초록

There is disclosed a carpet product. The carpet product comprises a polymer-coated carpet backing, a layer of silicate on the polymer-coated carpet backing, and a layer of polyurethane on the layer of silicate. A method of producing the carpet product is also disclosed.

대표청구항 ▼

1. A carpet product comprising: a primary backing tufted with yarn to form a face pile on one side of said backing and loop backs on the other side of said backing; a polymer coating on said other side of said backing to secure said loop backs thereto; a layer consisting essentially of silicate

1. A carpet product comprising: a primary backing tufted with yarn to form a face pile on one side of said backing and loop backs on the other side of said backing; a polymer coating on said other side of said backing to secure said loop backs thereto; a layer consisting essentially of silicate formed on said polymer coating; and a layer of polyurethane disposed on said layer of silicate. 2. The carpet product of claim 1, wherein said silicate layer is selected from sodium silicate, sodium metasilicate, sodium sesquisilicate, sodium orthosilicate, and mixtures thereof. 3. The carpet product of claim 1, wherein said silicate layer is sodium silicate. 4. The carpet product of claim 1, wherein said polyurethane layer is a polyurethane foam layer. 5. The carpet product of claim 1, wherein said polyurethane layer is an elastomeric polyurethane layer. 6. The carpet product of claim 1, wherein said silicate layer is a film. 7. The carpet product of claim 1, wherein said polymer coating is selected from styrene-butadiene rubber (SBR), ethyl vinyl acetate (EVA) and acrylic. 8. The carpet product of claim 1, wherein said polymer coating is styrene-butadiene. 9. A method comprising the steps of applying a layer consisting essentially of silicate to a polymer-coated carpet backing; curing the layer of silicate; applying a layer of polyurethane to said cured layer of silicate; and curing the layer of polyurethane. 10. The method of claim 9, wherein said silicate layer is selected from sodium silicate, sodium metasilicate, sodium sesquisilicate, sodium orthosilicate, and mixtures thereof. 11. The method of claim 9, wherein said silicate layer is sodium silicate. 12. The method of claim 9, wherein said silicate layer is applied at a rate so as to yield a dry silicate weight of approximately 0.01 to 0.25 ounces per square yard of carpet. 13. The method of claim 9, wherein said silicate layer is applied at a rate so as to yield a dry silicate weight of approximately 0.08 to 0.15 ounces per square yard of carpet. 14. The method of claim 9, wherein said layer of silicate is cured by heating at a temperature of approximately 220° to 375° F. 15. The method of claim 9, wherein said layer of silicate is cured by heating at a temperature of approximately 240° to 290° F. 16. The method of claim 9, wherein said polyurethane layer is a polyurethane foam layer. 17. The method of claim 9, wherein said polyurethane layer is an elastomeric polyurethane layer. 18. The method of claim 9, wherein said polymer coating is selected from styrene-butadiene rubber, ethyl vinyl acetate and acrylic. 19. A carpet product made by the method of claim 9. 20. A carpet product comprising: a polymer-coated carpet backing; a layer consisting essentially of silicate on said polymer-coated carpet backing; and a layer of polyurethane on said layer of silicate. 21. The carpet product of claim 20, wherein said polymer used to form said polymer-coated carpet backing is styrene-butadiene rubber. 22. The carpet product of claim 20, wherein said silicate is sodium silicate. 23. A carpet product comprising: a polymer-coated carpet backing, said polymer comprising styrene-butadiene rubber; a layer consisting essentially of sodium silicate on said polymer-coated carpet backing, said silicate layer being present in an amount of approximately 0.01 to 0.25 ounces per square yard of carpet; and a layer of polyurethane foam on said layer of silicate. 24. A carpet product comprising: a polymer-coated carpet backing; and a layer consisting essentially of silicate on said polymer-coated carpet backing.