Carpet and synthetic turf backings prepared from a polyether carbonate polyol

Patent metadata

Field	Value
Publication number	US-10119223-B2
Application number	US-201615211341-A
Country	US
Kind code	B2
Filing date	Jul 15, 2016
Priority date	Jul 15, 2016
Publication date	Nov 6, 2018
Grant date	Nov 6, 2018

Abstract

Disclosed are tufted carpet structures, including synthetic turf structures, such as synthetic grass structures, that include a polyurethane backing coating formed from a polyether carbonate polyol.

First claim

What is claimed is:

1. A carpet, comprising:
(a) rows of fiber bundles;
(b) a primary backing, wherein the rows of fiber bundles are tufted into the primary backing, and
(c) a coating deposited over at least a portion of the primary backing and covering the portion of the fiber bundles tufted into the primary backing, wherein the coating comprises a polyurethane that is a reaction product of:
(1) a polyisocyanate, and
(2) an isocyanate-reactive composition comprising:
(i) 10% to 50% by weight, based on the total weight of isocyanate-reactive components in the isocyanate-reactive composition, of a polyether carbonate polyol having incorporated carbon dioxide content, an OH functionality of 2 to 4, and a number average molar mass of 750 to 6000 grams/mole;
(ii) 20% to 80% by weight, based on the total weight of isocyanate-reactive components in the isocyanate-reactive composition, of a polyether polyol that is not a polyether carbonate polyol and that has a nominal functionality of at least 3 and an average OH number of 20 to 100; and
(iii) 5% to 25% by weight, based on the total weight of isocyanate-reactive components in the isocyanate-reactive composition, of a polyether diol that is not a polyether carbonate diol and has a M n of at least 1000 grams/mole.

2. The carpet of claim 1 , wherein the carpet is a synthetic turf and the fibers in the fiber bundles are made of a synthetic material comprising an acrylic polymer, nylon, a polyester, a polyurethane, a polyolefin, or a mixture of two or more thereof.

3. The carpet of claim 1 , wherein the polyether carbonate polyol is the addition reaction product of carbon dioxide and an alkylene oxide onto an H-functional starter.

4. The carpet of claim 1 , wherein the content of carbonate groups, calculated as CO 2 in the polyether carbonate polyol is within the range of 3 to 35% by weight.

5. The carpet of claim 1 , wherein the content of carbonate groups, calculated as CO 2 in the polyether carbonate polyol is within the range of 10 to 28% by weight.

6. The carpet of claim 3 , wherein the polyether carbonate polyol is the addition reaction product of carbon dioxide and alkylene oxide onto a H-functional starter in the presence of a multimetal cyanide catalyst (DMC catalyst).

7. The carpet of claim 1 , wherein the polyether carbonate polyol is present in an amount of 4 to 20% by weight, based on the total weight of the isocyanate-reactive composition.

8. The carpet of claim 1 , wherein the isocyanate-reactive composition further comprises chain extender have a molecular weight of 60 to 490 g/mol and two isocyanate-reactive groups per molecule.

9. The carpet of claim 8 , wherein the chain extender is present in an amount of 5% to 25%, based on the total weight of isocyanate-reactive components in the isocyanate-reactive composition.

10. The carpet of claim 9 , wherein the isocyanate-reactive composition further comprises a filler comprising a silicate, TiO 2 , glass fiber, carbon black, graphite, calcium carbonate, talc, mica, and/or a clay, wherein the filler is present in the isocyanate-reactive composition in an amount of 20 to 80% by weight, based on the total weight of the isocyanate-reactive composition.

11. The carpet of claim 2 , further comprising an infill comprising rubber particles.

12. A synthetic grass surface comprising synthetic grass blades having an end extending away from a backing, wherein the backing has deposited on at least one side thereof a coating comprising a polyurethane that is a reaction product of:
(1) a polyisocyanate, and
(2) an isocyanate-reactive composition comprising:
(i) 10% to 50% by weight, based on the total weight of isocyanate-reactive components in the isocyanate-reactive composition, of a polyether carbonate polyol having incorporated carbon dioxide content, an OH functionality of 2 to 4, and a number average molar mass of 750 to 6000 grams/mole;
(ii) 20% to 80% by weight, based on the total weight of isocyanate-reactive components in the isocyanate-reactive composition, of a polyether polyol that is not a polyether carbonate polyol and that has a nominal functionality of at least 3 and an average OH number of 20 to 100; and
(iii) 5% to 25% by weight, based on the total weight of isocyanate-reactive components in the isocyanate-reactive composition, of a polyether diol that is not a polyether carbonate diol and has a M r , of at least 1000 grams/mole.

13. The synthetic grass surface of claim 12 , wherein the content of carbonate groups, calculated as CO 2 in the polyether carbonate polyol is within the range of 3 to 35% by weight.

14. The synthetic grass surface of claim 12 , wherein the isocyanate-reactive composition further comprises:
(iv) a chain extender having a molecular weight of 60 to 490 g/mol and two isocyanate-reactive groups per molecule that is present in an amount of 5% to 25%, based on the total weight of isocyanate-reactive components in the isocyanate-reactive composition; and
(v) a filler comprising a silicate, TiO 2 , glass fiber, carbon black, graphite, calcium carbonate, talc, mica, and/or a clay, wherein the filler is present in the isocyanate-reactive composition in an amount of 20 to 80% by weight, based on the total weight of the isocyanate-reactive composition.

15. The synthetic grass surface of claim 12 , further comprising an infill comprising rubber particles.

Assignees

• Covestro Llc

Inventors

• Glaze Amanda
• Robinson Michael S
• Torres-Ramos Samuel

Classifications

• D06N2205/106

  Scrap or recycled particles · CPC title

• C08K2003/265

  Calcium, strontium or barium carbonate · CPC title

• D06N2203/068

  Polyurethanes · CPC title

• D06M15/568 Primary

  Reaction products of isocyanates with polyethers · CPC title

• D06N2211/066

  Floor coverings · CPC title