Patent GB-1420007-A (GB)
Title: Composite of fabric with flexible backing
IPC: D06N7/00
Filed: 1973-03-14
Abstract: 1420007 Coated fabric GOODYEAR TIRE & RUBBER CO 14 March 1973 12160/73 Heading B2E [Also in Division Dl] A structure suitable for use as a carpet comprises a yarn tufted through a primary backing of a woven or non woven fabric or film to create yarn bundles on its underside, the yarn bundles being integrally adhered to and at least 90% encapsulated by a surface coating having thickness 10-200 mils of a flexible backsizing and bundle wrap composition adhered to the back of the primary backing, the backsizing composition comprising an inorganic water insoluble granular material of average specific gravity greater than 1 and a particle size of 25-500 U.S. Standard mesh and a flexible cured polyurethane binder, the backsizing composition having an elongation at 25‹C of 200-700% and being deposited by applying a non-Newtonian mixture under s'hear as a topcoat to the back surface of the primary backing and corresponding yarn bundles without striking through the carpet, the mixture comprising 50-400 parts by weight of the granular material per 100 parts by weight of a liquid polyurethane reaction mixture free or containing <5% of volatile solvent and curing the reaction mixture. The liquid polyurethane reaction mixture comprises an organic polyisocyanate content of 2-3 and a liquid polymeric molecular weight of 700-5000 so long as it is liquid selected from polyester polyols, polyether polyols and hydroxyl terminated polymers of conjugated diene-hydrocarbons having a hydroxyl functionality of 2-3, the ratio in the reaction mixture of isocyanato groups to hydroxyl groups of the liquid polymeric reactive hydrogen-containing material being 0.6/ 1-3/1 for the one-shot method and 1.1/1 to 12/1 for the prepolymer method wherein a curative is used with the reaction mixture selected from at least one hydrocarbon diol and/or primary diamine where the ratio of amino groups and/or hydroxyl groups of the curative to isocyanato groups in excess of hydroxyl groups of the liquid polymeric reactive hydrogen-containing material is 0.5/1 to 1.5/1. The non-Newtonian mixture has handling characteristics equivalent to a Newtonian fluid having a viscosity of 2000-10000 centipoises at 25‹C. The backsizing composition may be cellular if water or blowing agents are mixed with the reaction mixture. The textile fibre for the primary backing or for the yarn can be jute; cotton, rayon, polyesters, wool, flax, paper, asbestos, nylon, glass. Suitable plastics films for the primary backing are polypropylene film, preferably used as strips of film interwoven to form a mat. Suitable granular materials are silicates, calcium carbonate, aluminium hydrate, zinc oxide, titanium dioxide, feldspar and barytes. The backsizing composition can be extended with up to 10 parts of an extender oil or wax. In a typical example 8.3 parts of hydrogenated diphenylene methane-4, 4-diisocyanate was added to the mixture of 100 parts polybutadiene polyol, 15 parts titanium dioxide having particle size smaller than 325 mesh, 8 parts zinc oxide having particle size smaller than 100 mesh, and 12 parts calcium carbide having particle size smaller than 100 mesh. The mixture was coated by spreading onto the back of carpet comprising a polyester yarn tufted into a square woven jute fabric backing and the mixture allowed to set and cure.