CA1167591A - Fiber-treating silicone-glycol lubricant copolymer compositioins - Google Patents
Fiber-treating silicone-glycol lubricant copolymer compositioinsInfo
- Publication number
- CA1167591A CA1167591A CA000384987A CA384987A CA1167591A CA 1167591 A CA1167591 A CA 1167591A CA 000384987 A CA000384987 A CA 000384987A CA 384987 A CA384987 A CA 384987A CA 1167591 A CA1167591 A CA 1167591A
- Authority
- CA
- Canada
- Prior art keywords
- carpet
- average value
- backing
- silicone
- fabric
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
Classifications
-
- 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
- D06M15/37—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
- D06M15/643—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds containing silicon in the main chain
- D06M15/647—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds containing silicon in the main chain containing polyether sequences
-
- 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
- D06M7/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made of other substances with subsequent freeing of the treated goods from the treating medium, e.g. swelling, e.g. polyolefins
-
- 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
- D06M2200/00—Functionality of the treatment composition and/or properties imparted to the textile material
- D06M2200/40—Reduced friction resistance, lubricant properties; Sizing compositions
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/647—Including a foamed layer or component
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/681—Spun-bonded nonwoven fabric
Abstract
Abstract of the Disclosure Fiber lubricant compositions having unusual lubricating properties for spunbonded, nonwoven carpet backing are disclosed. A needle-tufted carpet, prepared from a carpet backing bearing a composition of this invention, has unexpectedly high strength and unexpectedly low flammability. The compositions of this invention comprising a mixture of butyl stearate and certain silicone-glycol copolymers, are useful as a lubricant for synthetic fibers, in general.
Description
;7~ ~
-FIBER-TRE~TING SILICO~IE-GLYCOL LUBRICANT COPOLYMER COMPOSITIONS
Back round of the Invention The present invention relates to a fiber lubricant cornposition which is particularly useful for lubricatiny a spunbonded nonwoven fabric and to fibers and fabrics having said lubricant composition thereon.
More specifically the fiber lubricant composition of this invention consists essentially of a synergistic mixture of certain silicone-glycol copolymers and butyl stearate which, when applied to spunbonded nonwoven polypropylen carpet backing, provides unexpectedly good lubrication for needle-tufting of the backing and an unexpectedly low flammability of a tufted carpet produced therefrom.
A spunbonded fabric is a continuous filament nonwoven fabric made by combining all thle steps from polymer preparation to finished fabric in one process.
Curtains of polymer filaments are extruded, drawn, forwarded ~o a belt and combined there into a web wlth the required design. The web is then bonded and can be finished in the same single process.
The basic process steps or making spunbonded nonwoven fabrics are quite simple. Multiple spinnerettes extrude large numbers of polymer filaments which are drawn and oriented in groups, by rolls or by high velocity air, and then projected, in some desired geometrical array, as a web onto a slowly moving porous belt provided with suction to hold the web. The belt then carries the web to a bonding operation such as binder application and/or heater rolling and then to one or more further opera-tional steps in the process. These latter steps can be the traditional textile finishing steps such as prin~ing or embos6ing when process speed6 are compatible.
There are many spunbonded nonwoven fabrics available co~nercially. Examples of such materials are those based on synthetic fibers, such as polyesters, polyamides and polyolefins, such as polypropylene, polyethylene, or combinations of the foregoing. The particular fiber type used will depend on the nature of the finish~d product one wishes to make. End uses for spunbonded nonwoven fabrics ranges from such things as book covers, to clothing fabric to carpet backing.
One of the rnost significant commercial U52S
of spunbonded nonwoven abric is the use of spunbonded nonwoven polypropylene as a carpet backing. rrhe spunbonded nonwoven polypropylene fabric haa been substituted for ~he woven jute backing materials that have been used heretofore in tha production of carpets.
In this use the carpet yarn is threaded through a suitably large needle which is then punched through the spunbonded nonwoven polypropylene fabric, designated as the priJnary backing. A looper device catches the yarn on the opposite side of the backing to form loops or tufts and thP yarn and needle are then withdrawn to complete the formation of the loop or tuft. The backing fabric is then advanced and the cycle is repeated to form additional tufts. The tufts make up the pile or face of the final carpet. A
commercial tuftiny machine may have up to 2400 needles in a row all working in unison to make a carpet up to 15 eet in width.
The pri.mary backing, which is the spunbonded nonwoven polypropylene fabric, is the structural base of the carpet. It holds the tufts in place and provides dimensional stability and strength to the carpet. To the back of the tufted spunbonded nonwoven polypropylene backing there is applied a glue, for exarnple a latex of natural rubber or styrene-butadiene rubber, which coating firmly anchors the tufts in place and keeps them from pulling out. A jute or foam back may then be placed on the glued carpet backing to act as a pad or cushion.
~'7~ 1 In the develo~ment of this use of the spunbonded nonwoven abric it was found that the needles did extansive damage to the carpet backing on penetration of the structure, re.sulting in a large loss in strength duriny the tufting process.
Campbell, et al., U.S. Patent No. 3,867,188 issued February 18, 1975, discovered that when certain silicone-glycol copol~ners were applied to the spunbonded nonwoven polypropylene backing the penetration of the needle therethrough in the tufting process was facilitated and the backing damage and its attendant loss of strength could be significantly reduced.
Useful as Campbell et al's discovery is, it suffers rom a drawback co~non to previous processes comprising using a silicone as a lubricant for spunbonded nonwoven carpet backiny, i.e. increased fla~nmability of certain carpeting produced therefrom.
It appears that as the carpet yarn is punched through a carpet backing that has been lubricated with a silicone-containing composition it picks up some of the lubricant cornposition, thereby resulting in a carpet havin~ the lubricant composition on its facing as well as on its backing. It is thought that, at certain levels of add~on, silicone compositions are responsible for the enhanced flammability of some thermoplastic yarn materials, that is demonstrated in some testing procedures.
-7~ ~
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It is an object of this invention to provide a silicone-glycol-containing cornposition which is useful for lubricating spunbonded nonwoven carpet backing but which does not increase the flammability of a carpet prepared by needle-tufting a spunbonded nonwoven carpet backing treated therewith. It is a further object of this invention to provide an improved spunbonded nonwoven polypropylene carpet backing. It is another object o~ this invention to provide an improved spunbonded nonwoven fabric. It is an additional object of this invention to provids an improved fiber.
These objects, and others which will become obvious to one considering the following specification and appended claims, are obtained by preparing a mixture consisting essentially of from 1.0 to 9.0 parts by weight of butyl stearate and 1.0 part by weight of the sllicone-glycols disclosed by Campbell et al. in U.S. Patent No. 3,867,188 and applying the resulting composition to a fiber, such as those of a spunbonded nonwoven fabric.
It was surprising to discover that such a mixture, when applied to a spunbonded nonwoven polypropylene carpet backing at a concentration o~
approximately 1 percent by weight, based on the weight of the carpet backing, would not increase the flammability of a carpet prepared from the resulting polypropylene backing.
5~
While this invention is not to be limi-ted by theory, it is believed that the compositions of this invention operate, with respect to their carpet Elammability behavior, by simply allowing a slllall amount of silicone-glycol copol~ner to be applied to the polypropylene carpet backing, thereby not contributing to the flan~nability of a carpet produced therefrom.
However, it was completely unexpected to find that the compositions of this invention provide a level of lubrication of the spunbonded nonwoven car~et backing which ex.ceeds that obtained when either bu~yl stearate or the silico~le-glycols of Campbell et al.
noted above are applied alone to the spunbonded nonwoven backin~.
Detailed Descripti_n of the Invention This invention relates to a composition consisting essentially of (a) 1.0 part by weiyht of a silicone-glycol copolymer having the :Eormula (CH3)3Sio~(CH3)2Sio]Xc(CH3)(G)Sio]ySi(CH3)3 wherein G denot~s a silicon-bonded radical having the fonnula -R(OC3H6)zO.H~ R denotes an al~ylene radical containiny from 1 to 18 carbon atoms, x has an average value of from 40 to 90, y has an average value of from 1 to 10 and z has an average value of from 1 to 10, and (b) from 1.0 to 9.0 parts by weight of butyl stearate.
~ ~75~ ~
This invention also relates to a spunbonded nonwoven fabric having thereon a composition of this invention.
This invention further :relates to a spunbonded nonwoven polypropylene carpet backing having thereon an amount of the compositions of this invsntion, said arnount being sufficient to place on the carpet backing from 0.05 to 0.5 parts b~ weight, based on 100 parts by weight of the carpet backing, of the silicone-glycol copolymer cornponent in the compositlons of this invention.
This invention still further relates to a fiber having thereon a composition of this invention.
The silicone-glycol copolymer which is used in the ~ompositions of this invention is a trimethylsilyl endblocke~ siloxane which contains from 40 to 90 dimethylsiloxane units and from 1 to 10 methylglycolsiloxane units. The copolymers useful herein are water-insoluble because the water-soluble ~ilicone-glycol copolymers, when used in the preparation of needle-tufted carpet, allow the subsequently applied latex glue to wet and penetrate the polypropylene backing too far, resulting in a poor carpet.
i ;iL~7~1 The glycol radicals of the methylglycol-siloxane units are represented in the copol~ner formula by the qymbol G which is more specifically defined as havin~ the formula -R(OC3H6~zOH. 17he R
radical in this formula can be any alkylene unit containing from l to 18 carbon atolns. 17hus, for example, R can be a methylene, ethylene, propylene, butylene, isobutylene, hexylene, decylene, dodecylene or an octacdecylene radical. The ylycol portion represented by the (OC3H6)z portion of the structure i5, as can be seen from the formula~ an oxypropylene radical. The glycol radical is hydroxyl endblocked or, as is commonly stated in the art, an uncapped glycol. As indicated there can be an average of from l to lO oxypropylene units making up the ylycol portion of the structure, i.e., z has an averaye value of from l to 10. It is preferred, however, that z have an average value of from l to 5.
The averaye number of methy].glycolsiloxane units in the silicone-glycol copolymer can range from 1 to lO which is to say X can have an average value from 1 to lO. However, it is generally preferred that the average value of y be in the ranye of from l to 5.
The subscript x can have an average value of from 40 to 90, but preferably ranges in value from 50 to 75.
The subscript x defines the averaye number of dimethylsiloxane unit~ in the ~ilicone-glycol copolymer.
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, 9 Based on the disclosure of the structure herein the preparation of the silicone-glycol copol~ner set forth above will be obvious to those skilled in the art of the preparation of such materials. Preferably said silicone-glycol copolymer is prepared by firs preparing a siloxane of the structure Me3SiO(Me~SiO)x(MeHSiO)ySiMe3 in the well-known manner and thereater reacting therewith, in the presence of a platinum-containing hydrosilylation catalyst, an unsaturated glycol such as a glycol having the formula CH2=C~CH2(0C3H6)zOH, in sufficient quantity to react with all silicon-bonded hydrogen atoms on the siloxaneO The resulting silicone-~lycol copolymer is substantially free of silicon-bonded hydroyen radicals.
A preferred siloxane-glycol copolymer component in the compositions of this invention has the formula (CH3)3Sio[(cH3)2sio]67~(c~3)(Ho(c3H6o)2.5 CH2CH2CH2)Sio~3Si(cH3)3. Examples of other suitable silicone-glycol copolymers useful herein include Me3SiO(Me2SiO)40(MeSiO)SiMe3 C~2C~2CH20C3H60H
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Me3SiO(Me25iO)s~(MeSiO)sSi~qe3 C~2CH2CH2(0cH(cH3)cH2)30H
Me3SiO(Me2SiO)7s(Me5iO)~SiMe3 (CH2)3(0c3H6)5oH
Me35io(Me2sio)9o(Mesio)losiMe3 (CH2)3(0C3H6)10oH
Me3sio(Me2sio)65(~lesio)4siMe3 (CH2)l8(0c3H6)8oH
Me3SiO(Me2SiO)~(~(MeSiC~)7SiMe3 CH2CH(CH3)CH2(0C3H~)~OH
Butyl stearate is a well-known oleaginous liquid which is soluble in alcohol but substantially insoluble in waterO It is commercially available in various grades such as technical grade, cosmetic grade and cheMically pure grade. All of these grades of butyl stearate are suitable for use in this invention.
Butyl stearate is a well-known component of fiber lubricant, polish, coating, cosmetic, pharmaceutical and te~tile-treatiny compositions. Its identity and uses need no further elaboration here The compositions of this invention are single phase, homogeneous mixtures which can be prepared by any suitable method, such as by simple, but thorough, mixing of the components thereof.
The compositions of this invention may contain non essential components such as volatile diluents to provide emulsions or solu-tions thereof and trace ar~ounts of colorants, odorants and other adjuvants whicih are corNnon to textile-treating compositions.
A preferred composition of -this invention for treating spunbonded nonwoven carpet backiny consists essentially of 1.0 part by weight of the preferred siloxane-glycol copol~ner, detailed above, and 2 1/3 parts by weight of butyl stearate.
The compositions of this invention can be applied to a fiber or to a fabric by any of the well-known ~echniques such as padding, rolling, spraying and dipping. To assure a de.~irable degree of fiber-bonding, the fibers of a spunbonded fabric, such as those of a carpet backing, should be treated with the compositions of this invention after the fiber-bonding operation ha~ been cornpleted.
The amount of the compositions of this invention that is applied to the fiber or fabric will depend to some extent on the desired results but generally speaking will fall withln the range of 0.1-10 percent by weight based on the weight of the fiber or fabric. However, it is believed that generally an amount in the range of 0.5 S percent will meet most needs.
To confer desirable reduced-flammability characteristics to a polypropylene carpet made from a spunbonded nonwoven carpet backing of this invention the compositivn of this invention should be applied to the carpet backing in an amount that will place, on the carpet backing, from 0.05 to 0.5 parts by weight of the silicone-glycol com~onent for every 100 parts by weight of the spunbonded nonwoven carpet backing.
The compositions of this invention are useful for lubricating synthetic fibers, such as monofilament threads, polyfilament threads, yarns and tows and staple that are used to prepare woven, knitted and sewn fabrics. The compositions of this invention can be applied to a fiber before or after it is used to prepare a woven, knitted or sewn fabric.
7 ~ ~ ~
The following example~ are disclosed to further illustrate, but not limit, the present invention. All parts and percen~ages are by weight unless otherwise stated. Me denotes the methyl radical. Percent pick-up for fiber-lubricating composition by ~he carpet backing is based on ~le wei~ht of the carpet backing.
Pill Test - Flammability of a needle-tufted carpet sample was measured by this test wherein a raethenamine fuel pill is placed in the center of a 12"
x 12" carpet sample, previously dessicated and placed on a flat horizontal support, and ignited. A pass rating is given to the carpet if the region or burning does not extend beyond a distance of three inches frorn the pill.
Tongue Tear Test (TTT) - Lubrication of a needle-tufted carpet sample was measured by this test.
Higher values of TTT show greater lubrication of the backing.
The tufted non-woven sheet is cut into a sample 6 inches wide (cross-machine direction, across tufting rows) and 8 inches long (machine direction, along tufting rows~. The sample is cut in the center o the width 4 inches in the machine (tufting) direction. The sample is rnounted in an "Instron"
tester using l.S inch by 2 inch serrated clamps.
7 ~ ~ 1 With a jaw separation of 3 inches, one side of the sample cut is mounted in the upper jaw and the other side of the sample cut is mounted in the lower jaw.
The sample is uniformly spaced between the jaws. The full scale load is adjusted to a value greater than the tear strength expected for the sample. Using a cross head speed of 12 inches per minut~ and a chart speed of 1~ inches per lninute, the "Instron" is started and the sample is torn. An average of the three hiyhest stresses during tearing is taken. The tongue tear strength in pounds is reported as this averaye divided by 100 and multiplied by thP full scale load. In c~eneral severa} determinations are made and the average reported.
Tuf~ed Grab Tensile (~GT) - Effective __ lubrication of a carpet backiny to rleduce fiber breaking duriny needle-tufting without reducing tuft retention is measured by this test. Higher values of TGT show graater lubrication ~o the backing.
A tufted sample is cut into samples 4 inches wide by 6 inches lony in the tufting direction. The sample is mounted in an "Ins-tron" using a 1 inch by 2 inch clamp on the back side and a 1 inch square clamp on the front side at a jaw separation of 3 inches~ A
crosshead speed of 12 inches per minute is used. The peak of the "Instron" curve is read and reported as pounds breaking strength.
Examples A silicone-glycol copolymer having th~
approximate averaye formula Me3SiO(Me2SiO)67(MeSiO)3SiMe3 CH2CH2cH2(0c3H6)2.5oH
was mixed in various amount with five portions of butyl stearate to provide five compositions of this invention containing 9, 4, 2 1/3, 1 1/2 and 1 parts, respectively, of butyl stearate or every part of siloxane-glycol copolymer.
Seven pieces of spunbonded nonwoven polypropylene carpet backing, designated as TyparO-3301 by E. I. DuPont de Nemours and Co., Inc., were coated, using a gravure roll, with one of the above compositions of this invention or butyl stearate or the silicone-ylycol copolymer noted above. An eighth sam~le of carpet backin~ was not coated.
` ~ ~6 ~5~ J
The coated and noncoated carpet backiny samples were needle-tufted with a 1/10 guage needle fitted with 2600 denier Herculon~ brand polyproyplene yarn, 10 tufts per inch, to provide a carpet sample having a pile height o~ 1/4". The resulting carpet samples were examined for flammability, using the Pill Test, and for lubricity using the Tufted Tear Tensi~e and Tufted Grab Tensile tests, all described above.
These samples and test data are summarized in the Table.
The compositions of this invention (reference numbers 2 through 6) provide a greater amount o lubrication, as measured by the Tufted Grab Tensile Test than either of their components (reference numbers 1 and 7). Those carpet samples that were prepared from fabrics o~ this invention haviny no more than 0.5 percent silicone-glycol copolymer on the fabric (reference numbers 2 throu~h 5) were no more flammable than the control carpet or t:he carpet having only butyl stearate on its backing (reference n~umber 1~ .
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-FIBER-TRE~TING SILICO~IE-GLYCOL LUBRICANT COPOLYMER COMPOSITIONS
Back round of the Invention The present invention relates to a fiber lubricant cornposition which is particularly useful for lubricatiny a spunbonded nonwoven fabric and to fibers and fabrics having said lubricant composition thereon.
More specifically the fiber lubricant composition of this invention consists essentially of a synergistic mixture of certain silicone-glycol copolymers and butyl stearate which, when applied to spunbonded nonwoven polypropylen carpet backing, provides unexpectedly good lubrication for needle-tufting of the backing and an unexpectedly low flammability of a tufted carpet produced therefrom.
A spunbonded fabric is a continuous filament nonwoven fabric made by combining all thle steps from polymer preparation to finished fabric in one process.
Curtains of polymer filaments are extruded, drawn, forwarded ~o a belt and combined there into a web wlth the required design. The web is then bonded and can be finished in the same single process.
The basic process steps or making spunbonded nonwoven fabrics are quite simple. Multiple spinnerettes extrude large numbers of polymer filaments which are drawn and oriented in groups, by rolls or by high velocity air, and then projected, in some desired geometrical array, as a web onto a slowly moving porous belt provided with suction to hold the web. The belt then carries the web to a bonding operation such as binder application and/or heater rolling and then to one or more further opera-tional steps in the process. These latter steps can be the traditional textile finishing steps such as prin~ing or embos6ing when process speed6 are compatible.
There are many spunbonded nonwoven fabrics available co~nercially. Examples of such materials are those based on synthetic fibers, such as polyesters, polyamides and polyolefins, such as polypropylene, polyethylene, or combinations of the foregoing. The particular fiber type used will depend on the nature of the finish~d product one wishes to make. End uses for spunbonded nonwoven fabrics ranges from such things as book covers, to clothing fabric to carpet backing.
One of the rnost significant commercial U52S
of spunbonded nonwoven abric is the use of spunbonded nonwoven polypropylene as a carpet backing. rrhe spunbonded nonwoven polypropylene fabric haa been substituted for ~he woven jute backing materials that have been used heretofore in tha production of carpets.
In this use the carpet yarn is threaded through a suitably large needle which is then punched through the spunbonded nonwoven polypropylene fabric, designated as the priJnary backing. A looper device catches the yarn on the opposite side of the backing to form loops or tufts and thP yarn and needle are then withdrawn to complete the formation of the loop or tuft. The backing fabric is then advanced and the cycle is repeated to form additional tufts. The tufts make up the pile or face of the final carpet. A
commercial tuftiny machine may have up to 2400 needles in a row all working in unison to make a carpet up to 15 eet in width.
The pri.mary backing, which is the spunbonded nonwoven polypropylene fabric, is the structural base of the carpet. It holds the tufts in place and provides dimensional stability and strength to the carpet. To the back of the tufted spunbonded nonwoven polypropylene backing there is applied a glue, for exarnple a latex of natural rubber or styrene-butadiene rubber, which coating firmly anchors the tufts in place and keeps them from pulling out. A jute or foam back may then be placed on the glued carpet backing to act as a pad or cushion.
~'7~ 1 In the develo~ment of this use of the spunbonded nonwoven abric it was found that the needles did extansive damage to the carpet backing on penetration of the structure, re.sulting in a large loss in strength duriny the tufting process.
Campbell, et al., U.S. Patent No. 3,867,188 issued February 18, 1975, discovered that when certain silicone-glycol copol~ners were applied to the spunbonded nonwoven polypropylene backing the penetration of the needle therethrough in the tufting process was facilitated and the backing damage and its attendant loss of strength could be significantly reduced.
Useful as Campbell et al's discovery is, it suffers rom a drawback co~non to previous processes comprising using a silicone as a lubricant for spunbonded nonwoven carpet backiny, i.e. increased fla~nmability of certain carpeting produced therefrom.
It appears that as the carpet yarn is punched through a carpet backing that has been lubricated with a silicone-containing composition it picks up some of the lubricant cornposition, thereby resulting in a carpet havin~ the lubricant composition on its facing as well as on its backing. It is thought that, at certain levels of add~on, silicone compositions are responsible for the enhanced flammability of some thermoplastic yarn materials, that is demonstrated in some testing procedures.
-7~ ~
~9~=
It is an object of this invention to provide a silicone-glycol-containing cornposition which is useful for lubricating spunbonded nonwoven carpet backing but which does not increase the flammability of a carpet prepared by needle-tufting a spunbonded nonwoven carpet backing treated therewith. It is a further object of this invention to provide an improved spunbonded nonwoven polypropylene carpet backing. It is another object o~ this invention to provide an improved spunbonded nonwoven fabric. It is an additional object of this invention to provids an improved fiber.
These objects, and others which will become obvious to one considering the following specification and appended claims, are obtained by preparing a mixture consisting essentially of from 1.0 to 9.0 parts by weight of butyl stearate and 1.0 part by weight of the sllicone-glycols disclosed by Campbell et al. in U.S. Patent No. 3,867,188 and applying the resulting composition to a fiber, such as those of a spunbonded nonwoven fabric.
It was surprising to discover that such a mixture, when applied to a spunbonded nonwoven polypropylene carpet backing at a concentration o~
approximately 1 percent by weight, based on the weight of the carpet backing, would not increase the flammability of a carpet prepared from the resulting polypropylene backing.
5~
While this invention is not to be limi-ted by theory, it is believed that the compositions of this invention operate, with respect to their carpet Elammability behavior, by simply allowing a slllall amount of silicone-glycol copol~ner to be applied to the polypropylene carpet backing, thereby not contributing to the flan~nability of a carpet produced therefrom.
However, it was completely unexpected to find that the compositions of this invention provide a level of lubrication of the spunbonded nonwoven car~et backing which ex.ceeds that obtained when either bu~yl stearate or the silico~le-glycols of Campbell et al.
noted above are applied alone to the spunbonded nonwoven backin~.
Detailed Descripti_n of the Invention This invention relates to a composition consisting essentially of (a) 1.0 part by weiyht of a silicone-glycol copolymer having the :Eormula (CH3)3Sio~(CH3)2Sio]Xc(CH3)(G)Sio]ySi(CH3)3 wherein G denot~s a silicon-bonded radical having the fonnula -R(OC3H6)zO.H~ R denotes an al~ylene radical containiny from 1 to 18 carbon atoms, x has an average value of from 40 to 90, y has an average value of from 1 to 10 and z has an average value of from 1 to 10, and (b) from 1.0 to 9.0 parts by weight of butyl stearate.
~ ~75~ ~
This invention also relates to a spunbonded nonwoven fabric having thereon a composition of this invention.
This invention further :relates to a spunbonded nonwoven polypropylene carpet backing having thereon an amount of the compositions of this invsntion, said arnount being sufficient to place on the carpet backing from 0.05 to 0.5 parts b~ weight, based on 100 parts by weight of the carpet backing, of the silicone-glycol copolymer cornponent in the compositlons of this invention.
This invention still further relates to a fiber having thereon a composition of this invention.
The silicone-glycol copolymer which is used in the ~ompositions of this invention is a trimethylsilyl endblocke~ siloxane which contains from 40 to 90 dimethylsiloxane units and from 1 to 10 methylglycolsiloxane units. The copolymers useful herein are water-insoluble because the water-soluble ~ilicone-glycol copolymers, when used in the preparation of needle-tufted carpet, allow the subsequently applied latex glue to wet and penetrate the polypropylene backing too far, resulting in a poor carpet.
i ;iL~7~1 The glycol radicals of the methylglycol-siloxane units are represented in the copol~ner formula by the qymbol G which is more specifically defined as havin~ the formula -R(OC3H6~zOH. 17he R
radical in this formula can be any alkylene unit containing from l to 18 carbon atolns. 17hus, for example, R can be a methylene, ethylene, propylene, butylene, isobutylene, hexylene, decylene, dodecylene or an octacdecylene radical. The ylycol portion represented by the (OC3H6)z portion of the structure i5, as can be seen from the formula~ an oxypropylene radical. The glycol radical is hydroxyl endblocked or, as is commonly stated in the art, an uncapped glycol. As indicated there can be an average of from l to lO oxypropylene units making up the ylycol portion of the structure, i.e., z has an averaye value of from l to 10. It is preferred, however, that z have an average value of from l to 5.
The averaye number of methy].glycolsiloxane units in the silicone-glycol copolymer can range from 1 to lO which is to say X can have an average value from 1 to lO. However, it is generally preferred that the average value of y be in the ranye of from l to 5.
The subscript x can have an average value of from 40 to 90, but preferably ranges in value from 50 to 75.
The subscript x defines the averaye number of dimethylsiloxane unit~ in the ~ilicone-glycol copolymer.
3 ~ ~75~ ~
, 9 Based on the disclosure of the structure herein the preparation of the silicone-glycol copol~ner set forth above will be obvious to those skilled in the art of the preparation of such materials. Preferably said silicone-glycol copolymer is prepared by firs preparing a siloxane of the structure Me3SiO(Me~SiO)x(MeHSiO)ySiMe3 in the well-known manner and thereater reacting therewith, in the presence of a platinum-containing hydrosilylation catalyst, an unsaturated glycol such as a glycol having the formula CH2=C~CH2(0C3H6)zOH, in sufficient quantity to react with all silicon-bonded hydrogen atoms on the siloxaneO The resulting silicone-~lycol copolymer is substantially free of silicon-bonded hydroyen radicals.
A preferred siloxane-glycol copolymer component in the compositions of this invention has the formula (CH3)3Sio[(cH3)2sio]67~(c~3)(Ho(c3H6o)2.5 CH2CH2CH2)Sio~3Si(cH3)3. Examples of other suitable silicone-glycol copolymers useful herein include Me3SiO(Me2SiO)40(MeSiO)SiMe3 C~2C~2CH20C3H60H
~ ~75~
Me3SiO(Me25iO)s~(MeSiO)sSi~qe3 C~2CH2CH2(0cH(cH3)cH2)30H
Me3SiO(Me2SiO)7s(Me5iO)~SiMe3 (CH2)3(0c3H6)5oH
Me35io(Me2sio)9o(Mesio)losiMe3 (CH2)3(0C3H6)10oH
Me3sio(Me2sio)65(~lesio)4siMe3 (CH2)l8(0c3H6)8oH
Me3SiO(Me2SiO)~(~(MeSiC~)7SiMe3 CH2CH(CH3)CH2(0C3H~)~OH
Butyl stearate is a well-known oleaginous liquid which is soluble in alcohol but substantially insoluble in waterO It is commercially available in various grades such as technical grade, cosmetic grade and cheMically pure grade. All of these grades of butyl stearate are suitable for use in this invention.
Butyl stearate is a well-known component of fiber lubricant, polish, coating, cosmetic, pharmaceutical and te~tile-treatiny compositions. Its identity and uses need no further elaboration here The compositions of this invention are single phase, homogeneous mixtures which can be prepared by any suitable method, such as by simple, but thorough, mixing of the components thereof.
The compositions of this invention may contain non essential components such as volatile diluents to provide emulsions or solu-tions thereof and trace ar~ounts of colorants, odorants and other adjuvants whicih are corNnon to textile-treating compositions.
A preferred composition of -this invention for treating spunbonded nonwoven carpet backiny consists essentially of 1.0 part by weight of the preferred siloxane-glycol copol~ner, detailed above, and 2 1/3 parts by weight of butyl stearate.
The compositions of this invention can be applied to a fiber or to a fabric by any of the well-known ~echniques such as padding, rolling, spraying and dipping. To assure a de.~irable degree of fiber-bonding, the fibers of a spunbonded fabric, such as those of a carpet backing, should be treated with the compositions of this invention after the fiber-bonding operation ha~ been cornpleted.
The amount of the compositions of this invention that is applied to the fiber or fabric will depend to some extent on the desired results but generally speaking will fall withln the range of 0.1-10 percent by weight based on the weight of the fiber or fabric. However, it is believed that generally an amount in the range of 0.5 S percent will meet most needs.
To confer desirable reduced-flammability characteristics to a polypropylene carpet made from a spunbonded nonwoven carpet backing of this invention the compositivn of this invention should be applied to the carpet backing in an amount that will place, on the carpet backing, from 0.05 to 0.5 parts by weight of the silicone-glycol com~onent for every 100 parts by weight of the spunbonded nonwoven carpet backing.
The compositions of this invention are useful for lubricating synthetic fibers, such as monofilament threads, polyfilament threads, yarns and tows and staple that are used to prepare woven, knitted and sewn fabrics. The compositions of this invention can be applied to a fiber before or after it is used to prepare a woven, knitted or sewn fabric.
7 ~ ~ ~
The following example~ are disclosed to further illustrate, but not limit, the present invention. All parts and percen~ages are by weight unless otherwise stated. Me denotes the methyl radical. Percent pick-up for fiber-lubricating composition by ~he carpet backing is based on ~le wei~ht of the carpet backing.
Pill Test - Flammability of a needle-tufted carpet sample was measured by this test wherein a raethenamine fuel pill is placed in the center of a 12"
x 12" carpet sample, previously dessicated and placed on a flat horizontal support, and ignited. A pass rating is given to the carpet if the region or burning does not extend beyond a distance of three inches frorn the pill.
Tongue Tear Test (TTT) - Lubrication of a needle-tufted carpet sample was measured by this test.
Higher values of TTT show greater lubrication of the backing.
The tufted non-woven sheet is cut into a sample 6 inches wide (cross-machine direction, across tufting rows) and 8 inches long (machine direction, along tufting rows~. The sample is cut in the center o the width 4 inches in the machine (tufting) direction. The sample is rnounted in an "Instron"
tester using l.S inch by 2 inch serrated clamps.
7 ~ ~ 1 With a jaw separation of 3 inches, one side of the sample cut is mounted in the upper jaw and the other side of the sample cut is mounted in the lower jaw.
The sample is uniformly spaced between the jaws. The full scale load is adjusted to a value greater than the tear strength expected for the sample. Using a cross head speed of 12 inches per minut~ and a chart speed of 1~ inches per lninute, the "Instron" is started and the sample is torn. An average of the three hiyhest stresses during tearing is taken. The tongue tear strength in pounds is reported as this averaye divided by 100 and multiplied by thP full scale load. In c~eneral severa} determinations are made and the average reported.
Tuf~ed Grab Tensile (~GT) - Effective __ lubrication of a carpet backiny to rleduce fiber breaking duriny needle-tufting without reducing tuft retention is measured by this test. Higher values of TGT show graater lubrication ~o the backing.
A tufted sample is cut into samples 4 inches wide by 6 inches lony in the tufting direction. The sample is mounted in an "Ins-tron" using a 1 inch by 2 inch clamp on the back side and a 1 inch square clamp on the front side at a jaw separation of 3 inches~ A
crosshead speed of 12 inches per minute is used. The peak of the "Instron" curve is read and reported as pounds breaking strength.
Examples A silicone-glycol copolymer having th~
approximate averaye formula Me3SiO(Me2SiO)67(MeSiO)3SiMe3 CH2CH2cH2(0c3H6)2.5oH
was mixed in various amount with five portions of butyl stearate to provide five compositions of this invention containing 9, 4, 2 1/3, 1 1/2 and 1 parts, respectively, of butyl stearate or every part of siloxane-glycol copolymer.
Seven pieces of spunbonded nonwoven polypropylene carpet backing, designated as TyparO-3301 by E. I. DuPont de Nemours and Co., Inc., were coated, using a gravure roll, with one of the above compositions of this invention or butyl stearate or the silicone-ylycol copolymer noted above. An eighth sam~le of carpet backin~ was not coated.
` ~ ~6 ~5~ J
The coated and noncoated carpet backiny samples were needle-tufted with a 1/10 guage needle fitted with 2600 denier Herculon~ brand polyproyplene yarn, 10 tufts per inch, to provide a carpet sample having a pile height o~ 1/4". The resulting carpet samples were examined for flammability, using the Pill Test, and for lubricity using the Tufted Tear Tensi~e and Tufted Grab Tensile tests, all described above.
These samples and test data are summarized in the Table.
The compositions of this invention (reference numbers 2 through 6) provide a greater amount o lubrication, as measured by the Tufted Grab Tensile Test than either of their components (reference numbers 1 and 7). Those carpet samples that were prepared from fabrics o~ this invention haviny no more than 0.5 percent silicone-glycol copolymer on the fabric (reference numbers 2 throu~h 5) were no more flammable than the control carpet or t:he carpet having only butyl stearate on its backing (reference n~umber 1~ .
-17- i ~ 7593~
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a)~ ~ .~ ~ ~9r~ ~ r~ 1~Lt a tn a PE-~ E~
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,rL~ ~a ~d ~I ~ C) t~~ r~l . 3) ~~ ~ L~
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Claims (9)
1. A composition consisting essentially of (a) 1.0 part by weight of a silicone-glycol copolymer having the formula (CH3)3SiO[(CH3)2SiO]x[(CH3)(G)SiO]ySi(CH3)3 wherein G denotes a silicon-bonded radical of the formula -R(OC3H6)zOH
R denotes an alkylene radical containing from 1 to 18 carbon atoms, x has an average value of from 40 to 90, y has an average value of from l to 10, and z has an average value of from l to 10, and (b) from 1.0 to 9.0 parts by weight of butyl stearate.
R denotes an alkylene radical containing from 1 to 18 carbon atoms, x has an average value of from 40 to 90, y has an average value of from l to 10, and z has an average value of from l to 10, and (b) from 1.0 to 9.0 parts by weight of butyl stearate.
2. A composition as defined in claim 1 wherein R contains from 3 to 6 carbon atoms, x has an average value from 50 to 75, y has an average value from 1 to 5, and z has an average value from 1 to 5.
3. A composition as defined in claim 2 wherein R contains 3 carbon atoms, x has an average value of about 67, y has an average value of about 3, and z has an average value of about 2.5.
4. A spunbonded nonwoven fabric having thereon a composition defined by claim 1,
5. A fabric as defined by claim 4 which is selected from the group consisting of polyester fabrics and polyolefin fabrics.
6. A polyolefin fabric as defined by claim 5 which is a polypropylene fabric.
7. A polypropylene fabric as defined by claim 6 which is a spunbonded nonwoven carpet backing.
8. A carpet backing as defined by claim 7 which has thereon from 0.05 to 0.5 parts by weight of the silicone-gylycol copolymer for every 100 parts by weight of the carpet backing.
9. A synthetic fiber having thereon a composition defined by claims 1, 2 or 3.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US06/189,494 US4324720A (en) | 1980-09-22 | 1980-09-22 | Lubricant-bearing fibers and lubricant compositions therefor |
| US189,494 | 1980-09-22 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1167591A true CA1167591A (en) | 1984-05-15 |
Family
ID=22697570
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000384987A Expired CA1167591A (en) | 1980-09-22 | 1981-09-01 | Fiber-treating silicone-glycol lubricant copolymer compositioins |
Country Status (7)
| Country | Link |
|---|---|
| US (1) | US4324720A (en) |
| EP (1) | EP0048584B1 (en) |
| JP (1) | JPS6043474B2 (en) |
| BR (1) | BR8108802A (en) |
| CA (1) | CA1167591A (en) |
| DE (1) | DE3164740D1 (en) |
| WO (1) | WO1982001008A1 (en) |
Families Citing this family (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4420409A (en) * | 1981-12-11 | 1983-12-13 | Toray Silicone Company, Ltd. | Hydraulic system and hydraulic fluid compositions comprising siloxane-oxyalkylene copolymers |
| US5047159A (en) * | 1989-08-24 | 1991-09-10 | Henkel Corporation | Lubricant compositions having improved anti-deposition properties comprising a polyalkylene oxide-modified silicone oil |
| WO1991010771A1 (en) * | 1990-01-17 | 1991-07-25 | Stults Jerry F | Non-aqueous emulsion of silicone oil and stearine |
| US5696061A (en) * | 1995-11-14 | 1997-12-09 | Basf Corporation | Self-cleaning polypropylene fabric weaving lubricant |
| US5972497A (en) * | 1996-10-09 | 1999-10-26 | Fiberco, Inc. | Ester lubricants as hydrophobic fiber finishes |
| US7323074B2 (en) * | 2003-10-22 | 2008-01-29 | Polymer Group, Inc. | Hay baling laminate of a nonwoven and a knitted net |
| EP2524075A1 (en) | 2010-01-12 | 2012-11-21 | The Procter & Gamble Company | Treated laminates |
| EP2524082A2 (en) | 2010-01-12 | 2012-11-21 | Fiberweb, Inc. | Surface-treated non-woven fabrics |
Family Cites Families (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3717575A (en) * | 1971-05-25 | 1973-02-20 | Union Carbide Corp | Spandex lubricant |
| US3997450A (en) * | 1972-04-10 | 1976-12-14 | Fiber Industries, Inc. | Synthetic fibers of enhanced processability |
| US3867188A (en) * | 1973-07-25 | 1975-02-18 | Dow Corning | Spunbonded nonwoven fabric |
| GB1548224A (en) * | 1976-02-12 | 1979-07-04 | Goldschmidt Ag Th | Organosilicon compounds and textile fibre dressings which contain these compounds |
| FR2372268A1 (en) * | 1976-11-30 | 1978-06-23 | Rhone Poulenc Ind | PROCESS FOR LUBRICATING SEWING THREAD BY IMPREGNATION IN AQUEOUS BATHS CONTAINING ORGANOSILICIC POLYMERS |
-
1980
- 1980-09-22 US US06/189,494 patent/US4324720A/en not_active Expired - Lifetime
-
1981
- 1981-08-21 WO PCT/US1981/001128 patent/WO1982001008A1/en unknown
- 1981-08-21 BR BR8108802A patent/BR8108802A/en not_active IP Right Cessation
- 1981-08-21 JP JP56502900A patent/JPS6043474B2/en not_active Expired
- 1981-09-01 CA CA000384987A patent/CA1167591A/en not_active Expired
- 1981-09-15 EP EP81304208A patent/EP0048584B1/en not_active Expired
- 1981-09-15 DE DE8181304208T patent/DE3164740D1/en not_active Expired
Also Published As
| Publication number | Publication date |
|---|---|
| EP0048584A1 (en) | 1982-03-31 |
| EP0048584B1 (en) | 1984-07-11 |
| DE3164740D1 (en) | 1984-08-16 |
| WO1982001008A1 (en) | 1982-04-01 |
| JPS57501429A (en) | 1982-08-12 |
| BR8108802A (en) | 1982-08-24 |
| US4324720A (en) | 1982-04-13 |
| JPS6043474B2 (en) | 1985-09-28 |
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