Stock material or miscellaneous articles – Pile or nap type surface or component – Nap type surface
Reexamination Certificate
2002-06-18
2004-08-17
Lipman, Bernard (Department: 1713)
Stock material or miscellaneous articles
Pile or nap type surface or component
Nap type surface
C428S378000, C428S395000, C525S169000
Reexamination Certificate
active
06777059
ABSTRACT:
FIELD OF THE INVENTION
This invention relates to poly(trimethylene terephthalate) carpets, and manufacture and use thereof.
BACKGROUND OF THE INVENTION
U.S. Pat. Nos. 5,645,782 Howell et al., 6,109,015 Roark et al. and 6,113,825 Chuah; WO 99/19557 Scott et al.; H. Modlich, “Experience with Polyesters Fibers in Tufted Articles of Heat-Set Yarns, Chemiefasern/Textilind. 41/93, 786-94 (1991); and H. Chuah, “Corterra Poly(trimethylene terephthalate)—New Polymeric Fiber for Carpets”, The Textile Institute Tifcon '96 (1996) (available at http://www.shellchemicals.com/corterra/0,1098,281,00.html), all of which are incorporated herein by reference, describe carpets made with poly(trimethylene terephthalate) (“3GT”) fibers. Poly(trimethylene terephthalate) is disperse dyeable at atmospheric pressure, is easily pigmented and has low bending modulus, making it excellent for use in carpets. Poly(trimethylene terephthalate) carpets have good elastic recovery and resilience, and are resistant to most aqueous stains, such as coffee, cola, ink, mustard, grape juice, ketchup, etc. However, poly(trimethylene terephthalate) carpets are readily stained by oily materials such as motor oil and corn oil.
U.S. Pat. No. 6,109,015 Roark et al. describes that the spin finish used to improve yarn performance and spinning may include functional additives, such as stain resistance additives and anti-soiling additives, including fluorochemicals. It does not disclose which fluorochemicals are suitable for this use and makes no mention of carpet treatments.
Chuah et al., “Corterra™ PTT. A New Polymer For The Fiber Industry. An Update.”, in “From Theory to Practice for Changing Times”, AATCC International Dyeing Symposium (1998), describes the effect of use of “3M” on nylons and poly(trimethylene terephthalate) carpets. By “3M”, it is assumed that reference is to polyfluorooctanyl sulfonates or sulfonamides prepared by electrochemical fluorination which have been withdrawn from the market due to health concerns. The article shows tests of nylons and poly(trimethylene terephthalate) carpets “as is” and with soil-resist treatment, and nylons with both soil-resist and stain resist treatments. This article describes the inherent stain resistance of poly(trimethylene terephthalate) and does not describe or test poly(trimethylene terephthalate) with respect to oily materials.
There is a need for poly(trimethylene terephthalate) carpets that are not readily stained by oily materials such as motor oil, corn oil, shoe polish, and other hydrocarbon oils and waxes. The present invention provides such carpets and a method for treating poly(trimethylene terephthalate) carpets so that they are not readily stained by oily materials.
SUMMARY OF THE INVENTION
The invention is directed to a treated poly(trimethylene terephthalate) carpet prepared by a process comprising applying a polyfluoroacrylate emulsion to a poly(trimethylene terephthalate) carpet and curing the polyfluoroacrylate. The carpets have excellent properties, particularly repellency of oily materials.
In one embodiment, the invention is directed to a treated poly(trimethylene terephthalate) carpet prepared by a process comprising applying a telomer-based polyfluoroacrylate emulsion to a poly(trimethylene terephthalate) carpet and curing the polyfluoroacrylate at a temperature of about 200 to about 310° F., the treated poly(trimethylene terephthalate) carpet having an oil repellency rating of at least 4.
The invention is directed to a treated poly(trimethylene terephthalate) carpet prepared by a process comprising applying a polyfluoroacrylate emulsion to a poly(trimethylene terephthalate) carpet and curing the polyfluoroacrylate at a temperature of about 200 to about 310° F., the treated poly(trimethylene terephthalate) carpet having an oil repellency rating of at least 4.
The invention is also directed to a treated poly(trimethylene terephthalate) carpet prepared by a process comprising applying a polyfluoroacrylate emulsion to a poly(trimethylene terephthalate) carpet and curing the polyfluoroacrylate at a temperature of about 200 to about 310° F., the treated poly(trimethylene terephthalate) carpet having an oil repellency rating of at least 4, wherein the polyfluoroacrylate emulsion is prepared by emulsion polymerization of the following monomers in the following weight percentages, based on the total weight of the polyfluoroacrylate:
(a) from about 40% to about 75% of a monomer of formula I:
R
f
—CH
2
CH
2
—OC(O)—C(R)═CH
2
(I)
(b) from about 15% to about 55% of a monomer of formula II:
R
2
—OC(O)—C(R)═CH
2
(II)
(c) from about 0.5% to about 5% of a monomer of the formula III:
HO—CH
2
CH
2
—OC(O)—C(R)═CH
2
(III)
(d) from about 1.5% to about 5% of a monomer of the formula IV:
H—(OCH
2
CH
2
)
m
—O—C(O)—C(R)═CH
2
(IV)
(e) from about 1% to about 3% of a monomer of the formula V:
HO—CH
2
—NH—C(O)—C (R)═CH
2
(V)
(f) from 0% up to about 20% of vinylidene chloride (formula VI) or vinyl acetate (formula VII), or a mixture thereof:
CH
2
═CCl
2
(VI)
CH
3
—(O)COCH═CH
2
(VII),
wherein R
f
is a straight or branched-chain perfluoroalkyl group of from 2 to about 20 carbon atoms, each R is independently H or CH
3
; R
2
is an alkyl chain from 2 to about 18 carbon atoms; and m is 2 to about 10.
In yet another embodiment, the invention is directed to a treated poly(trimethylene terephthalate) carpet prepared by a process comprising applying a polyfluoroacrylate emulsion to a poly(trimethylene terephthalate) carpet and curing the polyfluoroacrylate, wherein the polyfluoroacrylate emulsion is prepared by emulsion polymerization of the following monomers in the following weight percentages, based on the total weight of the polyfluoroacrylate:
(a) from about 40% to about 50% of the monomer of formula (I);
(b) from about 40% to about 50% of the monomer of formula (II);
(c) from about 4% to about 5% of the monomer of formula (III);
(d) from about 4% to about 5% of the monomer of formula (IV);
(e) from about 1.5% to about 3% of the monomer of formula (V); and
(f) from 0% up to about 10% of the monomer of formula (VI) and/or (VII). Preferably the curing the polyfluoroacrylate is at a temperature of about 200 to about 310° F. and the treated poly(trimethylene terephthalate) carpet having an oil repellency rating of at least 4.
Preferably the carpet has a yellowing rating of 3 to 1. Preferably the polyfluoroacrylate emulsion is made without vinylidene chloride. In a preferred embodiment, the polyfluoroacrylate emulsion is preferably made with little (e.g., less than 1 wt %) or no vinylidene chloride and vinyl acetate.
In addition, the invention is directed to process of preparing the treated poly(trimethylene terephthalate) carpet comprising (a) applying the polyfluoroacrylate emulsion to the poly(trimethylene terephthalate) carpet and curing the polyfluoroacrylate at a temperature of about 200 to about 310° F., the treated poly(trimethylene terephthalate) carpet having an oil repellency rating of at least 4. Preferably the polyfluoroacrylate emulsion is an aqueous emulsion comprising 15-35 weight %, by weight of the emulsion, of the polyfluoroacrylate.
Curing is carried out in the range of about 200° F. (93° C.), preferably about 210° F. (99° C.), to about 310° F. (155° C.) and preferably up to about 305° F. (152° C.), more preferably up to about 300° F. (149° C.). Curing is preferably carried out for at least about 15 seconds, more preferably at least 30 seconds, and in some cases preferably at least about 1 minute, and up to about 10 minutes, preferably up to about 5 minutes, more preferably up to about 3 minutes, and most preferably up to about 90 seconds.
The treated poly(trimethylene terephthalate) carpet preferably has a water repellency rating of at least 6, preferably at least 7, and even more preferably of 8.
The treated poly(trimethylene terephthalate) carpet preferably has a corn oil stain repellency rating of 2 to 1.
The treated poly(trimethylene tere
Franchina Justine Gabrielle
Kurian Joseph Varapadavil
E.I. du Pont de Nemours and Company
Kuller Mark D.
Lipman Bernard
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