US4689256A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Flame retardant tufted carpet tile and method of preparing same
Assignee: PANDEL Inc A CORP OF
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Filing: 1986-08-29
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Granted: 1987-08-25
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Expires: 2006-08-29
Abstract
Abstract A flame-resistant carpet tile having low smoke values and improved flame resistance which carpet tile comprises a primary backing having a fibrous face and a fibrous back, a barrier layer adjacent to fibrous back to an acrylic polymer heavily loaded with a metallic flame-retardant salt filler material which acrylic polymer is compatible with a vinyl chloride polymer layer and a relatively thick vinyl chloride polymer backing layer adhering to the barrier layer. The method of preparing a flame-resistant carpet tile which comprises pre-coating the back of a carpet with an acrylic polymer latex containing a metallic salt flame-retardant filler material, coating the latex material with a PVC layer, thereafter laying the latex PVC coated carpet into the top surface of a liquid PVC backing layer, heating the laid-in carpet to fuse the PVC layers, cooling the carpet and cutting the carpet into carpet tile.
Inventors
- 👤 David K. Slosberg
- 👤 Gilbert S. Nowell
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-07 20:02
CPC Classifications
D; D06; D06N; D06N7/00; D06N7/0063; D06N7/0068; D06N3/00; D06N3/0056; D06N3/0063; D06N7/0071; D06N7/0073; D06N7/0081; D06N2203/00; D06N2203/04; D06N2203/045; D06N2203/048; D06N2205/00; D06N2205/02; D06N2205/026; D06N2205/04; D06N2209/00; D06N2209/06; D06N2209/067; Y; Y10; Y10T; Y10T428/00; Y10T428/23907; Y10T428/23979; Y10T428/23986; Y10T428/23993
Claims Analysis
Total Claims: 32
Claim 1
Independent Claim
90 words
A carpet tile having improvide flame resistance, which carpet tile comprises: (a) a primary backing having a fibrous face and a fibrous back; (b) a barrier layer adjacent the fibrous back of which barrier layer comprises a vinyl polymer and a metal salt, flame-ratardant filler material in an amount sufficient to provide a flame-retardant barrier layer, and which vinyl polymer is compatible with a thermoplastic polymer layer; and (c) a vinyl chloride resin backing layer bonded to the barrier layer, to impart stability and free-laying properties to the carpet tile.
Claim 2
Dependent Claim
90 words
A carpet tile having improvide flame resistance, which carpet tile comprises: (a) a primary backing having a fibrous face and a fibrous back; (b) a barrier layer adjacent the fibrous back of which barrier layer comprises a vinyl polymer and a metal salt, flame-ratardant filler material in an amount sufficient to provide a flame-retardant barrier layer, and which vinyl polymer is compatible with a thermoplastic polymer layer; and (c) a vinyl chloride resin backing layer bonded to the barrier layer, to impart stability and free-laying properties to the carpet tile.
Claim 3
Dependent Claim
14 words
The carpet tile of claim 1 wherein the metal salt filler comprises aluminum trihydrate.
Claim 4
Dependent Claim
24 words
The carpet tile of claim 1 wherein the carpet tile includes a fiberglass or polyester tissue or scrim sheet material in the backing layer.
Claim 5
Dependent Claim
23 words
The carpet tile of claim 1 wherein the carpet tile is characterized by an ASTM E-62 smoke value of about 400 or less.
Claim 6
Dependent Claim
23 words
The carpet tile of claim 1 wherein the carpet tile is characterized by a flame-resistance ASTM E-648 value of about 0.5 or higher.
Claim 7
Dependent Claim
26 words
The carpet tile of claim 1 wherein the vinyl polymer comprises a butadiene-acrylonitrile polymer having an excess of about 50% or more by weight of acrylonitrile.
Claim 8
Dependent Claim
39 words
The carpet tile of claim 1 wherein the barrier layer comprises from about 10 to 50 ounces per square yard, and the backing layer is a solid layer and has a thickness of from about 50 to 150 mils.
Claim 9
Dependent Claim
15 words
The carpet tile of claim 1 wherein the carpet tile is a tufted carpet tile.
Claim 10
Dependent Claim
16 words
The carpet tile of claim 1 wherein the backing layer is a vinyl chloride foam layer.
Claim 11
Dependent Claim
16 words
The carpet tile of claim 1 wherein the backing layer comprises a polyvinyl chloride polymer layer.
Claim 12
Dependent Claim
33 words
The carpet tile of claim 1 wherein the barrier layer comprises from about 100 to 250 parts by weight of the flame-retardant filler material per 100 parts by weight of the vinyl polymer.
Claim 13
Dependent Claim
25 words
The carpet tile of claim 1 wherein the flame-retardant filler material comprises an oxide, sulfate, borate, phosphate or carbonate of zinc, barium, magnesium or aluminum.
Claim 14
Dependent Claim
17 words
The carpet tile of claim 1 wherein the fibrous face and fibrous back comprises a polyamide fiber.
Claim 15
Dependent Claim
42 words
The carpet tile of claim 1 wherein the vinyl polymer is selected from the group consisting of: copolymer of acrylic and methacrylic acid and alkyl acrylates; acrylic-styrene copolymers; acrylonitrile-styrene copolymers; ethylene-vinyl acetate copolymers; polyvinyl acetate; and vinylidene chloride-acrylonitrile copolymers and combinations thereof.
Claim 16
Dependent Claim
23 words
The carpet tile of claim 1 wherein the backing layer is a solid layer of from about 50 to 200 mils in thickness.
Claim 17
Dependent Claim
23 words
The carpet tile of claim 1 wherein the backing layer is a foam layer of from about 100 to 350 mils in thickness.
Claim 18
Dependent Claim
112 words
A carpet tile having low smoke values by ASTM E-62 of 300 of less and improved flame resistance by ASTM E-648 of 0.5 or more, which carpet tile comprises a primary backing, having a tufted fibrous face and a fibrous back fiber; (a) a barrier layer adjacent to fibrous back which barrier layer comprises a vinyl-styrene copolymer containing from about 50 to 350 parts per 100 parts of the vinyl polymer of aluminum trihydrate and which barrier layer is compatible with a vinyl chloride resin backing layer; and (b) a solid vinyl chloride resin backing layer directly bonded to the barrier layer to impart stability and free-laying properties to the carpet tile.
Claim 19
Dependent Claim
112 words
A carpet tile having low smoke values by ASTM E-62 of 300 of less and improved flame resistance by ASTM E-648 of 0.5 or more, which carpet tile comprises a primary backing, having a tufted fibrous face and a fibrous back fiber; (a) a barrier layer adjacent to fibrous back which barrier layer comprises a vinyl-styrene copolymer containing from about 50 to 350 parts per 100 parts of the vinyl polymer of aluminum trihydrate and which barrier layer is compatible with a vinyl chloride resin backing layer; and (b) a solid vinyl chloride resin backing layer directly bonded to the barrier layer to impart stability and free-laying properties to the carpet tile.
Claim 20
Dependent Claim
23 words
The carpet tile of claim 15 wherein which includes a tissue or scrim-type sheet material imbedded in the vinyl chloride polymer backing layer.
Claim 21
Dependent Claim
24 words
The carpet tile of claim 17 wherein the fibrous face and back comprise a nylon fiber, and the vinyl polymer comprises a styrene-acrylic polymer.
Claim 22
Dependent Claim
105 words
In a method of preparing a flame-resistant carpet tile, which method comprises: applying a vinyl chloride resin backing layer to the back surface of a primary backing having a fibrous wear face surface and a fibrous back surface to form a carpet tile material, the improvement which comprises: (a) pre-coating the back surface of the primary backing with a thin precoat layer of a vinyl latex composition; and heating the pre-coat layer to form a barrier layer, which vinyl polymer is compatible with the vinyl chloride resin backing layer and which pre-coat latex composition contains a flame-retardant amount of a metal salt, flame-resistant filler compound.
Claim 23
Dependent Claim
105 words
In a method of preparing a flame-resistant carpet tile, which method comprises: applying a vinyl chloride resin backing layer to the back surface of a primary backing having a fibrous wear face surface and a fibrous back surface to form a carpet tile material, the improvement which comprises: (a) pre-coating the back surface of the primary backing with a thin precoat layer of a vinyl latex composition; and heating the pre-coat layer to form a barrier layer, which vinyl polymer is compatible with the vinyl chloride resin backing layer and which pre-coat latex composition contains a flame-retardant amount of a metal salt, flame-resistant filler compound.
Claim 24
Dependent Claim
69 words
The method of claim 20 wherein the flame-resistant carpet tile comprises: (a) the barrier layer comprising from about 100 to 250 parts by weight of a flame-retardant filler material per 100 parts by weight of the vinyl polymer; (b) the flame-retardant filler material comprises an oxide, sulfate, borate, phosphate or carbonate of zinc, barium, magnesium or aluminum; and (c) a fibrous face and fibrous back comprise a polyamide fiber.
Claim 25
Dependent Claim
10 words
The carpet tile produced by the method of claim 20.
Claim 26
Dependent Claim
40 words
The method of claim 20 wherein the vinyl polymer is selected from the group consisting of: copolymer of acrylic and methacrylic acid and alkyl acrylates; acrylic-styrene copolymers; acrylonitrile-styrene copolymers, ethylene-vinyl acetate copolymers; polyvinyl acetate; vinylidene chloride-acrylonitrile copolymers and combinations thereof.
Claim 27
Dependent Claim
29 words
The method of claim 20 which includes pre-coating the vinyl latex composition onto the back surface in an amount of from about 15 to 50 ounces per square yard.
Claim 28
Independent Claim
195 words
The method of preparing a flame-resistant carpet tile, which method comprises: (a) coating a first layer of a polyvinyl chloride resin plastisol on a support surface; (b) placing a dimensionally stable sheet material onto the top surface of the first layer and heating the layer to gel the layer and position the sheet material; (c) applying a second layer of a polyvinyl chloride plastisol onto the gelled surface of the first layer; (d) pre-coating the back of a primary backing having a fibrous wear-resistant face surface and a fibrous back surface, with a vinyl polymer latex composition, the latex composition containing a flame retardant amount of a metal salt filler comound, and wherein the vinyl latex polymer is compatible with the polyvinyl chloride, and heating the pre-coated layer to form a barrier layer; (e) coating a thin, polyvinyl chloride liquid plastisol layer over the barrier layer; (f) laying the coated barrier layer carpet onto the top surface of the plastisol of the second polyvinyl chloride layer; (g) heating the carpet so formed to fuse the polyvinyl chloride layers into an integrally-fused backing layer; (h) cooling the carpet; and (i) cutting the carpet into carpet tile.
Claim 29
Independent Claim
195 words
The method of preparing a flame-resistant carpet tile, which method comprises: (a) coating a first layer of a polyvinyl chloride resin plastisol on a support surface; (b) placing a dimensionally stable sheet material onto the top surface of the first layer and heating the layer to gel the layer and position the sheet material; (c) applying a second layer of a polyvinyl chloride plastisol onto the gelled surface of the first layer; (d) pre-coating the back of a primary backing having a fibrous wear-resistant face surface and a fibrous back surface, with a vinyl polymer latex composition, the latex composition containing a flame retardant amount of a metal salt filler comound, and wherein the vinyl latex polymer is compatible with the polyvinyl chloride, and heating the pre-coated layer to form a barrier layer; (e) coating a thin, polyvinyl chloride liquid plastisol layer over the barrier layer; (f) laying the coated barrier layer carpet onto the top surface of the plastisol of the second polyvinyl chloride layer; (g) heating the carpet so formed to fuse the polyvinyl chloride layers into an integrally-fused backing layer; (h) cooling the carpet; and (i) cutting the carpet into carpet tile.
Claim 30
Dependent Claim
10 words
The carpet tile produced by the method of claim 25.
Claim 31
Dependent Claim
34 words
The method of claim 25 wherein the metal salt filler compound comprises aluminum trihydrate, the vinyl latex polymer comprises a styrene-acrylic latex polymer, and the fibrous face and back surface comprise a nylon fiber.
Claim 32
Dependent Claim
10 words
The carpet tile produced by the method of claim 27.
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) | 1990-08-24 | 1991-02-23 | 1991-08-25 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1994-08-24 | 1995-02-23 | 1995-08-25 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1998-08-24 | 1999-02-23 | 1999-08-25 | $7700.00 | Window Closed / Lapsed |