Patent US855471A successfully refreshed from Google Patents.
US3661691A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Flame-retardant vinyl foam carpet and method
Assignee: PANDEL Inc A CORP OF
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Filing: 1970-12-28
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Granted: 1972-05-09
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Expires: 1990-12-28
Abstract
Abstract A flame-retardant vinyl resin-backed surface covering; e.g., tufted carpet, which carpet is characterized by enhanced flame resistance and reduced flammability-rate characteristics in that the vinyl backing is securely bonded to the tufted base and the thermoplastic primary backing is inhibited from shrinking and cracking under conditions of open-flame ignition. A vinyl foambacked tufted carpet is prepared by applying a carboxylated cross-linkable vinyl chloride resin composition to the back surface of a thermoplastic backing sheet containing a pile face surface of tufted yarns; heating the plastisol composition to cross-link the vinyl chloride resin and to bond the tufted yarns to the thermoplastic base fabric while maintaining the temperature below the shrinkable temperature of the base fabric; and laminating the foam vinyl backing to the surface of the cross-linked vinyl chloride resin composition.
Inventors
- 👤 David K Slosberg
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-25 13:49
CPC Classifications
D; D05; D05C; D05C17/00; D05C17/02; D05C17/023; D06; D06N; D06N7/00; D06N7/0063; D06N7/0071; D06N7/0086; D06N2203/00; D06N2203/04; D06N2203/045; D06N2203/048; D06N2205/00; D06N2205/02; D06N2205/026; D06N2209/00; D06N2209/06; D06N2209/067; Y; Y10; Y10S; Y10S428/00; Y10S428/92; Y10S428/921; Y10T; Y10T428/00; Y10T428/23907; Y10T428/23979; Y10T428/23986; Y10T428/23993
Claims Analysis
Total Claims: 21
Claim 1
Independent Claim
37 words
The method of claim 1 wherein the thermoplastic backing sheet comprises a nonwoven base sheet composed of polypropylene fibers, and which sheet is characterized by a pile face surface of tufted yarns secured to the backing sheet.
Claim 2
Dependent Claim
25 words
The method of claim 1 which includes heating the vinyl resin plastisol composition while maintaining the temperature of the thermoplastic base sheet below about 300*F.
Claim 3
Dependent Claim
71 words
The method of claim 1 which includes: a. bonding the primary and secondary backing sheets by heating the surface of the solidified vinyl resin plastisol composition by directing radiant heat onto the surface thereof; and, thereafter b. contacting the heated surface with a thermoplas-tic resin foam secondary backing sheet, and bonding the foam back-ing sheet to the fused surface through the residual heat retained in the heated surface of the resin.
Claim 4
Dependent Claim
75 words
The method of claim 1 which includes: a. saturating the fibers of the primary backing sheet with the vinyl chloride plastisol composition; b. heating the saturated backing sheet to a temperature sufficient to gell or fuse the vinyl resin plastisol saturant therein; and c. tufting fibers through the solid saturated thermoplastic backing sheet to provide a backing sheet which is characterized by a pile face surface of tufted yarns in the saturated thermoplastic base sheet.
Claim 5
Dependent Claim
68 words
The method of claim 1 which includes: a. casting a vinyl chloride resin plastisol composition containing a blowing amount of a blowing agent onto the cross-linked and fused vinyl chloride resin composition; and, thereafter b. heating the cast plastisol layer to a temperature sufficient to fuse and expand the layer, thereby forming a vinyl foam secondary backing sheet bonded to the cross-linked and fused vinyl chloride resin composition.
Claim 6
Dependent Claim
104 words
The method of claim 1 which includes: a. saturating the thermoplastic fibrous primary backing sheet with the vinyl chloride resin; b. gelling or fusing the saturated sheet at a temperature below about 300* F.; c. tufting fibers onto and through the saturated thermoplastic base sheet to provide a face surface of tufted yarns; d. heating the tufted saturated primary sheet to cross-link the vinyl chloride resin at a temperature below the shrinking temperature of the sheet; and, thereafter e. laminating a vinyl resin foam secondary backing sheet to the surface of the cross-linked fused vinyl chloride resin composition by heating one or both surfaces.
Claim 7
Dependent Claim
93 words
The method of claim 1 which includes; a. casting the vinyl chloride resin plastisol which contains a blowing agent onto the back of the primary backing sheet having a tufted pile face; b. heating to fuse and cross-link the vinyl chloride resin plastisol at a temperature insufficient to shrink the thermoplastic tufted base; c. casting a blowable cross-linkable or curable vinyl chloride resin plastisol onto the fused resin surface; and, thereafter, d. heating to fuse, to expand and to cross-link or cure the resin, thereby bonding the foam layer to the first layer.
Claim 8
Dependent Claim
68 words
The method of claim 1 wherein the cross-linkable vinyl chloride resin comprises a vinyl chloride resin plastisol composition which contains a vinyl chloride resin having pendant hydroxyl or carboxylic groups and a compound reactive with said groups to cross-link the resin, the cross-linkable vinyl chloride resin present in an amount ranging from about 0.5 to 25 parts of the resin per hundred parts of the vinyl chloride resin.
Claim 9
Dependent Claim
42 words
The method of claim 1 wherein the curable vinyl chloride resin comprises from about 10 to 60 percent by weight of a synthetic elastomeric nitrile rubber compatible with the vinyl chloride resin and a curing compound adapted to cure the nitrile rubber.
Claim 10
Dependent Claim
115 words
The method of claim 1 which includes: a. providing a vinyl resin composition comprising from about 10 to 40 percent by weight of a curable nitrile rubber and a small amount of a peroxide curing agent and a blowing amount of a blowing agent; b. casting the blowable curable nitrile rubber vinyl chloride resin plastisol composition onto the back surface of the primary backing sheet; c. contacting the surface of the nitrile vinyl chloride resin composition with the back surface of a primary backing sheet containing a plurality of tufted yarns therein; and d. heating the nitrile vinyl chloride resin composition to a temperature sufficient to form a cEllular-cured nitrile resin secondary backing sheet thereon.
Claim 11
Dependent Claim
162 words
The method of claim 1 which includes: a. casting a thin layer of a vinyl chloride resin composition containing a carboxylated vinyl chloride resin and a small amount of an amino-aldehyde resin adapted to cross-link with the carboxylated vinyl chloride resin onto the back surface of a primary backing sheet containing a tufted face surface and back stitches on the back surface thereof; b. heating said vinyl chloride resin composition to a temperature sufficient to gell or fuse the vinyl chloride, while maintaining a temperature below the heat-shrinking temperature of the primary backing sheet, directing radiant heat onto the back surface of the gelled or fused vinyl chloride resin composition; c. contacting the heated gelled or fused surface of the resin composition with a vinyl chloride closed-cell prefoamed vinyl foam layer, the temperature of the surface sufficient to melt a small portion of the vinyl chloride foam layer and to bond it to the resin surface, thereby providing an integral tufted carpet.
Claim 12
Dependent Claim
117 words
An integral flame-retardant surface covering, such as a carpet, which comprises in combination: a. a primary backing sheet comprising thermoplastic fibers, which fibers are subject to shrinkage at a temperature in excess of about 300* F; b. a face of carpet yarn secured to one surface of said primary sheet to provide a face surface thereon; and c. a layer of a fused cross-linked or cured vinyl chloride resin plastisol composition, as a secondary backing sheet, bonded and secured to the back surface of the primary backing sheet, the thermoplastic fibers of the base sheet maintained in a substantially nonheat-shrinkable form and inhibited from shrinkage on exposure to open flames by the fused cross-linked vinyl chloride resin.
Claim 13
Dependent Claim
36 words
The carpet of claim 13 wherein the backing sheet of thermoplastic fibers is composed of polypropylene fibers subject to heat shrinkage and the fused cross-linked vinyl chloride plastisol composition comprises a vinyl chloride resin foam layer.
Claim 14
Dependent Claim
23 words
The carpet of claim 13 wherein the fused cross-linked vinyl chloride plastisol composition comprises a cross-linked and cured vinyl chloride-nitrile rubber foam layer.
Claim 15
Dependent Claim
38 words
The carpet of claim 13 which includes a layer of thermoplastic foam, one surface of the foam sheet bonded to the surface of the fused cross-linked resin plastisol composition, the thermoplastic foam comprising a vinyl chloride cross-linked resin.
Claim 16
Dependent Claim
21 words
The carpet of claim 13 which includes the primary backing sheet saturated with a fused cross-linked vinyl chloride resin plastisol composition.
Claim 17
Dependent Claim
55 words
The carpet of claim 13 wherein the primary backing sheet comprises a nonwoven fabric having a face of tufted yarns and the fused cross-linked vinyl chloride resin plastisol composition is bonded to the back surface thereof, the fused layer filling in the interstices between the tufted yarn loops on the back of the primary sheet.
Claim 18
Dependent Claim
163 words
An integral flame-retardant vinyl foam-backed tufted carpet, which carpet comprises in combination: a. a base fabric sheet comprising thermoplastic fibers, which fibers are subject to shrinkage at temperatures in excess of about 250* F; b. tufted yarns secured through and to said base fabric sheet to provide a tufted pile face surface and the yarn loops on the back surface; and c. a layer of a fused cross-linked carboxylated vinyl chloride plastisol composition bonded to the back surface, the fused layer substantially filling in the interstices between the tufted yarn loops and the base fabric, the fused plastisol composition the sole adhesive employed to lock the tufted yarns to the base fabric, the thermoplastic fibers of the base fabric maintained in a substantially nonheat-shrinkable form and inhibited from shrinkage on exposure to open flames by the cross-linked vinyl chloride resin, a layer of thermoplastic resin as a secondary backing, one surface of thE sheet bonded to the surface of the fused plastisol composition.
Claim 19
Dependent Claim
16 words
The carpet of claim 19 wherein the secondary backing is a vinyl chloride resin foam sheet.
Claim 20
Dependent Claim
17 words
The carpet of claim 19 wherein the secondary backing is a cross-linked fused vinyl chloride resin sheet.
Claim 21
Dependent Claim
37 words
The carpet of claim 19 wherein the secondary backing is a fused cross-linked vinyl chloride resin closed-cell foam layer bonded to the surface of the fused cross-linked resin solely by the melted surface of the foam layer.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1975-05-09 | 1975-11-08 | 1976-05-09 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1979-05-09 | 1979-11-08 | 1980-05-09 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1983-05-09 | 1983-11-08 | 1984-05-09 | $7700.00 | Window Closed / Lapsed |