Adhesive-free carpet tiles and methods of installing adhesive-free carpet tiles

Abstract

Cushion backed carpet tiles and carpet tile installations which can be installed without adhesives are described. The carpet tiles are manufactured according to rigid specifications in order that no corner of any of the individual tiles is {fraction (1/16)}″ or greater off the floor due to curl, and no corner on the tile has cup of greater than {fraction (3/16)}″. In this way, a substantially to entirely adhesive-free carpet tile installation can be achieved, with the installation being capable of withstanding the rigors of a variety of typical types of wear, such as rolling traffic, etc., without shifting or snowplowing over adjacent tiles.

I claim:  
     
         1 . A cushion backed carpet tile suitable for use in adhesive-free installations, said carpet tile comprising: 
 an upper textile surface; and    a layer of foam material, said layer of foam material being functionally secured beneath said upper textile surface, and said layer of foam material being adapted to provide cushioning to a force pressing against said upper textile surface, said carpet tile having a plurality of corners wherein each of said corners has a cup of about {fraction (3/16)}″ or less and a curl of about {fraction (1/16)}″ or less.    
     
     
         2 . The cushion backed carpet tile according to  claim 1 , wherein each of said corners has a cup of about {fraction (2/16)}″ or less and a curl of about {fraction (1/32)}″ or less.  
     
     
         3 . The cushion backed carpet tile of  claim 1  wherein each of said corners has a curl of about {fraction (1/32)}″ or less.  
     
     
         4 . The cushion backed carpet tile of  claim 1  wherein said carpet tile has a thickness of about 0.2 to about 0.55″.  
     
     
         5 . The cushion backed carpet tile of  claim 2  wherein each of said corners has a curl of about  {fraction (1/32)}″ or less.    
     
     
         6 . The cushion backed carpet tile of  claim 1  wherein said foam material has a thickness of about 0.10 to about 0.25″.  
     
     
         7 . The cushion backed carpet tile of  claim 1  wherein said foam material has a thickness of about 0.20″.  
     
     
         8 . The cushion backed carpet tile of  claim 1  wherein said foam material is polyurethane.  
     
     
         9 . The cushion backed carpet tile of  claim 1  further comprising a backing layer secured to said foam material opposite to said upper textile surface.  
     
     
         10 . The cushion backed carpet tile of  claim 9  wherein said backing layer comprises about 40-100% by weight polyester and about 0-60% by weight polypropylene.  
     
     
         11 . The cushion backed carpet tile of  claim 10  wherein said backing layer comprises about 40 to about 80% by weight polyester and about 20 to about 60% by weight polypropylene.  
     
     
         12 . The cushion backed carpet tile of  claim 11  wherein said backing layer comprises about 50% polyester and about 50% polypropylene.  
     
     
         13 . The cushion backed carpet tile of  claim 9  wherein said backing layer is a felt layer.  
     
     
         14 . The cushion backed carpet tile of  claim 1  wherein said cushion backed carpet tile has a coefficient of sliding friction which is higher than its peel strength.  
     
     
         15 . The cushion backed carpet tile of  claim 1  wherein said Upper textile surface is a pile fabric.  
     
     
         16 . The cushion backed carpet tile of  claim 1  wherein said upper textile surface comprises a tufted or bonded pile fabric.  
     
     
         17 . An adhesive free cushion backed carpet tile installation comprising: 
 a plurality of carpet tiles positioned in an abutting relationship relative to each other and substantially freely overlying a predetermined surface, wherein each of said carpet tiles has a plurality of corners, with said corners having a cup of about {fraction (3/16)}″ or less and a curl of about {fraction (1/16)}″ or less.    
     
     
         18 . The adhesive free cushion backed carpet tile installation according to  claim 17 , wherein each of said corners has a cup of about {fraction (2/16)}″ or less.  
     
     
         19 . The adhesive free cushion backed carpet tile installation of  claim 17  wherein each of said corners has a curl of about {fraction (1/32)}″ or less.  
     
     
         20 . The adhesive free cushion back carpet tile installation of  claim 17  wherein each of said carpet tiles has a coefficient of sliding friction of which is higher than its peel strength.  
     
     
         21 . A method of laying no adhesive cushion backed carpet tile on to a surface, comprising the steps of: 
 a) reversibly securing at least one indicator carpet tile to said surface with a securing device or means;    b) placing a second carpet tile on said surface wherein said second carpet tile and said indicator carpet tile abut;    c) placing a third carpet tile on said surface wherein said third carpet tile abuts at least one of said indicator carpet tile and said second carpet tile;    d) placing at least one subsequent carpet tile on said surface wherein said subsequent carpet tile abuts at least one of said indicator carpet tile, said second carpet tile and said third carpet tile;    e) removing said indicator carpet tile and removing said securing device or means; and    f) replacing said indicator tile or a carpet tile in a location vacated by said indicator carpet tile.    
     
     
         22 . The method of laying no adhesive cushion backed carpet tile of  claim 21  wherein said third carpet tile abuts said second carpet tile.  
     
     
         23 . The method of laying low adhesive cushion backed carpet tile of  claim 21  wherein said third carpet tile abuts said indicator tile.  
     
     
         24 . The method of laying low adhesive cushion backed carpet tile of  claim 21  wherein said subsequent carpet tile abuts said indicator tile.  
     
     
         25 . The method of laying low adhesive cushion backed carpet tile of  claim 21  wherein said subsequent carpet tile abuts said second carpet tile.  
     
     
         26 . The method of laying low adhesive cushion backed carpet tile of  claim 21  wherein said subsequent carpet tile abuts said third carpet tile.  
     
     
         27 . The method of laying low adhesive cushion backed carpet tile of  claim 21  wherein said subsequent carpet tile abuts said indicator carpet tile and said third carpet tile.  
     
     
         28 . The method of laying low adhesive cushion backed carpet tile of  claim 21  wherein said indicator tile is placed in substantially the center of the surface.  
     
     
         29 . The method of laying low adhesive cushion backed carpet tile of  claim 21  further comprising the step of repeating said step of placing additional subsequent carpet tile until said surface is substantially covered.  
     
     
         30 . The method of laying no adhesive cushion backed carpet tile of  claim 21  wherein each of said cushion backed carpet tile has a cup of about {fraction (3/16)}″ or less and a curl of about {fraction (1/16)}″ or less.  
     
     
         31 . The method of laying low adhesive cushion backed carpet tile of  claim 21  further comprising the step of treating said surface to enhance the cofficient of friction thereof.  
     
     
         32 . A method of reversibly laying cushion backed carpet tile on a surface, comprising the steps of: 
 a) increasing the coefficient of friction of said surface;    b) laying an indicator carpet tile on said surface;    c) placing a second carpet tile on said surface wherein said second carpet tile and said indicator carpet tile abut;    d) placing a third carpet tile on said surface wherein said third carpet tile abuts at least one of a group consisting of said indicator carpet tile and said second carpet tile; and    e) placing at least one subsequent carpet tile on said surface wherein said subsequent carpet tile abuts at least one of said indicator carpet tile, said second carpet tile and said third carpet tile.    
     
     
         33 . A modular floor covering system for covering a floor wherein said modular floor covering system comprises a multiplicity of cushion backed carpet tiles wherein said cushion backed carpet tiles freely release from said floor.  
     
     
         34 . The modular floor covering system of  claim 33  wherein said cushion backed carpet tiles are inhibited from lateral displacement.  
     
     
         35 . The modular floor covering system of  claim 34  wherein said cushion backed carpet tiles comprise an upper textile surface with yarn protruding from a topside thereof; 
 a polyurethane cushion attached to a bottom side of said upper textile surface; and  
 felt attached to said polyurethane cushion opposite to said upper textile surface wherein said cushion backed carpet comprises a plurality of corners and said corners have a cup and about {fraction (3/16)}″ or less and curl of about {fraction (1/16)}″ or less.  
 
     
     
         36 . The modular floor covering system of  claim 35  further comprising a reinforcement layer between said upper textile surface and said polyurethane cushion.  
     
     
         37 . The modular floor covering system of  claim 36  wherein said reinforcement layer is fiberglass.  
     
     
         38 . The modular floor covering system of  claim 35  wherein said upper textile surface comprises a yarn and a primary backing.  
     
     
         39 . The modular floor covering system of  claim 38  wherein said cushion backed carpet tile further comprises a pre-coat backing layer.  
     
     
         40 . The modular floor covering system of  claim 39  wherein said pre-coat backing layer is latex.  
     
     
         41 . The modular floor covering system of  claim 35  wherein said upper textile surface comprises a yarn and adhesive.  
     
     
         42 . The modular floor covering system of  claim 41  further comprising a scrim between said upper textile surface and said polyurethane cushion.  
     
     
         43 . The modular floor covering system of  claim 35  further comprising a latex pre-coat adhesive between said upper textile surface and said polyurethane cushion.  
     
     
         44 . The modular floor covering system of  claim 43  further comprising a reinforcement layer between said upper textile surface and said polyurethane cushion.  
     
     
         45 . The modular floor covering system of  claim 44  wherein said reinforcement layer is fiberglass.  
     
     
         46 . The modular floor covering system of  claim 35  further comprising a hot melt adhesive between said upper textile surface and said polyurethane cushion.  
     
     
         47 . The modular floor covering system of  claim 46  further comprising a reinforcement layer between said hot melt adhesive and said polyurethane cushion.  
     
     
         48 . The modular floor covering system of  claim 47  wherein said reinforcement layer is fiberglass.  
     
     
         49 . A modular floor covering system comprising a multiplicity of cushion backed carpet tiles wherein each said carpet tile is interchangeable with at least one other said carpet tile and wherein said carpet tiles can be moved to alter a pattern on said multiplicity of cushion backed carpet tiles.  
     
     
         50 . A modular floor covering system comprising a multiplicity of installed cushion backed carpet tiles on a surface and at least one replacement cushion backed carpet tile not on said surface wherein said replacement cushion backed carpet tile has an identical pattern to at least one of said installed cushion backed carpet tile and wherein said at least one installed cushion backed carpet tile can be replaced by said replacement cushion backed carpet tile.  
     
     
         51 . A cushion backed carpet tile which is suitable for use without adhesive comprising: 
 an upper textile surface with yarn protruding from a topside thereof;    a polyurethane cushion attached to a bottom side of said upper textile surface; and    a reinforcement layer between said upper textile surface and said polyurethane cushion, wherein said cushion backed carpet comprises a plurality of corners and said corners have a cup and about {fraction (3/16)}″ or less and curl of about {fraction (1/16)}″ or less.    
     
     
         52 . The cushion backed carpet tile of  claim 51  further comprising felt attached to said polyurethane cushion opposite to said upper textile surface.  
     
     
         53 . The cushion backed carpet tile of  claim 51  wherein said reinforcement layer is fiberglass.  
     
     
         54 . The cushion backed carpet tile of  claim 51  wherein said upper textile surface comprises a yarn and a primary backing.  
     
     
         55 . The cushion backed carpet tile of  claim 54  wherein said cushion backed carpet tile further comprises a pre-coat backing layer.  
     
     
         56 . The cushion backed carpet tile of  claim 55  wherein said pre-coat backing layer is latex.  
     
     
         57 . The cushion backed carpet tile of  claim 51  wherein said upper textile surface comprises a yarn and adhesive.  
     
     
         58 . The cushion backed carpet tile of  claim 57  further comprising a scrim between said upper textile surface and said polyurethane cushion.  
     
     
         59 . The cushion backed carpet tile of  claim 51  further comprising a latex pre-coat adhesive between said upper textiles surface and said polyurethane cushion.  
     
     
         60 . The cushion backed carpet tile of  claim 59  further comprising felt attached to said polyurethane cushion opposite to said upper textile surface.  
     
     
         61 . The cushion backed carpet tile of  claim 60  wherein said reinforcement layer is fiberglass.  
     
     
         62 . The cushion backed carpet tile of  claim 60  further comprising a hot melt adhesive between said upper textile surface and said polyurethane cushion.  
     
     
         63 . The cushion backed carpet tile of  claim 62  further comprising a reinforcement layer between said hot melt adhesive and said polyurethane cushion.  
     
     
         64 . The cushion backed carpet tile of  claim 63  wherein said reinforcement layer is fiberglass.  
     
     
         65 . A carpet tile suitable for use in adhesive-free installations, said carpet tile comprising: 
 an upper pile fabric surface;    a layer of foam material, said layer of foam material being functionally secured beneath said upper pile fabric surface, and said layer of foam material being adapted to provide cushioning to a force pressing against said upper pile fabric surface, and said carpet tile having a plurality of corners wherein each of said corners has a cup of about {fraction (3/16)}″ or less and a curl of about {fraction (1/16)}″ or less.    
     
     
         66 . A carpet tile suitable for use in adhesive-free installations, said carpet tile comprising: 
 an upper pile textile surface with a fiber face weight of 12-40 ounces per square yard;    a layer of foam material, said layer of foam material being functionally secured beneath said upper pile textile fabric surface and said foam material has a thickness of 0.10 to 0.25″;    said layer of foam material being adapted to provide cushioning to a force pressing against said upper textile surface, and said carpet tile having a plurality of corners wherein each of said corners has a cup of about {fraction (3/16)}″ or less and a curl of about {fraction (1/16)}″ or less.    
     
     
         67 . The carpet tile of  claim 66  further comprising a backing material secured to said foam material opposite to said upper pile textile surface.  
     
     
         68 . The carpet tile of  claim 67  wherein said backing material is present in an amount of about 2-4 ounces per yard.  
     
     
         69 . The carpet tile of  claim 67  wherein said backing material is felt.  
     
     
         70 . The carpet tile of  claim 67  wherein said backing material comprises about 40-100% by weight polyester and 0-60% by weight polypropylene.  
     
     
         71 . The carpet tile of  claim 70  further comprising a stabilizing layer between said upper pile textile surface and said layer of foam material.  
     
     
         72 . A permeable floor covering system comprising: 
 a multiplicity of cushion backed carpet tiles wherein each of said multiplicity of cushion backed carpet tiles comprise: 
 an upper textile surface with yarn protruding from a topside thereof;  
 a polyurethane cushion attached to a bottom side of said upper textile surface; and  
 a plurality of corners with each said corner having a cup of about {fraction (3/16)}″ or less and curl of about {fraction (1/16)}″ or less.  
   
     
     
         73 . A flooring system for installation on a floor, comprising: 
 an element;    a carpet tile adapted for adhesive free installation over the element and having corners with each corner having a cup of about {fraction (3/16)}″ or less and a curl of about {fraction (1/16)}″ or less.    
     
     
         74 . The flooring system of  claim 73  wherein said carpet tile comprises an upper textile surface with yarn protruding from a topside thereof; and 
 a polyurethane cushion attached to a bottom side of said upper textile surface.  
 
     
     
         75 . Th flooring system of  claim 73 , wherein said element is at least one of a sensor, electrical wire, cable or connection, plumbing, telephone line or connection, computer cable or connection, computer network cable or connection, other wire or cable, conduit, access panel, safe, or the like.  
     
     
         76 . The flooring system as recited in  claim 73 , wherein the item is a sensor for monitoring heat, humidity, pedestrian traffic, pressure, temperature, or the like.  
     
     
         77 . The flooring system as recited in  claim 73 , wherein said floor is raised flooring which provides access to electrical, plumbing, telephone, computer, network, or internet cables, wires, conduits, or the like.  
     
     
         78 . A modular changeable at will floor system, comprising: 
 a plurality of adhesive free carpet tiles, which can be removed, reorganized, replaced, changed out, moved from one room to another, moved from one area to another, update inlays replaced, and the like.