Modular carpet systems

• US 9,988,760 B2
• Filed: 05/03/2012
• Issued: 06/05/2018
• Est. Priority Date: 05/04/2011
• Status: Active Grant

• Current Assignee: Tarkett USA Inc.
• Original Assignee: Tandus Centiva Inc. (Tarkett Holding GmbH)
• Inventors: Evans, Jr., Paul D., Moore, Gabe
• Primary Examiner(s): HUANG, CHENG YUAN
• Application Number:
  US13/463,194
• Publication Number:
  US 20120282459A1
• Time in Patent Office: 2,224 Days
• Field of Search: None
• CPC Class Codes: A47G 27/0475 Laying carpet tiles
• CPC Class Codes: B32B 2307/734 Dimensional stability
• CPC Class Codes: B32B 27/20 using fillers, pigments, thixotroping agents
• CPC Class Codes: D06N 2209/1628 Dimensional stability
• CPC Class Codes: D06N 7/0071 characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing
• CPC Class Codes: Y10T 428/25 Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
• CPC Class Codes: Y10T 428/26 Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
• CPC Class Codes: Y10T 428/2852 Adhesive compositions

Abstract

A modular carpet system includes a carpet tile and an adhesive. The carpet tile is operative for resisting deformation, even under adverse conditions. In some embodiments, the adhesive may comprise a silicone-based adhesive or a urethane-based adhesive.

Claims

1. A modular carpet system, comprising:

a first component comprising a carpet tile, the carpet tile comprising a face and a backing, wherein the backing is for being positioned in a facing relationship with an installation surface, wherein the backing comprises a polymer having at least 50% amorphous content, wherein the polymer having at least 50% amorphous content comprises polyvinyl butyral,

wherein the carpet tile is operative for remaining dimensionally stable under adverse conditions, the adverse conditions comprising at least one of

a moisture vapor emission rate of at least about 4 lb/24 hr/1000 sq. ft.,

an in situ relative humidity of at least about 80%, and

a surface moisture pH of at least about 8; and

a second component comprising an adhesive tape piece separate from the carpet tile, wherein the adhesive tape piece is for securing the carpet tile to at least one of an adjacent carpet tile and the installation surface, wherein the adhesive tape piece comprises a pressure-sensitive adhesive supported on a polymer film, the pressure-sensitive adhesive comprising a silicone-based adhesive having a shear strength of from about 21.7 lb-f/sq. in. to about 33.3 lb-f/sq. in., and an adhesive tack of greater than 3.5 lb-f/sq. in. prior to exposure to the adverse conditions, and the polymer film having a thickness of from about 1 mil to about 5 mil, and a tensile strength of from about 20,000 to about 40,000 lb/sq. in.,

wherein the adhesive tape piece is for being positioned beneath the carpet tile, so that the adhesive tape piece is disposed at least partially between the backing of the carpet tile and the installation surface, and so that the pressure-sensitive adhesive of the adhesive tape piece is in contact with the backing of the carpet tile, wherein the pressure-sensitive adhesive of the adhesive tape piece in contact with the backing of the carpet tile secures the carpet tile to the at least one of the adjacent carpet tile and the installation surface under the adverse conditions.

2. The modular carpet system of claim 1, wherein the adverse conditions comprise at least one of

a moisture vapor emission rate of at least about 5 lb/24 hr/1000 sq. ft.,

an in situ relative humidity of at least about 90%, and

a surface moisture pH of at least about 10.

3. The modular carpet system of claim 1, wherein the polymer of the backing further comprises modified polycarbonate, ultra high molecular weight polyethylene, atactic polypropylene, a silicone elastomer, a thermoplastic polyolefin, a thermoplastic elastomer, bitumen, or any combination thereof.

4. The modular carpet system of claim 1, wherein the backing further comprises a filler.

5. The modular carpet system of claim 4, wherein the backing comprises from about 25 to about 60 wt % polyvinyl butyral and from about 40 to about 75 wt % filler.

6. The modular carpet system of claim 1, wherein the backing further comprises a plasticizer.

7. The modular carpet system of claim 6, wherein the silicone-based adhesive resists being plasticized by the plasticizer after exposure to 140°

F. for 30 days.

8. The modular carpet system of claim 1, wherein remaining dimensionally stable under adverse conditions comprises having a change in length or width of less than about 0.15% after being immersed in water for at least about 2 hours.

9. The modular carpet system of claim 1, wherein remaining dimensionally stable under adverse conditions comprises having a change in length or width of less than about 0.15% as measured using ISO 2551.

10. The modular carpet system of claim 1, wherein remaining dimensionally stable under adverse conditions comprises having a planar deviation of less than about 0.078 in. after being immersed in water for about 2 hours.

11. The modular carpet system of claim 1, wherein the silicone-based adhesive has an adhesive tack of about 7.6 lb-f/sq. in. prior to exposure to adverse conditions.

12. The modular carpet system of claim 1, wherein the silicone-based adhesive has an adhesive tack of greater than 2.0 lb-f/sq. in. after being immersed in water for about 1 day.

13. The modular carpet system of claim 1, wherein the silicone-based adhesive has an adhesive tack of greater than 2.7 lb-f/sq. in. after being immersed in a pH 12 solution for about 1 day.

14. The modular carpet system of claim 1, wherein the polymer film of the adhesive tape piece comprises a polyester film.

15. The modular carpet system of claim 1, wherein the adhesive tape piece exhibits substantially no delamination after exposure to adverse conditions.

16. The modular carpet system of claim 1, wherein the adhesive tape piece has a thickness of from about 2.5 mil to about 3.5 mil.

17. The modular carpet system of claim 1, wherein the adhesive tape piece has a tensile strength of from about 25,000 to about 32,000 lb/sq. in.

18. The modular carpet system of claim 1, used in an installation comprising the adhesive tape piece and the carpet tile.

19. The modular carpet system of claim 1, wherein

the carpet tile is a first carpet tile of a plurality of carpet tiles, the plurality of carpet tiles being positioned in a side by side configuration in an installation with the adhesive tape piece positioned beneath the carpet tile, and

the adhesive tape piece maintains the plurality of carpet tiles in the side by side configuration within the installation.

20. The modular carpet system of claim 1, wherein the carpet tile is secured in an installation under adverse conditions with the adhesive tape piece positioned beneath the carpet tile, wherein the adverse conditions comprise at least one of

a moisture vapor emission rate of at least about 5 lb/24 hr/1000 sq. ft.,

an in situ relative humidity of at least about 90%, and

a surface moisture pH of at least about 10, and

wherein the carpet tile resists deformation under the adverse conditions.

21. The modular carpet system of claim 1, wherein the carpet tile is secured in an installation under adverse conditions with the adhesive tape piece positioned beneath the carpet tile, wherein the adverse conditions comprise at least one of

a moisture vapor emission rate of at least about 5 lb/24 hr/1000 sq. ft.,

an in situ relative humidity of at least about 90%, and

a surface moisture pH of at least about 10, and

wherein

the carpet tile resists deformation under the adverse conditions, and

the adhesive tape piece maintains the carpet tile in the installation under the adverse conditions.

22. The modular carpet system of claim 1, wherein

the silicone-based adhesive has an adhesive tack of greater than 2.0 lb-f/sq. in. after being immersed in water for about 1 day, and

remaining dimensionally stable under adverse conditions comprises the carpet tile undergoing a change in length or width of less than about 0.15% after being immersed in water for at least about 2 hours.

23. The modular carpet system of claim 22, wherein the initial adhesive tack of the silicone-based adhesive is about 7.6 lb-f/sq. in.

24. The modular carpet system of claim 22, wherein the backing of the carpet tile comprises from about 25 to about 60 wt % polyvinyl butyral.

25. The modular carpet system of claim 22, wherein the polymer film of the adhesive tape piece comprises a polyester film.

26. The modular carpet system of claim 22, wherein

the carpet tile is a first carpet tile of a plurality of carpet tiles, the plurality of carpet tiles being positioned in a side by side configuration in an installation with the adhesive piece positioned beneath the carpet tile, and

the adhesive tape piece maintains the plurality of carpet tiles in the side by side configuration within the installation.

27. The modular carpet system of claim 22, wherein the carpet tile is secured in an installation under adverse conditions with the adhesive tape piece positioned beneath the carpet tile, wherein the adverse conditions comprise at least one of

a moisture vapor emission rate of at least about 5 lb/24 hr/1000 sq. ft.,

an in situ relative humidity of at least about 90%, and

a surface moisture pH of at least about 10, and

wherein

the carpet tile resists deformation under the adverse conditions, and

the adhesive tape piece maintains the carpet tile in the installation under the adverse conditions.

28. A modular carpet system, comprising:

a plurality of carpet tiles, the carpet tiles each comprising a face and a backing, wherein the backing is for being positioned in a facing relationship with an installation surface, wherein the backing comprises polyvinyl butyral, and wherein the carpet tile is operative for remaining dimensionally stable under adverse conditions, the adverse conditions comprising at least one of

a moisture vapor emission rate of at least about 4 lb/24 hr/1000 sq. ft.,

an in situ relative humidity of at least about 80%, and

a surface moisture pH of at least about 8; and

a plurality of adhesive tape pieces, the adhesive tape pieces being for joining the carpet tile to at least one of an adjacent carpet tile and the installation surface, wherein the adhesive tape pieces comprise a silicone-based, pressure-sensitive adhesive supported on a polymer film, wherein the pressure-sensitive adhesive has a shear strength of from about 21.7 lb-f/sq. in. to about 33.3 lb-f/sq. in. prior to exposure to the adverse conditions,

wherein the adhesive tape pieces are for being positioned beneath the carpet tiles during installation of the carpet tiles, so that the adhesive tape pieces are disposed between the backing of the carpet tiles and the installation surface, and so that the pressure-sensitive adhesive is in contact with the backing of the carpet tiles, wherein the pressure-sensitive adhesive in contact with the backing of the carpet tiles joins each carpet tile to the at least one of the adjacent carpet tile and the installation surface under the adverse conditions.

29. The modular carpet system of claim 28, wherein the adverse conditions comprise at least one of

a moisture vapor emission rate of up to about 8 lb/24 hr/1000 sq. ft.,

an in situ relative humidity of up to about 85%, and

a surface moisture pH of up to about 11.

30. The modular carpet system of claim 28, wherein remaining dimensionally stable comprises having at least one of:

a change in length or width of less than about 0.15% after being immersed in water for at least about 2 hours,

a change in length or width of less than about 0.15% as measured using ISO 2551, and

a planar deviation of less than about 0.078 in. after being immersed in water for about 2 hours.

31. The modular carpet system of claim 28, wherein the silicone-based adhesive has at least one of:

an adhesive tack of greater than 3.5 lb-f/sq. in. prior to exposure to adverse conditions,

an adhesive tack of greater than 2.0 lb-f/sq. in. after being immersed in water for about 1 day, and

an adhesive tack of greater than 2.7 lb-f/sq. in. after being immersed in a pH 12 solution for about 1 day.

32. The modular carpet system of claim 28, wherein the silicone-based adhesive has an adhesive tack of about 7.6 lb-f/sq. in. prior to exposure to adverse conditions.

33. The modular carpet system of claim 28, wherein the backing comprises from about 25 to about 60 wt % polyvinyl butyral.

34. The modular carpet system of claim 28, wherein the polymer film of the adhesive tape pieces has

a thickness of from about 1 mil to about 5 mil, and

a tensile strength of from about 20,000 to about 40,000 lb/sq. in.

35. The modular carpet system of claim 28, used in an installation comprising the adhesive tape pieces and the plurality of carpet tiles, wherein

the carpet tiles are positioned in an edge to edge configuration with the adhesive tape pieces positioned beneath the carpet tiles, and

the adhesive tape pieces connect adjacent tiles to one another in the edge to edge configuration in the installation.

36. The modular carpet system of claim 28, wherein

the backing comprises from about 25 wt % to about 60 wt % polyvinyl butyral,

the silicone-based adhesive has an initial adhesive tack of greater than 3.5 lb-f/sq. in.,

the silicone-based adhesive has an adhesive tack of greater than 2.0 lb-f/sq. in. after being immersed in water for about 1 day, and

the carpet tile remaining dimensionally stable under adverse conditions comprises the carpet tile exhibiting a planar deviation of less than about 0.078 in. after being immersed in water for about 2 hours.

37. The modular carpet system of claim 36, wherein the backing comprises from about 40 wt % to about 75 wt % filler.

38. The modular carpet system of claim 36, wherein the polymer film of the adhesive tape pieces has

a thickness of from about 1 mil to about 5 mil, and

a tensile strength of from about 20,000 to about 40,000 lb/sq. in.

39. The modular carpet system of claim 36, used in an installation comprising the adhesive tape pieces and the plurality of the carpet tiles, wherein

the carpet tiles are positioned in an edge to edge configuration with the adhesive tape pieces positioned beneath the carpet tiles, and

the adhesive tape pieces secure the plurality of carpet tiles in the edge to edge configuration in the installation.

40. The modular carpet system of claim 28, wherein the backing further comprises a filler in an amount of from about 42 to about 65 wt % of the backing.

41. A modular carpet system, comprising:

a plurality of carpet tiles, the carpet tiles each comprising a face and a backing, wherein the backing is for being positioned in a facing relationship with an installation surface, wherein the backing comprises

polyvinyl butyral, and

from about 40 to about 75 wt % filler,

wherein the carpet tile is operative for remaining dimensionally stable under adverse conditions, the adverse conditions comprising at least one of

a moisture vapor emission rate of at least about 4 lb/24 hr/1000 sq. ft.,

an in situ relative humidity of at least about 80%, and

a surface moisture pH of at least about 8; and

a plurality of adhesive tape pieces wound into a roll, the adhesive tape pieces being separably joined to one another along lines of perforation, the adhesive tape pieces being for adhesively connecting the carpet tile to an adjacent carpet tile, wherein the adhesive tape comprises a silicone-based, pressure-sensitive adhesive on a polyester film, wherein the silicone-based, pressure-sensitive adhesive has an adhesive tack of greater than 3.5 lb-f/sq. in. prior to exposure to the adverse conditions,

wherein the adhesive tape pieces are for being positioned beneath the carpet tiles during installation of the carpet tiles, so that the adhesive tape pieces are disposed between the backing of the carpet tiles and the installation surface, and so that the pressure-sensitive adhesive is in contact with the backing of the carpet tiles, wherein the pressure-sensitive adhesive in contact with the backing of the carpet tiles adhesively connects the carpet tile to the adjacent carpet tile under the adverse conditions.

42. The modular carpet system of claim 41, wherein prior to exposure to the adverse conditions, the pressure-sensitive adhesive has a shear strength of from about 21.7 lb-f/sq. in. to about 33.3 lb-f/sq. in.

43. The modular carpet system of claim 42, wherein

the pressure-sensitive adhesive has an adhesive tack of greater than 2.0 lb-f/sq. in. after being immersed in water for about 1 day, and

the carpet tile undergoes a change in length or width of less than about 0.15% after being immersed in water for at least about 2 hours.

44. The modular carpet system of claim 41, wherein the polyester film of the adhesive tape pieces has

a thickness of from about 1 mil to about 5 mil, and

a tensile strength of from about 20,000 to about 40,000 lb/sq. in.