Carpet Tile and Method of Manufacturing Same

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.

1 . A carpet tile system comprising a pile fiber made of polypropylene, tufted into a primary backing that is combined with a secondary backing system, which includes a flame retardant in at least one of (a) the secondary backing system and (b) the pre-coat adhesive on the primary backing, the flame retardant provided in a sufficient concentration to achieve an ASTM E 648 Class I flammability rating. 
     
     
         2 . The carpet tile system of  claim 1  wherein the secondary backing system is a bitumen based secondary backing system. 
     
     
         3 . The carpet tile system of  claim 1  wherein the secondary backing system is a PVC-based secondary backing system. 
     
     
         4 . The carpet tile system of  claim 1  wherein the secondary backing system is a polyolefin-based secondary backing system. 
     
     
         5 . The carpet tile system of  claim 1  wherein the secondary backing system is a polyester-based secondary backing system. 
     
     
         6 . The carpet tile system of  claim 1  wherein the flame retardant is Magnesium Hydroxide Mg(OH) 2 . 
     
     
         7 . The carpet tile system of  claim 1  where in the flame retardant is Aluminium Hydroxide Al(OH) 3 . 
     
     
         8 . A carpet tile system comprising a pile fiber made of polyester, tufted into a primary backing that is combined with a secondary backing system, which includes a flame retardant in at least one of (a) the secondary backing system and (b) the pre-coat adhesive on the primary backing, the flame retardant provided in a sufficient concentration to achieve an ASTM E 648 Class I flammability rating. 
     
     
         9 . The carpet tile system of  claim 8  wherein the secondary backing system is a bitumen based secondary backing system. 
     
     
         10 . The carpet tile system of  claim 8  wherein the secondary backing system is a PVC-based secondary backing system. 
     
     
         11 . The carpet tile system of  claim 8  wherein the secondary backing system is a polyolefin-based secondary backing system. 
     
     
         12 . The carpet tile system of  claim 8  wherein the secondary backing system is a polyester-based secondary backing system. 
     
     
         13 . The carpet tile system of  claim 8  wherein the flame retardant is Magnesium Hydroxide Mg(OH) 2 . 
     
     
         14 . The carpet tile system of  claim 8  where in the flame retardant is Aluminium Hydroxide Al(OH) 3 . 
     
     
         15 . A carpet tile system comprising a pile fiber made of polypropylene or polyester, tufted into a primary backing that is combined with a secondary backing system, which includes a flame retardant in at least one of (a) the secondary backing system and (b) the pre-coat adhesive on the primary backing, the flame retardant provided in a sufficient concentration to achieve a superior rating to the rating normally achieved on a carpet tile with polyester or polypropylene pile fiber. 
     
     
         16 . The carpet tile system of  claim 15  wherein the secondary backing system is a bitumen based secondary backing system. 
     
     
         17 . The carpet tile system of  claim 15  wherein the secondary backing system is a PVC-based secondary backing system. 
     
     
         18 . The carpet tile system of  claim 15  wherein the secondary backing system is a polyolefin-based secondary backing system. 
     
     
         19 . The carpet tile system of  claim 15  wherein the secondary backing system is a polyester-based secondary backing system.