Substantially Flame Retardant-Free 3GT Carpet

• US 20080014403A1
• Filed: 07/06/2007
• Published: 01/17/2008
• Est. Priority Date: 07/13/2006
• Status: Active Grant

• Current Assignee: Covation Incorporated (Dell Technologies Inc.)
• Original Assignee: E. I. du Pont de Nemours and Company (Corteva, Inc.)
• Inventors: Kozlowski, John, Beare, Steven, Urove, Gregory, Chang, Jing
• Granted Patent: US 8,021,736 B2
• Time in Patent Office: Days
• US Class Current: 428/95
• CPC Class Codes: D05C 17/02 Tufted products
• CPC Class Codes: D06N 2201/02 Synthetic macromolecular fibres
• CPC Class Codes: D06N 2209/046 Anti-static
• CPC Class Codes: D06N 2209/067 Flame resistant, fire resistant
• CPC Class Codes: D06N 7/0065 characterised by the pile
• CPC Class Codes: D06N 7/0073 the back coating or pre-coat being applied as an aqueous dispersion or latex
• CPC Class Codes: Y10S 8/929 Carpet dyeing
• CPC Class Codes: Y10S 8/93 Pretreatment before dyeing
• CPC Class Codes: Y10T 428/23979 Particular backing structure or composition
• CPC Class Codes: Y10T 428/23993 Composition of pile or adhesive

Abstract

Substantially flame retardant-free carpets comprising poly(trimethylene terephthalate) yarn having minimal carrier and, optionally, minimal antistatic agent, are disclosed, as are methods for making such carpets.

Claims

1. A carpet comprising a poly(trimethylene terephthalate) yarn, a backing system and an adhesive system, wherein the poly(trimethylene terephthalate) yarn comprises a carrier in a range of from about 25 to about 3000 ppm by weight of the yarn, and/or an antistatic agent in an amount up to about 2500 ppm, and wherein the carpet is substantially flame retardant free.

2. The carpet of claim 1, wherein the poly(trimethylene terephthalate) yarn comprises the carrier in a range of from about 25 to about 2000 ppm by weight of the poly(trimethylene terephthalate) yarn.

3. The carpet of claim 1, wherein the poly(trimethylene terephthalate) yarn comprises the carrier in a range of from about 25 to about 1000 ppm by weight of the poly(trimethylene terephthalate) yarn.

4. The carpet of claim 1, wherein the poly(trimethylene terephthalate) yarn comprises the carrier in a range of from about 25 to about 500 ppm by weight of the poly(trimethylene terephthalate) yarn.

5. The carpet of claim 1, wherein the poly(trimethylene terephthalate) yarn comprises substantially no antistatic agent.

6. The carpet of claim 1, wherein the poly(trimethylene terephthalate) yarn comprises the antistatic agent in an amount up to about 2500 ppm by weight of the poly(trimethylene terephthalate) yarn.

7. The carpet of claim 1, wherein the poly(trimethylene terephthalate) yarn comprises the antistatic agent in an amount up to about 2500 ppm by weight of the poly(trimethylene terephthalate) yarn, and no carrier.

8. The carpet of claim 1, wherein the carpet contains less than about 2000 ppm (0.2 wt%) flame retardant(s), by weight of the carpet.

9. The carpet of claim 1, wherein the carpet contains no more than about 1755 ppm (0.1755 wt %) aluminum, no more than about 1100 ppm (0.11 wt %) phosphorous, and no more than about 1100 ppm (0.11 wt %) zinc, by weight of the carpet.

10. The carpet of claim 1, wherein the carpet has a Class I flammability rating, as determined by an ASTM-E648-based test.

11. A process of producing a substantially flame retardant-free carpet as set forth in claim 1, comprising the steps of:

(a) tufting a poly(trimethylene terephthalate) yarn to produce a carpet comprising a poly(trimethylene terephthalate) yarn, a backing system, and an adhesive system;

(b) applying a carrier to the poly(trimethylene terephthalate) yarn; and

(c) dyeing the poly(trimethylene terephthalate) yarn.

12. The process of claim 11, further comprising the step of applying an antistatic agent to the poly(trimethylene terephthalate) yarn.

13. The process of claim 11, wherein the tufting step (a) comprises the steps of:

(a1) tufting the poly(trimethylene terephthalate) yarn into a primary backing;

(a2) applying a latex adhesive to the primary backing; and

(a3) applying a secondary backing onto the latex adhesive.

14. The process of claim 11, wherein the carpet contains less than about 2000 ppm (0.2 wt %) flame retardant(s), by weight of the carpet.

15. The process of claim 11, wherein the carpet contains no more than about 1755 ppm (0.1755 wt %) aluminum, no more than about 1100 ppm (0.11 wt %) phosphorous, and no more than about 1100 ppm (0.11 wt %) zinc, by weight of the carpet.

16. A process of producing a substantially flame retardant-free carpet as set forth in claim 1, comprising the steps of:

(a) tufting a poly(trimethylene terephthalate) yarn to produce a carpet comprising a poly(trimethylene terephthalate) yarn, a backing system, and an adhesive system;

(b) dyeing the poly(trimethylene terephthalate) yarn; and

(c) applying an antistatic agent to the poly(trimethylene terephthalate) yarn.

17. The process of claim 16, further comprising the step of applying a carrier to the poly(trimethylene terephthalate) yarn prior to dyeing.

18. The process of claim 16, wherein the tufting step (a) comprises the steps of:

(a1) tufting the poly(trimethylene terephthalate) yarn into a primary backing;

(a2) applying a latex adhesive to the primary backing; and

(a3) applying a secondary backing onto the latex adhesive.

19. The process of claim 16, wherein the carpet contains less than about 2000 ppm (0.2 wt %) flame retardant(s), by weight of the carpet.

20. The process of claim 16, wherein the carpet contains no more than about 1755 ppm (0.1755 wt %) aluminum, no more than about 1100 ppm (0.11 wt %) phosphorous, and no more than about 1100 ppm (0.11 wt %) zinc, by weight of the carpet.