Carpets and Textile Layers Comprising a Polymer Blend and Methods of Making the Same

Abstract

Provided are carpets and textile layers comprising a plurality of fibers and layer for locking the plurality of fibers, and methods for making them.

What is claimed is: 
     
         1 . A carpet comprising:
 (a) a plurality of fibers; and   (b) an adhesion layer for locking the plurality of fibers, wherein the adhesion layer comprises a polymer blend containing:
 (i) a first propylene-based polymer, wherein the first propylene-based polymer is a homopolymer of propylene or a copolymer of propylene and ethylene or a C 4  to C 10  alpha-olefin; and 
 (ii) a second propylene-based polymer, wherein the second propylene-based polymer is a homopolymer of propylene or a copolymer of propylene and ethylene or a C 4  to C 10  alpha-olefin; wherein the second propylene-based polymer is different than the first propylene-based polymer; 
   wherein the polymer blend has a melt viscosity, measured at 190° C. according to ASTM D-3236, of about 500 to about 25,000 cP.   
     
     
         2 . The carpet of  claim 1 , wherein the polymer blend has a melt viscosity, measured at 190° C. according to ASTM D-3236, of about 1,000 to about 10,000 cP. 
     
     
         3 . The carpet of  claim 1 , wherein the adhesion layer substantially locks in the plurality of fibers. 
     
     
         4 . The carpet of  claim 1 , further comprising a nonwoven layer between the adhesion layer and the plurality of fibers. 
     
     
         5 . The carpet of  claim 1 , wherein the polymer blend comprises at least about 70 mol % of propylene-derived units. 
     
     
         6 . The carpet of  claim 1 , wherein the first propylene-based polymer and the second propylene-based polymer each comprises a copolymer of propylene and ethylene. 
     
     
         7 . The carpet of  claim 1 , wherein the polymer blend has a heat of fusion of between about 10 to about 90 J/g. 
     
     
         8 . The carpet of  claim 1 , wherein the first propylene-based polymer and the second propylene-based propylene polymer have a difference in heat of fusion of at least 10 J/g. 
     
     
         9 . The carpet of  claim 1 , wherein the adhesion layer is substantially free of latex. 
     
     
         10 . The carpet of  claim 1 , wherein the carpet comprises no more than 20 g/m 2  of latex. 
     
     
         11 . The carpet of  claim 1 , wherein the carpet comprises 0 g/m 2  of latex. 
     
     
         12 . The carpet of  claim 1 , wherein the adhesion layer further comprises a functionalized polymer. 
     
     
         13 . The carpet of  claim 1 , wherein the carpet has an average relative mass loss, as measured according to EN 1963-A, of less than about 10%. 
     
     
         14 . The carpet of  claim 1 , wherein the carpet has a tuft withdrawal force, as measured according to ISO 4949, of greater than about 3 N. 
     
     
         15 . A carpet comprising:
 (a) a primary backing layer having a face side and a back side;   (b) a plurality of fibers attached to the primary backing layer and extending from both the face side and the back side of the primary backing layer; and   (c) a second layer attached to the back side of the primary backing layer,   wherein at least one of the primary backing layer and the second layer comprises a polymer blend comprising:
 (i) a first propylene-based polymer, wherein the first propylene-based polymer is a homopolymer of propylene or a copolymer of propylene and ethylene or a C 4  to C 10  alpha-olefin; and 
 (ii) a second propylene-based polymer, wherein the second propylene-based polymer is a homopolymer of propylene or a copolymer of propylene and ethylene or a C 4  to C 10  alpha-olefin; wherein the second propylene-based polymer is different than the first propylene-based polymer; 
   wherein the polymer blend has a melt viscosity, measured at 190° C. according to ASTM D-3236, of about 500 to about 25,000 cP.   
     
     
         16 . The carpet of  claim 15 , wherein the primary backing layer comprises the polymer blend. 
     
     
         17 . The carpet of  claim 15 , wherein the second layer comprises the polymer blend. 
     
     
         18 . The carpet of  claim 15 , wherein the primary backing layer comprises a nonwoven layer, and the second layer comprises the polymer blend. 
     
     
         19 . The carpet of  claim 15 , further comprising a third layer attached to the second layer opposite to the primary backing layer. 
     
     
         20 . A textile layer comprising:
 (a) a plurality of fibers; and   (b) an adhesion layer for locking the plurality of fibers, wherein the adhesion layer comprises a polymer blend containing:
 (i) a first propylene-based polymer, wherein the first propylene-based polymer is a homopolymer of propylene or a copolymer of propylene and ethylene or a C 4  to C 10  alpha-olefin; and 
 (ii) a second propylene-based polymer, wherein the second propylene-based polymer is a homopolymer of propylene or a copolymer of propylene and ethylene or a C 4  to C 10  alpha-olefin; wherein the second propylene-based polymer is different than the first propylene-based polymer; 
   wherein the polymer blend has a melt viscosity, measured at 190° C. according to ASTM D-3236, of about 500 to about 25,000 cP.   
     
     
         21 . The textile layer of  claim 20 , wherein the plurality of fibers are oriented in the same plane as the adhesion layer. 
     
     
         22 . The textile layer of  claim 20 , wherein the adhesion layer is discontinuous. 
     
     
         23 . The textile layer of  claim 20 , wherein the adhesion layer locks in the plurality of fibers in a pattern or in discrete zones. 
     
     
         24 . A method for making a carpet or a textile layer, comprising the steps of:
 (a) providing a plurality of fibers;   (b) applying a melt comprising a polymer blend to the plurality of fibers to form an adhesion layer for locking the plurality of fibers,   wherein the polymer blend comprises:
 (i) a first propylene-based polymer, wherein the first propylene-based polymer is a homopolymer of propylene or a copolymer of propylene and ethylene or a C 4  to C 10  alpha-olefin; and 
 (ii) a second propylene-based polymer, wherein the second propylene-based polymer is a homopolymer of propylene or a copolymer of propylene and ethylene or a C 4  to C 10  alpha-olefin; wherein the second propylene-based polymer is different than the first propylene-based polymer, 
   wherein the polymer blend has a melt viscosity, measured at 190° C. according to ASTM D-3236, of about 500 to about 25,000 cP; and   (c) forming a carpet or a textile layer.   
     
     
         25 . The method of  claim 24 , wherein the polymer blend is applied via extrusion.