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Achieving Higher Filler Loading of Heavy Layer Mat Using a Two Step Process

IP.com Disclosure Number: IPCOM000240679D
Publication Date: 2015-Feb-17
Document File: 5 page(s) / 23K

Publishing Venue

The IP.com Prior Art Database

Abstract

Described herein is a two-step process for preparing heavy layer mats (“HLM”) for carpet backing or sound deadening sheets that utilizes Vistamaxx™ performance polymers and high loading levels of CaCO3. A traditional one-step process using a twin screw extruder that is directly connected to a two meters wide T-die requires either a time consuming fine tuning process or more sophisticated equipment. Further, when ethylene vinyl acetate (EVA) resins are used as the main carrier resin in a one-step processes, typically only a maximum filler loading of 65% is obtainable. By using the two-step process illustrated in this study that utilizes Vistamaxx™ performance polymers as main carrier resin, a HLM with a width greater than 1.8 m and a CaCO3 loading of more than 75% can be made.

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Achieving Higher Filler Loading of Heavy Layer Mat Using a Two Step Process

Abstract: Described herein is a two-step process for preparing heavy layer mats ("HLM") for carpet backing or sound deadening sheets that utilizes Vistamaxx™ performance polymers and high loading levels of CaCO3. A traditional one-step process using a twin screw extruder that is directly connected to a two meters wide T-die requires either a time consuming fine tuning process or more sophisticated equipment. Further, when ethylene vinyl acetate (EVA) resins are used as the main carrier resin in a one-step processes, typically only a maximum filler loading of 65% is obtainable. By using the two-step process illustrated in this study that utilizes Vistamaxx™ performance polymers as main carrier resin, a HLM with a width greater than 1.8 m and a CaCO3 loading of more than 75% can be made.

Background:

The heavy layer mat (HLM) that is mainly composed of carrier resins and fillers is a very important part of automotive carpets and sound deadening sheets (SDS). High quality heavy layer mats should have excellent acoustic performance (a minimum weight per a standard square area) and mechanical properties good enough for a secondary process, i.e., making the finished SDS or carpet.

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Development:

Traditional one-step processes utilize a...