Carpet latex compound

Abstract

A method of making a carpet latex compound, the method comprising the steps of providing a carboxylated styrene-butadiene latex, adding a rosin acid soap to the latex to provide a pre-compound latex, and adding to the precompound latex at least one of a filler, a thickener and a curative.

1 . A method of making a carpet latex compound, the method comprising the steps of: 
 providing a carboxylated styrene-butadiene latex;    adding a rosin acid soap to the latex to provide a pre-compound latex; and    adding to the precompound latex at least one of a filler, a thickener and a curative.    
     
     
         2 . A carpet comprising: 
 a backing;    a pile which is bonded to said backing with an admixture comprising: 
 a carboxylated styrene-butadiene rubber;  
 from about 0.05 parts by weight to about to about 10 parts by weight rosin acid soap phr;  
 from about 0.2 parts by weight to about 6.0 parts by weight emulsifier phr;  
 from about 250 parts by weight to about 800 parts by weight filler phr; and  
 from about 0.1 parts by weight to about 5.0 parts by weight thickener phr.  
   
     
     
         3 . A carpet as specified in  claim 2 , wherein said carboxylated styrene-butadiene rubber is comprised of repeat units which are derived from about 52 weight percent to about 69.5 weight percent styrene, from about 30 weight percent to about 45 weight percent 1, 3-butadiene, and from about 1 weight percent to about 3 weight percent itaconic acid; wherein said rosin acid soap is a potassium soap of rosin acid, a sodium soap of rosin acid or a lithium soap of rosin acid; and wherein said filler is an inorganic carbonate.  
     
     
         4 . A carpet as specified in  claim 2 , wherein said carboxylated styrene-butadiene rubber is comprised of repeat units which are derived from about 58 weight percent to about 63.4 weight percent styrene, from about 35 weight percent to about 40 weight percent, 1,3-butadiene, and from about 1.6 weight percent to about 2 weight percent itaconic acid; wherein said rosin acid soap is a potassium soap of rosin acid; and wherein said filler is calcium carbonate.  
     
     
         5 . A carpet comprising: 
 a pile;    a backing; and    a dried carpet latex compound bonding said pile to said backing, said carpet latex compound comprising: 
 a) a carboxylated styrene-butadiene latex,  
 b) a filler in an amount from about 250 parts by weight to about 800 parts by weight per 100 parts by weight of said latex,  
 c) a thickener in an amount from about 0.1 parts by weight to about 5.0 parts by weight per 100 parts by weight of said latex; and  
 d) optionally, a curative;  
 said carboxylated styrene-butadiene rubber, an emulsifier in an amount from about 0.2 phr to about 6.0 phr, and a rosin acid soap in an amount from about 0.05 phr to about 10 phr.  
   
     
     
         6 . A carpet according to  claim 5 , wherein said rosin acid soap is a potassium soap of rosin acid, a sodium soap of rosin acid, or a lithium soap of rosin acid, or combinations thereof.  
     
     
         7 . A carpet according to  claim 6 , including said curative, and wherein said curative is zinc oxide.  
     
     
         8 . A carpet according to  claim 6 , wherein said rosin acid soap is present at a level which is within the range of about 0.1 phr to about 5 phr, and wherein said filler is calcium carbonate.  
     
     
         9 . A carpet according to  claim 8 , wherein said carboxylated styrene-butadiene rubber is comprised of repeat units which are derived from about 52 weight percent to about 69.5 weight percent styrene, from about 30 weight percent to about 45 weight percent 1,3-butadiene, and from about 1 weight percent to about 3 weight percent itaconic acid.  
     
     
         10 . A carpet according to  claim 9 , wherein said carboxylated styrene-butadiene rubber is comprised of repeat units which are derived from about 58 weight percent to about 63.4 weight percent styrene, from about 35 weight percent to about 2 weight percent itaconic acid, and wherein said rosin acid soap is present at a level which is within the range of about 0.5 phr to about 1 phr.  
     
     
         11 . A carpet according to  claim 5 , wherein said filler is calcium carbonate, and wherein said carboxylated styrene-butadiene rubber is comprised of repeat units which are derived from about 52 weight percent to about 69.5 weight percent styrene, from about 30 weight percent to about 45 weight percent 1,3-butadiene and from about 1 weight percent to about 3 weight percent of an unsaturated carboxylic acid monomer which is acrylic acid, methacrylic acid, fumaric acid, or combinations thereof.  
     
     
         12 . The carpet of  claim 2 , where said rosin acid soap is present in an amount from about 0.25 parts by weight to about 2 parts by weight phr.  
     
     
         13 . The carpet of  claim 2 , where said rosin acid soap is present in an amount from about 0.5 parts by weight to about 1 parts by weight phr.  
     
     
         14 . The carpet of  claim 2 , where the emulsifier is a rosin acid soap.  
     
     
         15 . The carpet of  claim 2 , where the emulsifier is present in an amount from about 1 part by weight to about 5 parts by weight phr.  
     
     
         16 . The carpet of  claim 2 , where the emulsifier is present in an amount from about 2 parts by weight to about 4 parts by weight phr.  
     
     
         17 . The carpet of  claim 2 , where the carboxylated styrene-butadiene rubber is crosslinked.  
     
     
         18 . The carpet of  claim 5 , where the carboxylated styrene-butadiene rubber is crosslinked.