Bonding carpet backing using a latex extended with grafted mineral oil

Claim 1

A method which comprises coating the backing of a carpet comprising a plurality of fibers or tufts woven with a first fibrous backing with an aqueous curable adhesive composition and then applying with pressure a second fibrous backing material to said adhesive coated first fibrous backing to form a laminate, said adhesive being present in an amount sufficient to secure the ends of said fibers or tufts to said first backing material and to secure said second backing material to said first backing material, and then heating the resulting laminate at a temperature and for a time sufficient to dry said adhesive and said secondary backing and to cure said adhesive to bind the ends of the fibers or tufts of said carpet to said primary backing and said primary backing to said secondary backing together into a unitary laminate without adversely affecting the fibers or tufts of said carpet, said adhesive in said composition comprising a blend of a polymer and a minor amount by weight of extender for said polymer, said extender comprising a mineral oil containing, per 100 parts by weight of said oil, graft polymerized to said oil from about 2 to 20 parts by weight of an ethylenically unsaturated monomer having from 2 to 16 carbon atoms and said polymer being a copolymer of a diene selected from the group consisting of butadiene, isoprene and 2,3-dimethyl butadiene and at least one copolymerized monomer selected from the group consisting of acrylic acid, methacrylic acid, maleic acid, maleic anhydride, fumaric acid, itaconic acid, vinyl benzoic acid, α-chloro acrylic acid and crotonic acid.

Claim 2

A method which comprises coating the backing of a carpet comprising a plurality of fibers or tufts woven with a first fibrous backing with an aqueous curable adhesive composition and then applying with pressure a second fibrous backing material to said adhesive coated first fibrous backing to form a laminate, said adhesive being present in an amount sufficient to secure the ends of said fibers or tufts to said first backing material and to secure said second backing material to said first backing material, and then heating the resulting laminate at a temperature and for a time sufficient to dry said adhesive and said secondary backing and to cure said adhesive to bind the ends of the fibers or tufts of said carpet to said primary backing and said primary backing to said secondary backing together into a unitary laminate without adversely affecting the fibers or tufts of said carpet, said adhesive in said composition comprising a blend of a polymer and a minor amount by weight of extender for said polymer, said extender comprising a mineral oil containing, per 100 parts by weight of said oil, graft polymerized to said oil from about 2 to 20 parts by weight of an ethylenically unsaturated monomer having from 2 to 16 carbon atoms and said polymer being a copolymer of a diene selected from the group consisting of butadiene, isoprene and 2,3-dimethyl butadiene and at least one copolymerized monomer selected from the group consisting of acrylic acid, methacrylic acid, maleic acid, maleic anhydride, fumaric acid, itaconic acid, vinyl benzoic acid, α-chloro acrylic acid and crotonic acid.