Carpet Tile and Method of Manufacturing Same

Inactive Publication Date: 2017-11-02
NEXT FLOOR INC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

The invention provides a carpet tile that uses a new flame retardant called Aluminum Hydroxide to reduce its flammability. This flame retardant interacts with the pile fibers and the secondary backing system to achieve superior results. The concentration of flame retardant needed depends on factors like the pile fiber type, pile construction, pile weight, and secondary backing system. This new flame retardant helps make carpets safer and more resistant to fire outbreaks.

Problems solved by technology

Nylon is the most expensive of the three fibers.
However, as noted above, nylon fiber is the most expensive.

Method used

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  • Carpet Tile and Method of Manufacturing Same

Examples

Experimental program
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Effect test

Embodiment Construction

[0036]FIG. 1 (Prior Art) shows a typical prior art carpet, comprising a pile fiber 1, a secondary backing 2, and a primary backing 3 into which the pile fiber is tufted.

[0037]As stated above, the preferred embodiment of the invention uses Aluminum Hydroxide (Al(OH)3) as a flame retardant in the secondary backing 2. However, other embodiments of this invention could use Magnesium Hydroxide (Mg(OH)2) as the flame retardant and such other embodiments could also put the flame retardant into the pre-coat adhesive on the primary backing instead putting it in the secondary backing.

[0038]Due to the interactions with different parts of the carpet tile during combustion, the concentration of Aluminum Hydroxide which should be included in the carpet tile depends on the type of fiber, pile construction, the pile weight and the secondary backing system of the carpet tile. The appropriate concentration for any given carpet tile must be determined by routine experimentation, based on the following...

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Abstract

The carpet tile system uses preferably Aluminum Hydroxide (Al(OH)3) as a flame retardant in the secondary backing of the carpet tile or in the pre-coat adhesive on the primary backing, or alternatively uses Magnesium Hydroxide (Mg(OH)2). The flame retardant has been optimized to interact with the other components of the system to produce a carpet tile that achieves flammability ratings that are comparable or superior to carpet tiles with more expensive pile fibers.

Description

BACKGROUND OF THE INVENTION[0001]This invention relates to carpet tiles, and in particular to carpet tiles which use relatively inexpensive fibers and achieve a flammability rating comparable to or better than the flammability rating of carpet tiles using more expensive fibers.[0002]This invention primarily relates to carpet tiles which use a bitumen backing system. However, the invention may also improve the flammability of carpet tiles using other backing systems.[0003]There are three principal synthetic fibers that are used in commercial carpet: nylon (polyamide), polyester and polypropylene. Nylon is the most expensive of the three fibers. One of the benefits of using nylon is that you can generally achieve a better flammability rating than with the other two. Today the majority (more than 90%) of carpet tile sold in North America is made from nylon fiber.[0004]There are two kinds of polyester in common use, namely PET (polyethylene terephthalate) and PTT (polytrimethylene terep...

Claims

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Application Information

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IPC IPC(8): D06N7/00
CPCD06N7/0071D06N2201/02D06N2201/0254D06N2203/042D06N3/123D06N2203/048D06N2203/061D06N3/0063D06N3/045D06N3/06D06N7/0068D06N2209/067D06N2203/08D06N2213/06
InventorECKHARDT, RYANECKHARDT, WALTERECKHARDT, MICHAEL
OwnerNEXT FLOOR INC