Extruded carpet backing with resin and elastomer components

Abstract

Highly flexible compositions of matter useful in the preparation of carpet backing are disclosed comprising thermoplastic resin compositions including copolymers of ethylene and unsaturated esters of lower carboxylic acids, such as vinyl esters and/or lower alkyl acrylates, in admixture with olefinic elastomers and substantial amounts of filler. The preferred thermoplastic resins employed include the copolymers of ethylene and vinyl acetate, and the preferred olefinic elastomers disclosed are ethylene copolymer elastomers, such as copolymers of ethylene and propylene, as well as terpolymers of ethylene, propylene and a diene, and the compositions preferably include a stearate or stearic acid and a hydrocarbon oil component. Carpet constructions are also disclosed comprising a plurality of carpet fibers and a thermoplastic barrier coating comprising the above combination of a thermoplastic resin, an olefinic elastomer and a substantial portion of filler material. Preferably a thermoplastic adhesive pre-coat layer is employed to bind the fibers together, and this is employed with a tufted carpet to adhere the carpet tufts to a woven or non-woven carpet scrim. These carpet constructions are preferably utilized in automotive carpeting applications. Methods for preparing said carpet constructions are also disclosed, comprising preparing the above thermoplastic barrier coating, applying (preferably by extrusion) an adhesive precoat to the surface of the carpet fibers so as to bind the fibers securely together, and applying the barrier coating so as to provide a strong and highly flexible carpet construction.