers are present in an amount of from 10 to 50 weight percent based on total monomers of the second latex polymer said first and second latex being present in an amount of at least about 7% by weight based on the total dry weight of the composite, said first latex being present in an amount of about 50% to about 90% by weight based on the total weight of the first and second latexes; and (c) a poly(dimethyl diallyl ammonium chloride) activating agent of the formula:
wherein n = 600 - 3500, in an amount sufficient to render improved plasticizer stiffness and elongation to the flooring felt composite, (d) a filler in an amount of at least about 10% by weight based on the total dry weight of composite; and (e) a fiber or fibers in an amount of at least about 5% by weight based on the total dry weight of composite.
(a) a first latex polymer selected from the group consisting of: an acrylate copolymer; a copolymer of a monovinylidene monomer and an acyclic conjugated diene; and a copolymer of a monovinylidene monomer and an .alpha.,.beta.-ethylenically unsaturated carboxylic acid ester;
(b) a second latex polymer comprising .alpha.,.beta.-ethylenically unsaturated carboxylic acid monomers and nonionic vinyl monomers wherein the .alpha.,.beta.-ethylenically unsaturated carboxylic acid monomers are present in an amount of from 10 to 50 weight percent based on total monomers of the second latex polymer said first and second latex being present in an amount of at least about 7% by weight based on the total dry weight of the composite, said first latex being present in an amount of about 50% to about 90% by weight based on the total weight of the first and second latexes; and (c) a poly(dimethyl diallyl ammonium chloride) activating agent of the formula:
wherein n = 600 - 3500, in an amount sufficient to render improved plasticizer stiffness and elongation to the flooring felt composite, (d) a filler in an amount of at least about 10% by weight based on the total dry weight of composite; and (e) a fiber or fibers in an amount of at least about 5% by weight based on the total dry weight of composite.
2. The felt composite as claimed in claim 1 further comprising a flocculant.
3. The felt composite as claimed in claim 1 wherein the activating agent is present in an amount of from about 25 to about 60 weight percent based on the weight of the second latex copolymer.
4. The felt composite of claim 2 wherein the flocculant is selected from the group consisting of alum and cationic wet strength resins.
5. The felt composite of claim 4 wherein the flocculant is present in an amount of from about 0.5 lbs/ton (0.25 g/kg) solids to about 6 lbs/ton (3 g/kg) solids based on the weight of the total felt composite.
6. The felt composite of claim 5 wherein the amount of the first latex and the second latex is from about 7 to about 25 weight percent of the dry weight of the felt composite.
7. A process for preparing flooring felt which comprises:
(a) preparing a slurry comprising:
(i) fibers in an amount of from 5 to 75 weight percent based on the dry weight of the felt composite;
(ii) a filler in an amount of from 10 to 85 weight percent based on the total dry weight of the felt composite;
(iii) a wet strength resin in an amount of from 0 to 1 weight percent of total composite based on dry weight of composite; and (iv) an activating agent, poly(dimethyl diallyl ammonium chloride) in an amount sufficient to render improved plasticizer stiffness and elongation to the flooring felt, said activating agent having the formula:
wherein n = 600-3500 (b) adjusting the pH of the slurry to from 6 to 12;
(c) contacting the slurry to form an aqueous dispersion with a blend of a first latex polymer selected from: an acrylate copolymer; a copolymer of a monovinylidene monomer and an acyclic conjugated diene; or a copolymer of a monovinylidene monomer and an .alpha.,.beta.-ethylenically unsaturated carboxylic acid ester; and a second latex polymer comprising .alpha.,.beta.-ethylenically unsaturated carboxylic acid monomers and nonionic vinyl monomers wherein the .alpha.,.beta.-ethylenically unsaturated carboxylic acid monomers are present in an amount of from 10 to 50 weight percent based on total monomers of the second latex polymer, wherein the first and second latexes are present in an amount of from 7 to 25 weight percent of the felt composite, based on the dry weight of the total felt composite said first latex being present in an amount of about 50%
to about 90% by weight based on the total weight of the first and second latexes;
(d) distributing and draining the aqueous dispersion on a porous substrate to form a wet web; and (e) drying the web.
(a) preparing a slurry comprising:
(i) fibers in an amount of from 5 to 75 weight percent based on the dry weight of the felt composite;
(ii) a filler in an amount of from 10 to 85 weight percent based on the total dry weight of the felt composite;
(iii) a wet strength resin in an amount of from 0 to 1 weight percent of total composite based on dry weight of composite; and (iv) an activating agent, poly(dimethyl diallyl ammonium chloride) in an amount sufficient to render improved plasticizer stiffness and elongation to the flooring felt, said activating agent having the formula:
wherein n = 600-3500 (b) adjusting the pH of the slurry to from 6 to 12;
(c) contacting the slurry to form an aqueous dispersion with a blend of a first latex polymer selected from: an acrylate copolymer; a copolymer of a monovinylidene monomer and an acyclic conjugated diene; or a copolymer of a monovinylidene monomer and an .alpha.,.beta.-ethylenically unsaturated carboxylic acid ester; and a second latex polymer comprising .alpha.,.beta.-ethylenically unsaturated carboxylic acid monomers and nonionic vinyl monomers wherein the .alpha.,.beta.-ethylenically unsaturated carboxylic acid monomers are present in an amount of from 10 to 50 weight percent based on total monomers of the second latex polymer, wherein the first and second latexes are present in an amount of from 7 to 25 weight percent of the felt composite, based on the dry weight of the total felt composite said first latex being present in an amount of about 50%
to about 90% by weight based on the total weight of the first and second latexes;
(d) distributing and draining the aqueous dispersion on a porous substrate to form a wet web; and (e) drying the web.
8. A process for preparing flooring felt which comprises:
(a) preparing a slurry comprising:
(i) fibers in an amount of from 5 to 75 weight percent based on the dry weight of the felt composite;
(ii) a filler in an amount of from 10 to 85 weight percent based on the total dry weight of the felt composite;
(iii) a wet strength resin in an amount of from 0 to 1 weight percent of total composite based on dry weight of composite;
(iv) an activating agent, poly(dimethyl diallyl ammonium chloride) in an amount sufficient to render improved plasticizer stiffness and elongation to the flooring felt composite, said activating agent having the formula:
wherein n - 600 - 3500 (b) adjusting the pH of the slurry from about 6 to 12;
(c) contacting the slurry to form an aqueous dispersion, with a blend of latex having (i) a first portion of a first latex polymer selected from: an acrylate copolymer; a copolymer of a monovinylidene monomer and an acyclic conjugated diene; or a copolymer of a monovinylidene monomer and an .alpha.,.beta.-ethylenically unsaturated carboxylic acid ester;
(ii) a second latex polymer comprising .alpha.,.beta.-ethylenically unsaturated carboxylic acid monomers and nonionic vinyl monomers wherein the .alpha.,.beta.-ethylenically unsaturated carboxylic acid monomers are present in an amount of from 10 to 50 weight percent based on total monomers of the second latex polymer; and (iii) a flocculant in an amount of from 0.5 lbs/ton (0.25 g/kg) solids to 6 lbs/ton (3 g/kg) solids based on the dry weight of the total felt composite;
(d) contacting the resultant aqueous dispersion with a second portion of the first latex polymer in an amount of from 6 to 70 weight percent of the total amount of first latex added, wherein the total amount of latex present in the felt composite is in an amount of from 7 to 25 weight percent of the felt composite, based on the dry weight of the total felt composite and said first latex being present in an amount of about 50% to about 90% by weight based on the total weight of the first and second latexes;
(e) distributing and draining the aqueous dispersion on a porous substrate to form a wet web; and (f) drying the web.
(a) preparing a slurry comprising:
(i) fibers in an amount of from 5 to 75 weight percent based on the dry weight of the felt composite;
(ii) a filler in an amount of from 10 to 85 weight percent based on the total dry weight of the felt composite;
(iii) a wet strength resin in an amount of from 0 to 1 weight percent of total composite based on dry weight of composite;
(iv) an activating agent, poly(dimethyl diallyl ammonium chloride) in an amount sufficient to render improved plasticizer stiffness and elongation to the flooring felt composite, said activating agent having the formula:
wherein n - 600 - 3500 (b) adjusting the pH of the slurry from about 6 to 12;
(c) contacting the slurry to form an aqueous dispersion, with a blend of latex having (i) a first portion of a first latex polymer selected from: an acrylate copolymer; a copolymer of a monovinylidene monomer and an acyclic conjugated diene; or a copolymer of a monovinylidene monomer and an .alpha.,.beta.-ethylenically unsaturated carboxylic acid ester;
(ii) a second latex polymer comprising .alpha.,.beta.-ethylenically unsaturated carboxylic acid monomers and nonionic vinyl monomers wherein the .alpha.,.beta.-ethylenically unsaturated carboxylic acid monomers are present in an amount of from 10 to 50 weight percent based on total monomers of the second latex polymer; and (iii) a flocculant in an amount of from 0.5 lbs/ton (0.25 g/kg) solids to 6 lbs/ton (3 g/kg) solids based on the dry weight of the total felt composite;
(d) contacting the resultant aqueous dispersion with a second portion of the first latex polymer in an amount of from 6 to 70 weight percent of the total amount of first latex added, wherein the total amount of latex present in the felt composite is in an amount of from 7 to 25 weight percent of the felt composite, based on the dry weight of the total felt composite and said first latex being present in an amount of about 50% to about 90% by weight based on the total weight of the first and second latexes;
(e) distributing and draining the aqueous dispersion on a porous substrate to form a wet web; and (f) drying the web.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA000587860A CA1305805C (en) | 1989-01-10 | 1989-01-10 | Composite flooring felt for vinyl flooring containing latexes and an activator and a process for preparing the same |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA000587860A CA1305805C (en) | 1989-01-10 | 1989-01-10 | Composite flooring felt for vinyl flooring containing latexes and an activator and a process for preparing the same |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1305805C true CA1305805C (en) | 1992-07-28 |
Family
ID=32996918
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000587860A Expired - Fee Related CA1305805C (en) | 1989-01-10 | 1989-01-10 | Composite flooring felt for vinyl flooring containing latexes and an activator and a process for preparing the same |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA1305805C (en) |
-
1989
- 1989-01-10 CA CA000587860A patent/CA1305805C/en not_active Expired - Fee Related
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