Substantially flame retardant-free 3GT carpet
View Patent ↗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.
1. A carpet comprising a poly(trimethylene terephthalate) yarn tufted into a backing with an adhesive applied thereto, wherein the poly(trimethylene terephthalate) yarn comprises a carrier in a range of from 25 to 3000 ppm by weight of the yarn, up to 760 ppm by weight of an antistatic agent; wherein the carpet is substantially flame retardant free, and wherein the carpet exhibits an average burn distance of >3 inches according to ASTM D-2859.
2. The carpet of claim 1 , wherein the poly(trimethylene terephthalate) yarn comprises the carrier in a range of from 25 to 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 25 to 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 25 to 500 ppm by weight of the poly(trimethylene terephthalate) yarn.
5. The carpet of claim 1 , wherein the carpet contains less than 2000 ppm (0.2 wt %) flame retardant(s), by weight of the carpet.
6. The carpet of claim 1 , wherein the carpet contains no more than 1755 ppm (0.1755 wt %) aluminum, no more than 1100 ppm (0.11 wt %) phosphorous, and no more than 1100 ppm (0.11 wt %) zinc, by weight of the carpet.
7. 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.
8. The process of claim 7 , further comprising the step of applying an antistatic agent to the poly(trimethylene terephthalate) yarn.
9. The process of claim 7 , 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.
10. The process of claim 7 , wherein the carpet contains less than about 2000 ppm (0.2 wt %) flame retardant(s), by weight of the carpet.
11. The process of claim 7 , 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.
12. 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.
13. The process of claim 12 , further comprising the step of applying a carrier to the poly(trimethylene terephthalate) yarn prior to dyeing.
14. The process of claim 12 , 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.
15. The process of claim 12 , wherein the carpet contains less than about 2000 ppm (0.2 wt %) flame retardant(s), by weight of the carpet.
16. The process of claim 12 , 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.