Dyeable polyolefin backing for tufted surface coverings

Claim 2

As a surface covering, a dyed carpet or upholstery fabric comprising a polyolefin backing material having a polymeric coating thereon, and face yarns tufted to said backing, said coating being selected from: A. homopolymers and copolymers of a quaternary monomer prepared by reacting an epihalohydrin of the formula ##STR2## with an amine salt of the formula H 2 C=C(R)C(O)O--A--N(CH 3 ) 2 .sup.. HY; and B. the reaction product of homopolymers or copolymers of said amine salt and said epihalohydrin; wherein R is hydrogen or methyl, X is iodine, bromine or chlorine, A is a (C 2 -C 6 ) alkylene group having at least two carbon atoms in a chain between adjoined O and N atoms or A may be a polyoxyethylene group of the formula (CH 2 CH 2 O) x CH 2 CH 2 wherein x is at least 1, and Y is an anion.

Claim 3

A surface covering as in claim 1 wherein said backing material is selected from woven and nonwoven polyethylene or polypropylene.

Claim 4

A surface covering as in claim 1 wherein said backing material is a fabric of slit polypropylene film and said film is dyed after application of said polymeric coating and after tufting.

Claim 5

A surface covering as in claim 1 wherein said backing material is a nonwoven polypropylene fabric and said fabric of non-woven polypropylene is dyed after application of said coating and after tufting.

Claim 6

A surface covering as in claim 1 wherein said polymeric coating is a copolymer of said quaternary monomer and at least one other α,β-monoethylenically unsaturated monomer.

Claim 7

A surface covering as in claim 5 wherein said other monomer is a lower alkyl ester of acrylic or methacrylic acid.

Claim 8

A surface covering as in claim 1 wherein said polymeric coating is a copolymer of a quaternary monomer prepared by reacting (a) a hydrogen acid salt of dimethylaminoethyl methacrylate and epichlorohydrin, and (b) a (C 1 -C 4 ) alkyl acrylate, a mixture of a (C 1 -C 4 )alkyl acrylate and acrylonitrile, or a mixture of a (C 1 -C 4 ) alkyl acrylate and dimethylaminoethyl methacrylate, in proportions of 1-10 wt.% of said quaternary monomer to 99-90 wt.% of said alkyl acrylate or mixtures.

Claim 9

A surface covering as in claim 7 wherein said alkyl acrylate is ethyl acrylate.

Claim 10

A surface covering as in claim 7 wherein the amount of said ethyl acrylate is 92-95 wt.%.

Claim 11

A surface covering as in claim 7 wherein said alkyl acrylate is ethyl acrylate, and said mixture with dimethylaminoethyl methacrylate contains up to 50% by weight of said methacrylate.

Claim 12

A surface covering as in claim 1 wherein the amount of polymeric coating on the polyolefin backing is about 1-20% by weight of said backing.

Claim 13

A process for preparing a dyed carpet or upholstery fabric which comprises coating a polyolefin backing material with a polymer composition selected from A. homopolymers and copolymers of a quaternary monomer prepared by reacting an epihalohydrin of the formula ##STR3## with an amine salt of the formula H 2 C=C(R)C(O)O--A--N(CH 3 ) 2 .sup.. HY; and B. the reaction product of homopolymers or copolymers of said amine salt and said epihalohydrin; wherein R is hydrogen or methyl, X is iodine, bromine or chlorine, A is a (C 2 -C 6 ) alkylene group having at least two carbon atoms in a chain between adjoined O and N atoms or A may be a polyoxyethylene group of the formula (CH 2 CH 2 O) x CH 2 CH 2 wherein x is at least 1, and Y is an anion and dyeing and tufting the resulting coated backing material.

Claim 14

A process for preparing a dyed carpet or upholstery fabric which comprises coating a polyolefin backing material with a polymer composition selected from A. homopolymers and copolymers of a quaternary monomer prepared by reacting an epihalohydrin of the formula ##STR3## with an amine salt of the formula H 2 C=C(R)C(O)O--A--N(CH 3 ) 2 .sup.. HY; and B. the reaction product of homopolymers or copolymers of said amine salt and said epihalohydrin; wherein R is hydrogen or methyl, X is iodine, bromine or chlorine, A is a (C 2 -C 6 ) alkylene group having at least two carbon atoms in a chain between adjoined O and N atoms or A may be a polyoxyethylene group of the formula (CH 2 CH 2 O) x CH 2 CH 2 wherein x is at least 1, and Y is an anion and dyeing and tufting the resulting coated backing material.

Claim 15

A process as in claim 12 wherein said backing is selected from woven and nonwoven polyethylene or polypropylene.

Claim 16

A process as in claim 12 wherein said backing material is a fabric of slit polypropylene film and said fabric of polypropylene film is dyed after application of said polymeric coating and after tufting.

Claim 17

A process as in claim 12 wherein said backing material is a nonwoven polypropylene fabric and said fabric of non-woven polypropylene is dyed after application of said coating and after tufting.

Claim 18

A process as in claim 12 wherein said polymeric coating is a copolymer of said quaternary monomer and at least one other α,β-monoethylenically unsaturated monomer.

Claim 19

A process as in claim 12 wherein said polymeric coating is a copolymer of said quaternary monomer and a (C 1 -C 4 )alkyl acrylate, a mixture of a (C 1 -C 4 )alkyl acrylate and acrylonitrile, or a mixture of a (C 1 -C 4 )alkyl acrylate and dimethylaminoethyl methacrylate.

Claim 20

A process as in claim 17 wherein said (C 1 -C 4 )alkyl acrylate is ethyl acrylate.