US-20260124825-A1 - THERMALLY BONDED ARTICLES

US20260124825A1US 20260124825 A1US20260124825 A1US 20260124825A1US-20260124825-A1

Abstract

Embodiments of the present disclosure are directed towards thermally bonded articles including a polyethylene filament material and a multilayer backing material, where the polyethylene filament material is thermally bonded to the multilayer backing material.

Inventors

Albert Carbonell Blanch
Georgia Natacha Eftalie Bitinis
Joseph L. Deavenport

Assignees

DOW GLOBAL TECHNOLOGIES LLC

Dates

Publication Date: 20260507
Application Date: 20241104

Claims (10)

1 . A thermally bonded article comprising: a polyethylene filament material; and a multilayer backing material that is thermally bonded to the polyethylene filament material, wherein the multilayer backing material includes a first reduced-density polyethylene layer, a high-density polyethylene layer, and a second reduced-density polyethylene layer.
2 . The thermally bonded article of claim 1 , wherein the polyethylene filament material comprises a reduced-density polyethylene.
3 . The thermally bonded article of claim 1 , wherein the high-density polyethylene layer is formed adjacent to the first reduced-density polyethylene layer and the second reduced-density polyethylene layer, while the inner layer separates the first reduced-density polyethylene layer and the second reduced-density polyethylene layer.
4 . The thermally bonded article of claim 1 , wherein the first reduced-density polyethylene layer and the second reduced-density polyethylene layer include a same reduced-density polyethylene.
5 . The thermally bonded article of claim 4 , wherein the same reduced-density polyethylene has density less than 0.940 g/cm 3 .
6 . The thermally bonded article of claim 1 , wherein the polyethylene filament material, the first reduced-density polyethylene layer, and the second reduced-density polyethylene layer include a same linear low-density polyethylene.
7 . The thermally bonded article of claim 1 , wherein the polyethylene filament material includes a first linear low-density polyethylene and the first reduced-density polyethylene layer and the second reduced-density polyethylene layer include a second linear low-density polyethylene, wherein the first linear low-density polyethylene is different than the second linear low-density polyethylene.
8 . The thermally bonded article of claim 1 , wherein the multilayer backing material has a thickness from 20 to 150 micrometers.
9 . The thermally bonded article of claim 1 , wherein: the first reduced-density polyethylene layer is from 5% to 20% of a total thickness of a combination of the first reduced-density polyethylene layer, the high-density polyethylene layer, and the second reduced-density polyethylene layer; the second reduced-density polyethylene layer is from 5% to 20% of the total thickness of the combination of the first reduced-density polyethylene layer, the high-density polyethylene layer, and the second reduced-density polyethylene layer; and the high-density polyethylene layer is from 60% to 90% of the total thickness of the combination of the first reduced-density polyethylene layer, the high-density polyethylene layer, and the second reduced-density polyethylene layer.
10 . The thermally bonded article of claim 1 , wherein the high-density polyethylene layer includes a high-density polyethylene having a density greater than or equal to 0.945 g/cm 3 .

Description

FIELD OF DISCLOSURE Embodiments of the present disclosure are directed towards thermally bonded articles including a polyethylene filament material and a multilayer backing material, where the polyethylene filament material is thermally bonded to the multilayer backing material. BACKGROUND Artificial turf is a synthetic surface that can mimic the appearance and feel of natural grass, commonly used in sports fields, residential lawns, and commercial landscapes. It is made by tufting synthetic fibers into a backing material, which is then coated with an adhesive for stability. The fibers are cut to a specific height to create a uniform, grass-like pile. Artificial turf is valued for its low maintenance requirements, durability, and ability to withstand heavy use in various climates. However, there remains a need for articles that can provide one or more advantageous properties. SUMMARY The present disclosure provides various embodiments, including, without limitation, the following. A thermally bonded article including: a polyethylene filament material and a multilayer backing material that is thermally bonded to the polyethylene filament material, wherein the multilayer backing material includes a first reduced-density polyethylene layer, a high-density polyethylene layer, and a second reduced-density polyethylene layer. DETAILED DESCRIPTION The present disclosure is directed toward thermally bonded articles including a polyethylene filament material and a multilayer backing material that is thermally bonded to the polyethylene filament material, wherein the multilayer backing material includes a first reduced-density polyethylene layer, a high-density polyethylene layer, and a second reduced-density polyethylene layer. As used and discussed further herein, a “reduced-density polyethylene” has a lower density as compared to a “high-density polyethylene”, i.e., HPDE. As used and discussed further herein, a “reduced-density polyethylene” has a density less than 0.940 g/cm3, in contrast to a “high-density polyethylene”, which has a density equal to or greater than 0.945 g/cm3. Advantageously, the thermally bonded articles disclosed herein are made from polyethylene. The thermally bonded articles disclosed herein may be referred as mono-material articles as they are made from one material, i.e. polyethylene. Mono-material articles are advantageously more recyclable as compared to multi-material articles, i.e. articles made from more than one polypropylene. Mono-material articles, such as the thermally bonded articles disclosed herein, are desirable for a number of applications, such as artificial turf, where recyclability after an intended lifetime may be preferrable. Polypropylene, which has previously been utilized for primary backing leading to a multi-material turf system in combination with polyethylene filament, can have a relatively higher melting point as compared to polyethylene. This relatively higher melting point is also undesirable for thermal bonding. Advantageously, the thermally bonded articles disclosed herein can provide an improved, i.e. greater, seal strength as compared other articles that have a similar filament material and similar core material, e.g., in the backing material. This improved seal strength is desirable for a number of applications, such as artificial turf, where the improved seal strength may improve the useability properties, e.g. tuft lock, and/or extend the intended lifetime of the artificial turf. As mentioned, the thermally bonded articles disclosed herein include a polyethylene filament material. As used herein, “polyethylene” incudes various polyethylene polymers, such as high-density polyethylene (HDPE), linear low-density polyethylene (LLDPE), ultra low-density polyethylene (ULDPE), medium-density polyethylene (MDPE), and low-density polyethylene (LDPE), among others. The term “polymer” refers to a polymeric compound prepared by polymerizing monomers, whether of a same or a different type. The generic term polymer thus embraces the term “homopolymer,” which refers to a polymer prepared from only one type of monomer as well as “copolymer,” which refers to a polymer prepared from two or more different monomers. “Polyethylene” e.g., polyethylene polymers, refer to polymers comprising greater than 50% by mole of units derived from ethylene monomer. Embodiments provide that from 55 to 100 wt % of the polyethylene is derived from ethylene monomers, based on a total weight of the polyethylene. All individual values and subranges from 55 to 100 wt % are included; for example, the polyethylene can have from a lower limit of 55, 60, 70, or 75 wt % of units derived ethylene monomers to an upper limit of 100, 99.9, 97, 95, 90, 85, or 80 wt % of units derived ethylene monomers based upon the total weight of the polyethylene. One or more embodiments provide that from 0.1 to 45 wt % of polyethylene is derived from comonomers, when a comonomer is utilized, based on a total weight o