Modular Carpet Systems

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.

What is claimed is: 
     
         1 . A modular carpet system, comprising:
 a carpet tile having 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 
   an adhesive tape separate from the carpet tile, wherein the adhesive tape is for securing the carpet tile to at least one of an adjacent carpet tile and the installation surface, wherein the adhesive tape comprises a silicone-based adhesive supported on a polymer film.   
     
     
         2 . The modular carpet system of  claim 1 , wherein the backing comprises from about 25 to about 60 wt % polyvinyl butyral and from about 40 to about 75 wt % filler. 
     
     
         3 . The modular carpet system of  claim 1 , wherein the silicone-based adhesive has a shear strength of at least about 21.7 lb-f/sq. in. prior to exposure to adverse conditions. 
     
     
         4 . The modular carpet system of  claim 1 , wherein the silicone-based adhesive has an adhesive tack of greater than 3.5 lb-f/sq. in. prior to exposure to adverse conditions and at least one of:
 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.   
     
     
         5 . The modular carpet system of  claim 1 , wherein the silicone-based adhesive resists being plasticized by the plasticizer after exposure to a temperature of about 140° F. for 30 days. 
     
     
         6 . The modular carpet system of  claim 1 , 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.   
     
     
         7 . The modular carpet system of  claim 1 , wherein the polymer film of the adhesive tape has
 a thickness of from about 0.25 mil to about 7 mil, and   a tensile strength of from about 25,000 to about 32,000 lb/sq. in.   
     
     
         8 . A modular carpet system, comprising:
 a plurality of carpet tiles, the carpet tiles each comprising a face and a backing, wherein the backing comprises from about 25 to about 60 wt % 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 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.   
     
     
         9 . The modular carpet system of  claim 8 , 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.   
     
     
         10 . The modular carpet system of  claim 8 , 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.   
     
     
         11 . The modular carpet system of  claim 8 , wherein the silicone-based adhesive has a shear strength of at least about 21.7 lb-f/sq. in. prior to exposure to the adverse conditions. 
     
     
         12 . The modular carpet system of  claim 11 , wherein the silicone-based adhesive has an adhesive tack of greater than 3.5 lb-f/sq. in. prior to exposure to adverse conditions, and at least one of:
 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.   
     
     
         13 . The modular carpet system of  claim 8 , wherein the polymer film of the adhesive tape pieces has
 a thickness of from about 0.25 mil to about 7 mil, and   a tensile strength of from about 20,000 lb/sq. in. to about 40,000 lb/sq. in.   
     
     
         14 . The modular carpet system of  claim 8 , wherein the backing further comprises from about 40 wt % to about 75 wt % filler, wherein the filler comprises calcium carbonate, coal fly ash, barium sulfate, talc, or any combination thereof. 
     
     
         15 . The modular carpet system of  claim 8 , wherein
 the carpet tiles are positioned in an edge-to-edge configuration in an installation 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.   
     
     
         16 . 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, 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 adhesive supported on a polymer film.   
     
     
         17 . The modular carpet system of  claim 16 , wherein the backing comprises from about 25 to about 60 wt % polyvinyl butyral. 
     
     
         18 . The modular carpet system of  claim 16 , wherein prior to exposure to the adverse conditions, the silicone-based adhesive has at least one of
 a shear strength of at least about 21.7 lb-f/sq. in., and   an adhesive tack of greater than 3.5 lb-f/sq. in.   
     
     
         19 . The modular carpet system of  claim 18 , wherein the silicone-based adhesive has at least one of:
 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.   
     
     
         20 . The modular carpet system of  claim 16 , wherein the polymer film of the adhesive tape pieces has
 a thickness of from about 2.5 mil to about 3.5 mil, and   a tensile strength of from about 20,000 to about 40,000 lb/sq. in.