| HS Code | 336735 |
| Product Name | Fulatex PD0124 |
| Brand | Fulatex |
| Model Number | PD0124 |
| Product Type | Latex Mattress |
| Core Material | Natural Latex |
| Cover Material | Organic Cotton |
| Dimensions | 180 x 200 x 20 cm |
| Firmness | Medium-firm |
| Density | 80D |
| Country Of Origin | Malaysia |
| Certification | OEKO-TEX Standard 100 |
As an accredited Fulatex PD0124 factory, we enforce strict quality protocols—every batch undergoes rigorous testing to ensure consistent efficacy and safety standards.
| Packing | Fulatex PD0124 is supplied in 200 kg polyethylene-lined steel drums, securely sealed and labeled with hazard and handling information. |
| Container Loading (20′ FCL) | Fulatex PD0124 is loaded as a 20′ FCL, with drums securely palletized and strapped to prevent movement during transit. |
| Shipping | Fulatex PD0124 is shipped in sealed, corrosion-resistant containers to prevent leakage and contamination. Keep containers upright, secured, and clearly labeled. Transport in dry, ventilated vehicles away from incompatible materials and extreme temperatures. Personnel should wear appropriate PPE during handling. Shipping documentation includes the SDS and product specifications. |
| Storage | Store Fulatex PD0124 in tightly sealed original containers in a cool, dry, well-ventilated area, away from direct sunlight, heat sources, and ignition risks. Maintain temperatures between 5–35°C; do not allow freezing. Keep containers upright and closed when not in use, and separate from oxidizing agents or incompatible chemicals. Use within recommended shelf life to ensure product stability. |
| Shelf Life | Shelf life is typically 12 months when stored unopened in its original container at recommended conditions, avoiding freezing and direct sunlight. |
In a 2.4 m wide carded-thermobonded line running viscose/polyester 45/55 at 50 g/m², Fulatex PD0124, a carboxylated styrene-butadiene dispersion, is metered through an air-assisted spray bar with 0.3 mm nozzles. The latex is diluted to 10–12% solids and sieved through a 100-mesh screen before spraying. Foam application replaces spray when the target dry add-on falls below 8%. The compound contains 3–5 dry parts of melamine-formaldehyde crosslinker per 100 dry parts of latex and 0.3–0.6 dry parts of an ethoxylated nonionic wetting agent. Curing is performed in a three-zone stenter at 135°C, 145°C, 150°C with dwell time 2.5–3.0 min. The critical processing window is 145–150°C; below 140°C, wet tensile retention drops below 55% after a 30-min soak at 23°C in deionized water. Above 152°C, surface brittleness appears and elongation at break per ISO 9073-3:2023 falls below 20%.
The production bottleneck on this line is edge crusting. Trim sections dry faster under higher air turbulence, producing flaking dust and binder deposits on the stenter clips. An edge-oil system with 0.5–0.8% silicone emulsion reduces edge deposition, but the silicone-to-latex ratio must be controlled within ±0.1 percentage point. Excess silicone reduces dry tensile strength measured per ASTM D5035-19 by more than 12% at 15% add-on. Wet wipes produced from the latex-bonded acquisition layer require wet tensile strength above 3.5 N/25 mm per ISO 9073-3:2023 after 10 min immersion in 0.9% NaCl at 40°C to survive pre-moistened converting. Published data for this exact saline-soak configuration is limited; the threshold aligns with comparable carboxylated SBR latices in the 48–52% solids range.
Fulatex PD0124 enters carpet precoat compounds at 18–22 dry parts per 100 dry parts of calcium carbonate. The filler slurry is dispersed in a Cowles dissolver at 15–20 m/s tip speed; the latex is added under sweep agitation at 10–15 rpm to avoid shear-induced destabilization. Final compound solids are held at 78–80%. Brookfield RVF viscosity at 20 rpm is 1,800–2,500 mPa·s for knife-over-roll precoat. When the compound is converted to air-foam for secondary backing, a foam generator set at 300–500 rpm produces a wet foam density of 0.35–0.45 g/cm³. The foam is coated onto tufted greige at 300–450 g/m² wet and dried at 130–140°C.
A failure mode in tufted nylon loop carpet occurs when precoat filler loading rises above 300 phr and the latex binder drops below 16 dry parts. The tuft bind measured per ASTM D1335-17 falls below 13.3 N for nylon cut-pile. At filler loadings below 150 phr, compound viscosity drops below 800 mPa·s and strike-through into the carpet backing increases. The operable dry-weight ratio of filler to binder is therefore 3.5:1 to 5.5:1. Viscosity drift between precoat batches is typically 300–500 mPa·s at 20 rpm; in-line correction uses 0.1% aqueous ammonia. The compound temperature must be kept below 35°C because higher temperatures accelerate ammonia loss and promote skin formation in the foam generator.
Saturating kraft for gasket base and abrasive backing is impregnated in a flooded-nip trough at 60–80 m/min. The bath is maintained at pH 8.0–9.0 with ammonium hydroxide; the anionic charge of the carboxylated SBR colloid remains stable, but zeta potential shifts from approximately -40 mV at pH 7.0 to -55 mV at pH 8.5. Retention in a 0.20 mm saturating kraft sheet is 18–22% dry pick-up. The impregnated sheet is dried at 110–120°C. If the bath temperature exceeds 35°C, ammonium hydroxide loss causes pH drift to 6.5 and increases interference from cationic retention aids. Aluminum sulfate additions above 0.5% on dry fibre must be avoided because the trivalent cation collapses the electrical double layer and forms visible microgels.
The latex is compounded with 8–12 dry parts of melamine-formaldehyde per 100 dry parts of latex. The impregnated paper is cured at 150°C for 60 seconds in a festoon dryer. Crosslink density, inferred from methyl ethyl ketone swell ratio, reaches 2.8–3.2 at 150°C. Below 145°C the solvent swell ratio rises above 4.0 and the abrasive backing separates under 150 N/m peel. Published data for Fulatex PD0124 in gear-pump impregnation at this exact swell ratio is limited; the values align with carboxylated SBR saturants at 48–52% solids.
| Application | Standard | Clause/Method | Controlled parameter |
|---|---|---|---|
| Nonwoven tensile | ISO 9073-3:2023 | Clause 5 | Breaking force, elongation |
| Carpet tuft bind | ASTM D1335-17 | Section 7 | Tuft withdrawal force |
| Cement tile adhesive transverse deformation | ISO 13007-2:2013 | Clause 5 | Transverse deformation |
| Textile flock abrasion | ISO 12947-2:2016 | Martindale cycles | End point |
| Food contact paper | FDA 21 CFR 176.170 | Subpart B | Extractives |
Where SBR latex competes against polyvinyl alcohol in C2TE-class tile adhesives, Fulatex PD0124 is introduced at a polymer-to-cement ratio of 0.25 on CEM I 42.5. The latex is added to the mix water after the superplasticizer but before the cellulose ether. Mixing with a planetary paddle at 285 rpm for 3 min produces a lump-free mortar. The latex-modified mortar is tested for transverse deformation per ISO 13007-2:2013. Transverse deformation above 5 mm is achievable at P/C 0.30, but open time measured per EN 1346:2007 depends on the film-forming temperature of the latex. A lower film-forming temperature improves flexibility but increases surface skinning. A 0.1% addition of mineral-oil defoamer prevents pinholes in spread adhesive films. Pinholes are counted under a 30× stereo microscope after 24 h at 23°C and 50% RH. In two-component flexible waterproofing slurries, the latex is combined with a powder blend at a liquid-to-powder ratio of 1:4 by weight and applied in two coats with a 2.5 mm notched trowel.
In textile flocking, Fulatex PD0124 is thickened with 0.8–1.2 dry parts of alkali-swellable acrylic thickener to a Brookfield RVF viscosity of 8,000–12,000 mPa·s at 20 rpm. The thickened adhesive is applied by engraved roller at 120–160 g/m² to cotton twill. Flock fibres are applied electrostatically at 60–80 kV with fibre length 0.2–0.4 mm. The adhesive must remain open for 10–15 s before flash-off at 80°C. Cure is performed at 120–130°C for 2–3 min. The low-temperature cure profile is effective only when the adhesive pH is held at 8.0–8.5; below 7.5, the carboxylated SBR thickener response collapses and flock penetration becomes uneven.
Interlining base cloth requires a lower add-on and higher wash resistance. The compound is foamed to 0.10–0.15 g/cm³ and knife-coated at 15–20 g/m² dry add-on. The coated interlining is bonded to shell fabric by fusing at 140°C for 12 s under 3 kPa. Wash durability is assessed with 30 machine wash cycles at 40°C using 4 g/L ECE reference detergent per ISO 6330:2021. Delamination is measured by peel force per ISO 2411:2017; a value below 5 N/25 mm after washing indicates under-crosslinking or excessive thickener loading. The acrylic thickener must be diluted with deionized water before addition to avoid shock gelation; direct addition to the neat latex at 6.0% solids creates local viscosity spikes above 30,000 mPa·s and uneven roller transfer.
Resilient flooring felt requires a frothed compound that penetrates 400–600 g/m² needled fibre webs without forming a surface film. Fulatex PD0124 is compounded with hydrated alumina at 70–80 phr and antimony trioxide at 3–5 phr. The alumina surface is mildly acidic; the bath pH is corrected to 8.5–9.0 with ammonium hydroxide before latex addition. Mixing is performed in a low-shear paddle mixer at 60–80 rpm for 15 min to reduce air entrapment. The frothed compound is applied through a knife-over-roll coater at 500–700 g/m² wet. Drying is carried out in a forced-air oven at 130–145°C. If the drying temperature exceeds 150°C, antimony trioxide can catalyse discolouration at the felt surface. The dried felt is calendered at 160°C under 2.5 MPa to compress the pore structure and improve dimensional stability per ISO 2551. Published data for Fulatex PD0124 in flame-retardant felt at this exact filler loading is limited; the processing boundaries reflect publicly documented behaviour of carboxylated SBR latices in alumina trihydrate-filled compounds.
For simple paper-to-paper laminating, the latex is applied at 6–8 g/m² dry and nipped at 60°C without a crosslinker.
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Fulatex PD0124 is supplied as an aqueous anionic polymer dispersion; distributor documentation places the material in the carboxylated styrene-butadiene latex category. It is handled in converting plants for saturated paper, nonwoven web reinforcement, and polymer-modified cementitious mortars. Published multi-lot certificates for this exact model designation are not openly consolidated in ISO or ASTM repositories. Consequently, property values cited below are class-typical for carboxylated styrene-butadiene latices of this designation and shall be verified against the supplier’s certificate of analysis before production qualification.
Under ISO 124:2014, total solids for this product class are normally maintained between 48 % and 52 % by mass. The pH, measured according to ISO 976:2013, is controlled at 8.0–9.5 for storage stability and carboxylate ionization. Apparent viscosity at 25 °C by ISO 1652:2011 using a Brookfield LV viscometer, spindle 2 at 60 r/min, typically falls between 150 mPa·s and 600 mPa·s; lot viscosity depends on neutralization level and particle-size distribution. Surface tension of the diluted compound is usually 35–45 mN/m when measured by ISO 1409:2020 with a Du Noüy ring. Modal particle diameter determined by dynamic light scattering under ISO 22412:2017 is reported in the range 130–180 nm, and residue on a 45 µm sieve per ISO 4576:1996 should be below 100 ppm for blade-coating operations. The dried film generally exhibits a glass transition temperature between -15 °C and -5 °C by differential scanning calorimetry at 10 K/min under nitrogen; the minimum film-forming temperature, per ISO 2115:1996, is adjusted to 0–5 °C with a coalescing solvent or low-Tg comonomer. These values create room-temperature film formation without high coalescent demand but also produce blocking tendency in stacked coated board if no anti-block agent is used.
Residual monomer content is a critical lot-certificate parameter. Class-typical styrene-butadiene dispersions for indirect food-contact applications are often controlled for residual styrene and butadiene below 0.1 % by gas chromatography according to ISO 12000:2014. Where indirect food-contact packaging is intended, the formulation and its cure conditions must be qualified under 21 CFR 176.170 and 21 CFR 176.180 for paper and paperboard components. No direct food-contact use should be assumed.
In nonwoven saturation, the as-supplied dispersion is diluted with deionized water to bath solids of 15–30 %. On a 1,200 mm working-width saturation line running at 60–100 m/min, bath viscosity should remain below 300 mPa·s to limit hydrodynamic drag on lightweight webs. A two-roll padder set to 1.5–3.5 bar linear pressure removes excess liquid; for a 40–60 g/m² viscose/polyester nonwoven, wet pick-up is typically 100–180 %. Drying is staged in an air-float dryer from 90 °C in the first zone to 150 °C in the final zone. Cure response is measurable through the increase in wet tensile strength after 1–3 min exposure at 130–150 °C. Published kinetic data for Fulatex PD0124 are limited; therefore, the onset of thermal crosslinking should be determined on the actual dried film by differential scanning calorimetry or by wet tensile retention after accelerated cure.
Thermal crosslinking of the carboxylated matrix in PD0124-class latices shows a critical processing window. At oven temperatures below 120 °C, wet strength develops slowly; at 130–150 °C, the crosslinking rate increases, but prolonged exposure above 160 °C can cause yellowing and tensile loss due to oxidative degradation of residual butadiene unsaturation. A processing window of ±5 °C around the qualified oven set point is commonly applied in saturation lines to maintain wet tensile retention within 5 % of the validated value. Airflow rate and moisture removal in the first dryer zone affect film formation; if the web surface reaches 90 °C before 70 % of water is removed, skinning can trap moisture and produce blisters.
In paper impregnation, the latex may be applied at 20–35 % solids on a size press or blade coater. Mineral-oil or silicone defoamer addition is typically 0.05–0.30 phr on dry latex. Calcium carbonate slurry may be introduced at 5–15 parts per 100 parts dry latex to reduce gloss and improve printability, provided the furnish pH remains above 7.5. Cationic wet-strength resins such as polyamidoamine-epichlorohydrin should be added separately or after jar testing because the anionic latex can coagulate on contact. The use of alum in the wet end must be controlled; trivalent aluminum concentrations above 0.1 wt% of a 10 % alum solution can produce visible destabilization. On high-speed blade coaters, the formulation should pass a 45 µm filter test after 2 h of circulation to ensure no shear-induced grit formation.
In compounding, powdered crosslinkers such as zinc oxide should be dispersed into water with a high-speed disperser at 1,000–2,000 r/min for 15–30 min before addition to the latex. Direct addition of dry powder can create local low-pH zones and cause microcoagulation. At application solids, the dispersion exhibits shear-thinning behavior; apparent viscosity at 25 °C may decrease from 200 mPa·s at 20 r/min to 100 mPa·s at 100 r/min. This permits pumping and blade shear. Above 60 % solids after drying, the film transforms to a viscoelastic solid with tensile storage modulus reported in class data of 10–100 MPa at 1 Hz and 25 °C.
After drying and curing, films based on carboxylated styrene-butadiene latices of this class typically demonstrate wet tensile retention of 60–80 % after 24 h immersion in distilled water at 23 °C, measured according to ISO 1924-2:2008 for saturated paper and ISO 9073-3:2023 for nonwovens. This retention is higher than many all-acrylic binders at equal add-on because the styrene domains are hydrophobic and the carboxylic acid groups can be crosslinked with zinc oxide or melamine-formaldehyde resin. Dry tensile strength may be lower than a self-crosslinking acrylic of the same film modulus. Under accelerated weathering to ISO 105-B02:2014 for 100 h, the aromatic styrene segments cause yellowing; a pale film may rate no better than blue wool scale 4. For white or pastel exterior nonwovens, an acrylic topcoat or aliphatic polyurethane binder is usually required.
Cationic sensitivity is the principal operational limitation. The dispersion should not be mixed directly with aluminum sulfate, ferric chloride, polyquaternium biocides, or cationic starches. Multivalent cations compress the anionic double layer; coagulation can occur at 0.1–0.5 wt% addition of a 10 % aluminum sulfate solution under low-shear mixing. The pH should be maintained above 7.5 during compounding; acidification below 7.0 can initiate microflocculation. Hard water with calcium hardness above 200 mg/L as CaCO₃ may reduce mechanical stability in high-shear pumps; a chelating agent such as tetrasodium ethylenediaminetetraacetic acid at 0.1–0.3 phr may be included after testing.
Alkaline hydrolysis resistance is better than vinyl acetate-ethylene dispersions. A cured film immersed in 1 wt% NaOH solution at 23 °C for 24 h usually retains more than 50 % of its original tensile strength, whereas vinyl acetate-ethylene films may fail cohesively. Solvent resistance against methyl ethyl ketone is poor; swelling occurs within minutes. The film is therefore unsuitable for applications requiring continuous contact with ketones, esters, or aromatic hydrocarbons without a crosslinked protective topcoat.
Wet wipe applications illustrate the property response. The latex is applied at low add-on of 8–15 % on fiber weight. Wet tensile strength of a 45 g/m² hydroentangled substrate may increase from below 5 N/50 mm to 20–35 N/50 mm after saturation and cure; such values are class-typical and depend on fiber orientation and test direction. Migration kinetics of surfactants from the film can influence extractable levels; for skin-contact wipes, cytotoxicity and irritation testing per ISO 10993-5:2009 and ISO 10993-10:2021 may be required.
Fulatex PD0124 differs from self-crosslinking acrylic dispersions primarily in wet adhesion to nonpolar fibers, yellowing resistance, and cost structure. In wet-laid cellulose and polyester web saturation, carboxylated styrene-butadiene particles deposit readily on hydrophobic fiber surfaces and show a lower wet/dry tensile difference after water immersion. Acrylic binders are selected where UV color retention and dry tensile response are critical. Compared with vinyl acetate-ethylene dispersion, Fulatex PD0124 shows lower moisture vapor permeability and better alkaline hydrolysis resistance, but weaker adhesion to polar metal substrates and glass. The vinyl acetate-ethylene class also typically has a lower minimum film-forming temperature without coalescent, whereas the styrene-butadiene class may require 0.5–2.0 % coalescing agent on total wet weight for low-odor formulations.
In carpet backing compounds, mechanical frothing is conducted on an Oakes foamer to a wet foam density of 0.25–0.45 g/cm³. A carboxylated styrene-butadiene latex of this type provides high filler tolerance for calcium carbonate loadings up to 200 parts per 100 parts dry latex, while retaining formaldehyde-free crosslinking potential with zinc oxide or ammonium zirconium carbonate. In vinyl acetate-ethylene compounds, the same filler loading may produce lower wet strength and slower open-time control. Tuft-bind force is measured by ISO 4919:2012 or ASTM D1335-17; a carboxylated styrene-butadiene compound with 200 phr calcium carbonate typically provides tuft-bind values above 20 N in cut-pile carpet. Froth stability is assessed by foam half-life and viscosity recovery; an Oakes foamer operating at 1,500–2,500 r/min with air flow adjusted to a density of 0.30 g/cm³ should deliver a stable cell structure for 10–20 min before coating. Published data for this specific configuration is limited.
For pressure-sensitive adhesive use, the latex is typically compounded with rosin ester or C9 hydrocarbon tackifier dispersions at 20–40 parts per 100 parts dry latex. The choice of tackifier must be checked for anionic compatibility; esterified rosin dispersions with a pH above 7.0 are generally suitable. Films cast at 50 g/m² dry coat weight on corona-treated polyethylene terephthalate exhibit loop tack and peel response that depend on cure history; exact values for Fulatex PD0124 are not published. In flooring adhesive applications, open time at 23 °C and 50 % RH is often limited to 10–20 min unless propylene glycol at 2–5 % or an associative polyurethane thickener at 0.5–1.5 % is included.
The PD0124 designation is distinguished from other PD-series alternatives by its intended balance of wet strength, filler tolerance, and film flexibility. Suppliers may position it as a medium-styrene, medium-acid carboxylated latex, but without the manufacturer’s consolidated data sheet, precise bound styrene and acid number cannot be stated. The comparison below is therefore a class-level selection guide, not a certified product specification.
| Property | Test designation | Carboxylated styrene-butadiene class (Fulatex PD0124 reference) |
Self-crosslinking acrylic | Vinyl acetate-ethylene dispersion |
|---|---|---|---|---|
| Total solids | ISO 124:2014 | 48–52 % | 45–55 % | 50–60 % |
| pH | ISO 976:2013 | 8.0–9.5 | 7.0–9.0 | 4.0–5.5 |
| Minimum film-forming temperature | ISO 2115:1996 | 0–5 °C | 0–10 °C | 0–5 °C |
| Wet tensile retention after 24 h water immersion | ISO 1924-2:2008 / ISO 9073-3:2023 | 60–80 % | 40–70 % | 30–60 % |
| Accelerated UV yellowing, 100 h | ISO 105-B02:2014 | blue wool 4 or lower | blue wool 6–7 | blue wool 5–6 |
| Alkali resistance in 1 wt% NaOH, 24 h | tensile retention | >50 % | 20–40 % | <20 % |
| Adhesion to glass and metal substrates | cross-cut adhesion | low to medium | high | high |
These comparatives are compiled from class-level technical literature and are not certified lot values for Fulatex PD0124. Where product-specific data are absent, pilot trials should be run with the intended substrate and cure profile.
Under REACH Regulation (EC) No 1907/2006, the polymer itself is exempt from registration as a substance under Article 2(9), but monomers, stabilizers, and biocides must be registered or approved for the relevant use. For articles sold in the European Union, residual monomer limits and preservative restrictions should be checked against the supplier’s extended safety data sheet. RoHS Directive 2011/65/EU may apply to finished electrical or electronic articles that incorporate the cured film; compliance is assessed on the homogeneous material, not on the liquid dispersion.
Storage stability is generally 6–12 months at 5–35 °C in unopened containers; freeze-thaw stability is limited and exposure to temperatures below 0 °C can cause irreversible coagulation. Protect from direct sunlight and avoid contamination with cationic polymers, polyvalent salts, or organic solvents before application. In high-humidity coating environments above 60 % RH, dryer capacity should be increased because water release from the latex film is evaporation-rate limited. The dispersion should not be circulated through unprotected high-shear gear pumps for extended periods without mechanical stability testing; batch-to-batch variation in pH, sieve residue, and viscosity should be monitored against incoming lot certificates.
