U.S. patent number RE34,951 [Application Number 07/983,778] was granted by the patent office on 1995-05-23 for flame retardant tufted carpet tile and method of preparing same.
This patent grant is currently assigned to Interface, Inc.. Invention is credited to Gilbert S. Nowell, David K. Slosberg.
United States Patent |
RE34,951 |
Slosberg , et al. |
May 23, 1995 |
**Please see images for:
( Certificate of Correction ) ** |
Flame retardant tufted carpet tile and method of preparing same
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: |
Slosberg; David K. (Atlanta,
GA), Nowell; Gilbert S. (Marietta, GA) |
Assignee: |
Interface, Inc. (La Grange,
GA)
|
Family
ID: |
25415684 |
Appl.
No.: |
07/983,778 |
Filed: |
December 1, 1992 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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Reissue of: |
902318 |
Aug 29, 1986 |
04689256 |
Aug 25, 1987 |
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Current U.S.
Class: |
428/95; 427/355;
427/359; 427/389.9; 427/394; 427/412; 428/96; 428/97 |
Current CPC
Class: |
D06N
3/0063 (20130101); D06N 7/0073 (20130101); D06N
7/0081 (20130101); D06N 7/0068 (20130101); Y10T
428/23986 (20150401); Y10T 428/23993 (20150401); Y10T
428/23979 (20150401); D06N 2205/026 (20130101); D06N
2205/04 (20130101); D06N 2203/048 (20130101); D06N
2209/067 (20130101) |
Current International
Class: |
D06N
7/00 (20060101); D06N 3/00 (20060101); B32B
033/00 () |
Field of
Search: |
;428/95,96,97
;427/355,359,389,9,394,412 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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183922 |
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Jul 1922 |
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GB |
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1451335 |
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Sep 1976 |
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WO |
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|
Primary Examiner: Lesmes; George F.
Assistant Examiner: Morris; Terrel
Attorney, Agent or Firm: Kilpatrick & Cody
Claims
What is claimed is:
1. 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 which barrier layer
comprises a .Iadd.non-halogenated latex .Iaddend.vinyl polymer and
a .[.metal salt,.]. flame retardant filler material in an amount
sufficient to provide a flame-retardant barrier layer, .Iadd.which
filler material comprises a compound selected from the group
consisting of (i) a metal salt hydrate which generates water upon
heating; and (ii) a metal salt of a borate, oxide, carbonate,
phosphate, or sulfate of aluminum, barium, magnesiu, or zinc,
.Iaddend.and which .Iadd.latex .Iaddend.vinyl polymer is compatible
with a .[.theromoplastic polymer.]. .Iadd.vinyl chloride resin
.Iaddend.backing layer; and
(c) a .[.vinyl.]. .Iadd.polyvinyl .Iaddend.chloride resin backing
layer bonded to the barrier layer, to impart stability and
free-laying properties to the carpet tile.
2. The carpet tile of claim 1 wherein the .[.metal salt.]. filler
comprises aluminum trihydrate.
3. The carpet tile of claim 1 wherein the carpet tile includes a
fiberglass or polyester tissue or scrim sheet material in the
backing layer.
4. The carpet tile of claim 1 wherein the carpet tile is
characterized by an ASTM .[.E-62.]. .Iadd.E-662 .Iaddend.smoke
value of about 400 of less.
5. 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.
6. The carpet tile of claim 1 wherein the .Iadd.latex
.Iaddend.vinyl polymer comprises a butadiene-acrylonitrile polymer
having an excess of about 50% or more by weight of
acrylontrile.
7. 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.
8. The carpet tile of claim 1 wherein the carpet tile is a tufted
carpet tile.
9. The carpet tile of claim 1 wherein the backing layer is a vinyl
chloride foam layer. .[.
10. The carpet tile of claim 1 wherein the backing layer comprises
a polyvinyl chloride polymer layer. .].
11. 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.
12. 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.
13. The carpet tile of claim 1 wherein the fibrous face and fibrous
back comprises a polyamide fiber.
14. The carpet tile of claim 1 wherein the .Iadd.latex
.Iaddend.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.
15. The carpet tile of claim 1 wherein the backing layer is a solid
layer of from about 50 to 200 mils in thickness.
16. The carpet tile of claim 1 wherein the backing layer is a foam
layer of from about 100 to 350 mils in thickness.
17. A carpet tile having low smoke values by ASTM .[.E-62.].
.Iadd.E-662 .Iaddend.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 .Iadd.non-halogenated latex .Iaddend.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.]. .Iadd.polyvinyl.Iaddend.chloride resin
backing layer directly bonded to the barrier layer to impart
stability and free-laying properties to the carpet tile.
18. The carpet tile of claim 15 .[.wherein.]. which includes a
tissue or scrim-type sheet material imbedded in the vinyl chloride
polymer backing layer.
19. The carpet tile of claim 17 wherein the fibrous face and back
comprise a nylon fiber, and the .Iadd.latex ep vinyl polymer
comprises a styrene-acrylic polymer.
20. In a method of preparing a flame-resistant carpet tile, which
method comprises: applying a polyvinyl 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 materials,
the improvement which comprises:
(a) pre-coating the back surface of the primary backing with a thin
precoat layer of a .Iadd.non-halogenated .Iaddend.vinyl
.Iadd.polymer .Iaddend.latex composition; and heating the precoat
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
sale, flame-resistant filler compound, .Iadd.which compound is
selected from the group consisting of (i) a metal salt hydrate
which generates water upon heating; and (ii) a metal salt of a
borate, oxide, carbonate, phosplhate, or sulfate of aluminum,
varium, magnesium, or zinc. .Iaddend.
21. 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 .Iadd.latex .Iaddend.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.
22. The carpet tile produced by the method of claim 20.
23. The method of claim 20 wherein the .Iadd.latex .Iaddend.vinyl
polymer is selected from the group consisting of: copolymer of
acrylic and methacrylic acid and alkyl acrylates; acrylic-styrene
copolymers; acrylonitrile-styrene copolymers.[.,.]. .Iadd.;
.Iaddend.ethylene-vinyl acetate copolymers; polyvinyl acetate;
.[.vinylidene chloride-acrylonitrile copolymers.]. and combinations
thereof.
24. 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.
25. 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; p1 (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
.Iadd.non-halogenated .Iaddend.vinyl polymer latex composition, the
latex composition containing a flame retardant amount of a metal
salt filler .[.comound.]. .Iadd.compound.Iaddend., .Iadd.which
compound is selected from the group consisting of i) a metal salt
hydrate which generates water upon heating; and (ii) a metal salt
of a borate, oxide, carbonate, phosphate, or sulfate of aluminum,
barium, magnesium, or zinc, .Iaddend.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.
26. The carpet tile produced by the method of claim
27. 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.
28. The carpet tile produced by the method of claim 27. .Iadd.
29. The carpet tile of claim 1, wherein the non-halogenated latex
vinyl polymer comprises ethylene vinyl acetate copolymer. .Iaddend.
.Iadd.30. The carpet tile of claim 1, wherein the fibrous face
comprises nylon, and the non-halogenated latex vinyl polymer
comprises ethylene vinyl acetate
copolymer. .Iaddend. .Iadd.31. The carpet tile of claim 1, wherein
the fibrous face comprises nylon, the non-halogenated latex vinyl
polymer comprises ethylene vinyl acetate copolymer, and the primary
backing comprises polypropylene. .Iaddend. .Iadd.32. The carpet
tile of claim 1, wherein the fibrous face comprises nylon, the
non-halogenated latex vinyl polymer comprises ethylene vinyl
acetate copolymer, and the metal salt
comprises an aluminum salt. .Iaddend. .Iadd.33. The carpet tile of
claim 1, wherein the fibrous face comprises nylon, the
non-halogenated latex vinyl polymer comprises ethylene vinyl
acetate copolymer, and the metal salt comprises a magnesium salt.
.Iaddend.
Description
BACKGROUND OF THE INVENTION
Carpet tiles are typically composed of a fibrous or wear-type
surface and an undersurface secured to a primary backing and
containing a thick layer of a thermoplastic backing material, such
as for example, of polyvinyl chloride resin as a solid or a foam,
bitumen or atactic polypropylene. Often glass fiber scrim or tissue
is employed with the primary backing and embedded in the backing
layer in order to impart dimensional stability to the carpet tile.
Typical carpet tiles and carpet tile production methods are
described for example in U.S. Pat. No. 4,582,554 issued Apr. 15,
1986 hereby incorporated by reference.
It is desirable to provide for a carpet tile which has a low flame
resistance and low smoke value. Flame-resistant carpets have been
prepared by applying a carboxylated cross-linkable vinyl chloride
resin composition to the back surface of a thermoplastic backing
sheet which serves as the primary backing and then heating the
vinyl chloride composition to cross-link the vinyl chloride resin
and to bond the tufted yarns to the base of the primary backing. In
such a method, the temperature of the cross-linking in heating is
maintained below the shrinkable temperature of the polymeric
fibrous primary backing is then laminated to the surface of the
cross-linked vinyl chloride resin composition (see for example U.S.
Pat. No. 3,661,691 issued May 9, 1972 hereby incorporated by
reference).
The flame-retardant, vinyl-foam carpet and method of the patent
provides for improved flame resistance by bonding the surface of
the primary backing coated with a cross-linked vinyl resin to a
secondary backing wherein the primary and secondary backing are
prevented from shrinking and separating when exposed to open-flame
conditions. This improvement is related to flame-retardant
vinyl-foam backing carpet and not to carpet tile, which requires a
very thick, heavy thermoplastic backing layer to secure a free-lay,
dimensionally stable carpet tile.
SUMMARY OF THE INVENTION
The invention relates to a flame-resistant, low smoke value carpet
tile and to the method of preparing the same. In particular, the
invention concerns a flame-resistant carpet tile having low smoke
values in which a pre-coat barrier layer is employed which is
compatible with the backing layer and which barrier layer contains
flame-retardant filler material.
It has been found that the application of a pre-coat latex barrier
layer containing a flame-retardant filler material as a pre-coat
for plastic-backed carpet tiles provides for a unique
flame-resistant, low smoke value carpet tile. In particular, it has
been discovered that the employment of a vinyl, particularly an
acrylic-type pre-coating latex, which contains a metallic salt, and
more particularly aluminum trihydrate, when employed as a pre-coat
for a vinyl chloride resin carpet tile backing layer, provides for
an improved flame-resistant, low-smoke value carpet tile. Carpet
tile, so prepared, will typically register 0.5 or more on flame
retardance when tested in accordance with the Flooring Radiant
Panel Test ASTM E-648. This ASTM test essentially measures the watt
density which is required to ignite the carpet in that the higher
the test number, the more flame-resistant the carpet. In addition,
the carpet tile typically has a value of less than about 400, e.g.
200 or less, on the smoke density value test .[.NBS ASTM E-62.].
.Iadd.ASTM E662. .Iaddend.A typical prior art polyvinyl chloride
vinyl carpet tile without the pre-coat barrier layer has smoke
values of 600 to 700 or more. Therefore, the improved carpet tile
generally has a significant reduction in smoke value properties and
has greater flame resistance than ordinary, commercially produced
polyvinyl chloride carpet tile.
Synthetic fibrous material such as polyamides used for carpet
faces, like nylon, by itself, reduces low smoke values. Vinyl
halide resins, such as polyvinyl chloride resins used as carpet
tile backing either as a solid or a foam backing layer, does
reduce, by itself, low smoke values. However, when the vinyl halide
resin is directly in contact with the nylon fiber, the burning of
the vinyl halide resin on exposure to heat and open flame gives off
hydrogen chloride which attacks the nylon and makes the nylon burn
more readily with higher than normal smoke values, e.g. over 600 to
700.
It has been discovered that the use of a pre-coat barrier layer
which provides for a separation of the nylon or other fibrous
carpet material from the underlying vinyl chloride or other
halogenated backing resin provides carpet tile with excellent flame
retardance and low smoke values. The pre-coat barrier layer serves
to lock in the fiber on the back of the primary carpet tile
backing, such as the tufted back layer. The pre-coat barrier layer
does serve to separate the fibrous back surface of the carpet tile
from the halogenated resin backing layer. Further the pre-coat
barrier layer contains one or more flame-retardant agents, such as
metal salts, and particularly metal salt hydrates, which generate
water on heating, like aluminum trihydrate, to act as a flame
retardant and also to reduce smoke values.
The carpet tiles of the invention having a low smoke value and
improved flame resistance comprise a primary backing, such as a
woven or non-woven thermoplastic backing sheet, such as a woven
polypropylene backing or a non-woven polyester, with a fibrous face
or wear surface, such as a tufted face, and a fibrous back surface,
such as a loop or tufted surface where the carpet tile is tufted,
and a barrier layer formed from the latex pre-coat adjacent and
bonded to the fibrous back, which barrier layer comprise a vinyl
polymer loaded with a flame-retardant filler material, and more
typically with a metallic salt material. Importantly, the barrier
or pre-coat layer employed must substantially separate the vinyl
chloride backing layer from the fibrous back surface and be
compatible with and directly bond to the thermoplastic backing
layer, such as the vinyl chloride polymer backing layer used in the
carpet tile.
The carpet tile has a relatively thick thermoplastic backing layer,
e.g. 50 to 350 mils, e.g. 60 to 100 mils from the back of the yarn
layer to the back of the carpet tile, such as a vinyl chloride
polymer layer, adhering to the compatible barrier layer, and which
backing layer imparts stability and free-laying properties to the
carpet tile. Where the backing layer is solid, the thickness
generally ranges from 50 to 200 mils, and where a cushion foam
layer, from 100 to 350 mils. The pre-coat also serves to lock the
back fibers to the back of the primary backing. Actually, if
desired, the carpet tile may incorporate within the backing layer
and the primary backing one or more additional scrim or tissue
materials such as a glass fiber or polyester or a combination glass
fiber polyester scrim material. Generally, the scrim material may
be employed adjacent to the primary backing or closely adjacent
thereto. In addition glass fiber or tissue materials may be
employed within the thermoplastic backing layer to impart
dimensional stability and improved laying properties of the carpet
tile.
The backing layer may comprise a solid thermoplastic layer wherein,
for example, the backing layer is cast as a wet plastisol onto a
release surface and subsequent heat forced to the pre-coated
carpet, or may comprise a foam thermoplastic foam layer, such as a
pre-formed vinyl chloride layer, which, for example, is laminated
to the pre-coated carpet. In one method, the pre-formed foam layer
is directly heat laminated to the pre-coated carpet with the aid of
and by residual heat in the vinyl chloride pre-coat layer to direct
bond a polyvinyl chloride (PVC) foam layer to the PVC pre-coat
layer (see for example U.S. Pat. No. 3,560,284, issued Feb. 2,
1971, hereby incorporated by reference).
The barrier layer, formed from pre-coating the back fibrous surface
of the primary backing, typically is formed of a vinyl polymer,
acrylic-like polymer latex. However, it is important that the latex
employed as the pre-coat, or to form the barrier layer, be
compatible with and bonds to the thermoplastic backing layer,
typically with the polyvinyl chloride backing layer. It has been
found that styrene-treated butadiene rubber (SBR) and carboxylated
styrene-treated butadiene rubber latex and natural rubber latices
are not satisfactory as pre-coat barrier layers since they are not
compatible with the PVC backing of carpet tiles. Since such
polymers are not compatible with the polyvinyl chloride, they lead
to poor bond and little or no adhesion. Furthermore, there is a
tendency for these latices, on a long-term aging, to extract
plasticizer from the thermoplastic backing layer so that on aging,
you get further rapid deterioration of the vinyl halide
thermoplastic backing layer.
The fibrous material and yarns employed in the carpet tile as face
and back yarn with the primary backing may comprise synthetic,
natural or a combination of synthetic and natural fiber, such as
but not limited to: polyamides like nylon; olefins like
polypropylene; wool and wool blends; acrylic; acrylic-nylon blends
and polyester yarns and combinations and blends thereof.
The flame-resistant carpet tile may be prepared by pre-coating,
e.g. from about 15 to 50 ounces, such as 20 to 40, per square yard,
the back of a primary backing containing a fibrous face and a
fibrous back with an acrylic-type, pre-coated latex and heating the
latex to drive off water to provide for a solid barrier layer. The
latex composition employed is typically an aqueous acrylic latex
containing a high selected amount of a flame-retardant filler
material. Generally, and optionally, the barrier layer is then
coated with a thin, liquid thermoplastic layer such as a vinyl
chloride resin plastisol layer. A thermoplastic backing layer is
generally formed on a releasable support such as a fiuorocarbon,
glass fiber endless belt or a stainless steel support sheet through
casting, and optionally, a glass tissue is placed in the backing
layer to provide for the dimensional stability. Thereafter, the
pre-coated carpet is then laid into the liquid backing layer, the
backing layer being liquid at the laying-in station, and then the
carpet heated to fuse the vinyl resin, cooled and cut into carpet
tile sections.
The flame-retardant carpet tile may also be prepared by other than
the indirect coating technique predescribed, such as for example,
by a direct coating onto the back of the carpet. In the direct
coating method, the carpet is fed fibrous face down under a coating
knife and the thermoplastic backing material, such as PVC plastisol
backing is cast or coated in a layer of defined thickness directly
onto the pre-coated carpet, and the cast PVC plastisol backing
layer heated from above using radiant panels to fuse the solid
backing layer.
In one embodiment, the first layer of a polyvinyl chloride
plastisol is coated over to an endless belt support surface to a
.[.define.]. .Iadd.defined .Iaddend.thickness, and thereafter, a
glass tissue or scrim sheet material is placed on top of and wetted
by the liquid first layer, and the layer then heated to gel and to
fix in place the glass tissue on or about the top surface of the
first polyvinyl chloride PVC layer. Thereafter, a second layer is
applied over the gelled first layer to imbed the glass fiber tissue
or scrim to provide a backing layer for proper thickness, for
example 50 to 250 mils. The back of the primary backing is then
pre-coated with a flame-resistant latex pre-coat, e.g. 10 to 40
ounces per square yard, and heated to drive off the water and to
form a barrier layer cross-linked or non-cross-linked. A PVC
plastisol layer, e.g. 2 to 20 mils, is then coated onto the barrier
layer. Thereafter, the latex PVC coated carpet is laid at a
laying-in station into the top surface of the liquid second PVC
plastisol layer on the support. Thereafter, the carpet is then
heated to fuse all of the PVC layers and to form the thick backing
layer, then cooled, and cut into carpet tile.
The polymer pre-coat latex composition generally comprises a vinyl
such as an acrylic-type polymer which may be composed of copolymers
containing acrylic acid or methacrylic acid and alkyl acrylates,
such as ethyl acrylate, methyl acrylate and polymethylacrylate.
Such acrylic latex compositions are well known and may include
desired various amounts of cross-linking agents and other additives
and materials such as stabilizers, plasticizers, dispersing agents,
thickeners, surfactant, as well as various filler-type materials.
The acrylic polymer also may comprise an acrylonitrile polymer,
such as a butadiene-acrylonitrile copolymer, provided there is a
high amount of the acrylonitrile present in the copolymer, that is
typically more than 50% and generally more than 60% to 70% in order
to provide compatibility with the thermoplastic backing layers.
The polymers used in the pre-coat composition generally should be
non-halogenated polymers, or where halogenated polymers are used,
high amounts of flame-retardant agents and filler must be employed.
In one preferred embodiment, the pre-coat carpets would comprise
vinyl polymers, such as, but not limited to: acrylic-styrene
copolymer; acrylonitrile-styrene copolymer; vinyl, short-chain
fatty acid copolymer like ethylene-vinyl vinyl acetate, polyvinyl
acetate and vinyl acetate; acrylite polymer; and combinations
thereof.
Halogenated polymer latices may be used in small amounts, but are
not preferred, such as vinyl chloride latex and vinylidene
chloride-acrylonitrile latex; however, high amounts of filler
material should be used to reduce the effects of the halogenated
content of the polymer. Non-halogenated latices permit lower
amounts of filler material and provide a tougher, generally more
adherent film and barrier layer which is better for tuft back and
moisture resistance. Halogenated latices are not generally useful,
except in small quantities with non-halogenated latices, where
nylon is the fibrous material.
The pre-coat acrylic latex composition importantly employs a high
amount of a flame-retardant additive in order to impart and serve
as a flame-retardant barrier layer. Generally, the flame-resistant
filler material employed comprises a metal salt, such as a
muiti-valent metal salt composed of barium, zinc, .magnesium,
aluminum and the like, such as the oxides, the carbonates, borates,
sulfates and phosphates of such metals. In particular, it has been
found that the employment of a zinc salt like zinc oxide or zinc
borate, a magnesium-like magnesium oxide or magnesium carbonate, a
barium salt such as barium sulfate, and more particularly, aluminum
oxide or aluminum trihydrate alone or in combination with other
non-halogenated agents are particularly useful in the pre-coat
latex. The employment of aluminum trihydrate is particularly
desirable since this compound gives off water at high ignition
temperatures and therefore generates steam instead of smoke and
tends to lower the smoke value of the carpet tile and limit noxious
gases. The amount of flame-resistant filler material to be employed
in the pre-coat composition may vary as desired, but typically
ranges from about 50 to 350 parts, e.g. 100 to 250 parts per weight
per 100 parts of the acrylic polymer.
Carpet tiles are different from the production of ordinary tufted
or other fibrous-faced carpets because there is no requirement on a
typical carpet for a heavy backing layer. In carpet tile, a rigid,
stabilized mass of a thermoplastic backing layer is required in
order to hold down the carpet tile, that is to call it a free-lay
carpet tile. Generally, the backing layer has a high filler content
and is employed or with various scrim materials such as of glass
fibers, polyester or a combination, to impart dimensional
stability. Generally, the thermoplastic backing layer is polyvinyl
chloride layer. The primary backing may be comprised of any type of
fibrous-type material, such as a thermoplastic material, like
non-woven polypropylene or a polyester material. The loaded latex
barrier layer, which is quite thin, then acts as a barrier sheet to
shield the base from heat and improves the flame resistance and
smoke values. Generally, the barrier layer has a thickness and is
placed directly on and against the back surface of the loop or
fiber containing primary backing and is applied in an amount to
cover completely the loop backs and to lock in loops.
The invention will be described for the purposes of illustration
only in connection with certain embodiments. However, it is
recognized that various changes, modifications, improvements and
additions may be made to describe the embodiments all falling
within the spirit and scope of the invention.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic, illustrated, cross-sectional view of a flame
.[.resistance.]. .Iadd.resistant .Iaddend.carpet tile of the
invention; and
FIG. 2 is a block form diagram of a process for preparing the
flame-resistant carpet tile of FIG. 1.
DESCRIPTION OF THE EMBODIMENTS
FIG. 1 shows a flame-resistant carpet tile 10 composed of a
nylon-tufted fibrous face 12, a primary backing 14, such as a
non-woven polypropylene sheet, a flame-resistant barrier layer 16,
formed of a pre-coated acrylic latex containing aluminum trihydrate
as a flame-retardant filler, the latex pre-coat, as illustrated,
penetrates the back loops of the nylon fiber layer 12. The carpet
tile 10 includes a thin pre-coat PVC layer 18 coated directly onto
the acrylic pre-coat layer 16 and a solid polyvinyl chloride
backing layer 20, a glass fiber scrim 22 secured between the PVC
layer 20 and another PVC layer 24. The PVC layers 18, 20 and 24 are
integrally bonded to each other in the illustrated method of
preparing the carpet.
The PVC pre-coat layer 18 is not necessary and may be omitted.
Further, the solid PVC backing layers 20 and 24 may be replaced
with a single backing layer so that the back of the latex
pre-coated carpet may be simply laid into the top surface of a wet,
single PVC plastisol backing layer prior to heat fusion of the
single backing layer.
The carpet as illustrated has a flame-retardant thin barrier layer
which is compatible with the PVC precoat backing layer and which
helps to lock in the back loops of the primary backing and
separates the halogenated backing layer from the nylon backing
layer of the carpet tile.
A vinyl latex pre-coat formulation suitable for use and compatible
.[.iwth.]. .Iadd.with .Iaddend.a PVC backing layer is as
follows:
The carpet tile had a flame retardance on the radiant panel test of
about 0.5 or more, e.g. 0.7 to 0.9, and a smoke value of about 300
or less, e.g. 225 to 275.
______________________________________ VINYL LATEX PRE-COAT
FORMULATION Ingredients Parts by Weight
______________________________________ 1. UNOCAL 76.sup.1 200 a
styrene-acrylic latex (latex) 2. Water 15 3. Aluminum trihydrate
(ATH) 150 (smoke and flame retardant 4. CELLOID.sup.2 211 1
(dispersing agent for ATH) 5. ACRYSOL.sup.3 ASE 60 1.5 (as needed)
(polyacrylate salts as thickener) 6. Aqueous ammonia To pH 8.5
Brookfield viscosity 4/20 3 groups solids 68%
______________________________________ .sup.1 a trademark of Union
Oil Company .sup.2 a trademark of North Chemical Company, Inc. of
Marietta, Georgia .sup.3 a trademark of Rohm & Haas Company
FIG. 2 illustrates a block form diagram of a method of preparing a
flame-resistant carpet tile as shown in FIG. 1. The method of the
process is to cast or coat a layer of about 35 to 50 mils thick of
a fibrous polyvinyl chloride (PVC) plastisol as the first coating
on a flouro-carbon-coated endless belt. This first PVC layer forms
the back surface of the carpet and normally contains fillers
therein, such as calcium carbonate or other particulate inert
filler-type material, to provide weight thereto and lower cost.
Glass fiber tissue sheet material is then laid onto the top surface
of the first PVC plastisol layer, and this first layer is then
heated in an oven, for example, from the bottom using heated
platens beneath the endless belt, such as by circulating hot oil
through the plates adjacent to the bottom of the endless belt, to
gel the first layer and to fix the glass fiber tissue on or about
the top surface. Then a second coat, a PVC plastisol coat, of about
25 to 50 mils, which may be the same of a different PVC plastisol,
is applied over the first gel layer and the tissue sheet therein in
order to bury the glass fiber tissue sheet intermediate the two PVC
layers.
A carpet composed of a primary backing to which has been tufted a
fibrous material to form a fibrous-face wear surface and a back
loop or a back fibrous surface is pre-coated with .[.an the.].
.Iadd.a .Iaddend.latex pre-coat formulation containing a high
amount of aluminum trihydrate and heated to form a thin barrier
layer. A PVC vinyl precoat that is a plastisol is then applied by a
lick roller over the barrier layer. The carpet containing the
barrier layer and the PVC pre-coat is then passed through a
laying-in station and the back surface laid directly onto the top
liquid plastisol of the second PVC backing layer. Typically, the
laying-in station is very close to the second layer coating, the
second layer PVC coating station. After the laying-in, the carpet
is then sent though a fusing oven whereby the PVC layers are then
fused to form an integral PVC backing layer. The carpet is then
cooled and then cut into carpet tiles. The process thus involves a
pre-coating station for pre-coating the latex then heating the
latex at a station for pre-coating the latex layer with a pre-coat
PVC layer and two stations for coating PVC to form the bulk of the
backing layer.
The carpet tile so produced thus has a good bond between the
vinyl-styrene barrier layer and the thermoplastic backing layer.
The backing layer not only helps to lock in the fibers, but more
importantly serves to improve the flame resistance and reduce the
smoke values.
* * * * *