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.

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.