U.S. patent application number 15/961018 was filed with the patent office on 2018-08-23 for modular carpet systems.
The applicant listed for this patent is Tandus Centiva Inc.. Invention is credited to Paul D. Evans, JR., Gabe Moore.
Application Number | 20180237984 15/961018 |
Document ID | / |
Family ID | 46125514 |
Filed Date | 2018-08-23 |
United States Patent
Application |
20180237984 |
Kind Code |
A1 |
Evans, JR.; Paul D. ; et
al. |
August 23, 2018 |
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.
Inventors: |
Evans, JR.; Paul D.; (Sugar
Valley, GA) ; Moore; Gabe; (Acworth, GA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Tandus Centiva Inc. |
Dalton |
GA |
US |
|
|
Family ID: |
46125514 |
Appl. No.: |
15/961018 |
Filed: |
April 24, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13463194 |
May 3, 2012 |
9988760 |
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15961018 |
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61482336 |
May 4, 2011 |
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61505160 |
Jul 7, 2011 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
D06N 7/0071 20130101;
A47G 27/0475 20130101; Y10T 428/26 20150115; Y10T 428/2852
20150115; D06N 2209/1628 20130101 |
International
Class: |
D06N 7/00 20060101
D06N007/00; A47G 27/04 20060101 A47G027/04 |
Claims
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.degree. 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.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 13/463,194, filed May 3, 2012, which claims
the benefit of U.S. Provisional Application No. 61/482,336, filed
May 4, 2011, and U.S. Provisional Application No. 61/505,160, filed
Jul. 7, 2011, all of which are incorporated by reference herein in
their entirety.
TECHNICAL FIELD
[0002] This disclosure generally relates to modular carpet systems
(i.e., carpet tile systems). More particularly, this disclosure
relates to modular carpet systems that are suitable for use in a
wide variety of installation environments.
BACKGROUND
[0003] Modular carpet systems (i.e., carpet tile systems) are often
sought to be installed in a wide range of environments.
Unfortunately, such environments often expose such systems to
adverse elements, such as standing water, alkaline conditions, high
humidity, and other potentially challenging conditions.
Conventional modular carpet systems are generally not able to
withstand such conditions, and therefore, tend to loosen, buckle,
shrink, and/or warp over time. Thus, there is a need for a modular
carpet system that can be used in adverse installation conditions
without degradation or failure.
SUMMARY
[0004] This disclosure is directed generally to a modular carpet
(e.g., carpet tile) system for use in a wide variety of
installation environments. In particular, the modular carpet system
may be suitable for use even in adverse installation
conditions.
[0005] The modular carpet system generally includes a carpet tile,
and an adhesive for securing the carpet tiles in a desired position
(e.g., in a side-by-side relationship with other carpet tiles) on
an installation surface. The carpet tile may generally resist
deformation or warping, even in adverse installation conditions.
Such conditions may include installation on a floor having a
moisture vapor emission rate (MVER) of at least about 4 lb/24
hr/1000 sq. ft., an in situ relative humidity (RH) in the floor of
at least about 80%, a surface moisture pH of at least about 8, or
any combination thereof. Likewise, the adhesive may resist failure
or substantial loss of adhesion, even in adverse installation
conditions.
[0006] The carpet tile may generally include a face comprising
woven or tufted face yarns, and a backing (commonly referred to as
a "secondary backing") for being positioned in a facing
relationship with the installation surface. In one example, the
backing may comprise a polymer or polymeric material that is at
least 50% amorphous, for example, polyvinyl butyral (PVB). The
adhesive may comprise any suitable adhesive, for example, a
silicone-based adhesive or a polyurethane-based adhesive. However,
numerous other materials may be suitable. The adhesive component
may be provided as an adhesive coating, a fastener (e.g., an
adhesive tape or unsupported adhesive), or in any other suitable
manner.
[0007] Although these systems are suitable for use in adverse
environments, they can also be used in standard environments which
do not have adverse conditions. Further, the systems may be used on
any suitable installation surface. For example, the installation
surface may comprise a floor or flooring surface (e.g., concrete,
wood, etc.) that may be primed, painted, or coated with other
materials, or may comprise an underlayment (e.g., for cushioning or
waterproofing) or other material disposed between the actual floor
or flooring surface and the carpet tile. For convenience, the terms
"floor", "flooring", "surface", "flooring surface", and
"installation surface" are used herein interchangeably.
[0008] Other features, aspects, and embodiments will be apparent
from the following description.
DESCRIPTION
[0009] This disclosure is directed generally to a modular carpet
(e.g., carpet tile) system for use in a wide variety of
installation environments, including adverse installation
environments. The modular carpet system of this disclosure
generally includes a modular carpet (e.g., carpet tile) that can
remain dimensionally stable (i.e., such that it resists both
deformation in the x, y, and z directions and deviation from a
planar state), even in adverse installation conditions, and an
adhesive that can resist substantial loss in adhesion, even in
adverse installation conditions.
[0010] In sharp contrast, a carpet tile that is not dimensionally
stable may begin to buckle, warp, or curl, thereby pulling away
from the adhesive and/or the installation surface, while an
unstable adhesive may begin to lose adhesion, thereby releasing the
carpet tile from its secured position. Thus, if the stability of
either the tile or the adhesive is significantly impaired by the
adverse condition, the tiles may undesirably shift or move from
their desired edge-to-edge (e.g., side-by-side) configuration.
[0011] The modular carpet system of this disclosure may be able to
withstand (i.e., remain stable in) a variety of adverse conditions.
For example, the modular carpet system may generally be stable when
installed on a floor having a moisture vapor emission rate (MVER)
of at least about 4 lb/24 hr/1000 sq. ft., at least about 5 lb/24
hr/1000 sq. ft., at least about 6 lb/24 hr/1000 sq. ft., at least
about 7 lb/24 hr/1000 sq. ft., at least about 8 lb/24 hr/1000 sq.
ft., at least about 9 lb/24 hr/1000 sq. ft., at least about 10
lb/24 hr/1000 sq. ft., at least about 11 lb/24 hr/1000 sq. ft., at
least about 12 lb/24 hr/1000 sq. ft., at least about 13 lb/24
hr/1000 sq. ft., at least about 14 lb/24 hr/1000 sq. ft., at least
about 15 lb/24 hr/1000 sq. ft., or at least about 16 lb/24 hr/1000
sq. ft., as measured using ASTM F1869-04 or any other suitable test
method.
[0012] As another example, the modular carpet system may be stable
when installed on a floor having an in situ relative humidity of at
least about 80%, at least about 85%, at least about 90%, or at
least about 95%, as measured for example, using ASTM F2170-02 or
any other suitable test method. In one specific example, the
modular carpet system may be stable when installed on a floor
having an in situ relative humidity of 100%, as measured using ASTM
F2170-02 or any other suitable test method.
[0013] As still another example, the modular carpet system may be
stable when installed on a floor having a surface pH (e.g., surface
moisture pH) of at least about 8, at least about 9, at least about
10, at least about 11, at least about 12, or at least about 13, as
measured using ASTM F710-05 or any other suitable test method.
[0014] As yet another example, the modular carpet system may be
stable when installed on a floor having any combination of the
above features.
[0015] The present inventors have discovered that the use of a tile
that remains dimensionally stable, even when exposed to adverse
conditions, in combination with an adhesive that can withstand
adverse conditions without a substantial loss in adhesion provides
substantial benefits that previously had not been able to be
achieved by known tile systems. Specifically, by using these
components in combination, the system may be installed in many
environments that would previously have been considered entirely
unsuitable. Thus, the present system fills a substantial void in
the marketplace.
[0016] Turning now to the individual components of the system, a
carpet tile that is dimensionally stable generally exhibits little
or no change in its length, width, or thickness, or deviation from
a planar state, in response to various environmental factors, so
the entire tile is able to remain in a substantially facing
relationship (e.g., an opposing, contacting face-to-face
relationship) with the installation surface over time. The
dimensional stability of a carpet tile therefore includes both
components of linear stability (i.e., change in length or width (MD
or CD), for example, growth or shrinkage) and planar stability
(i.e., a deviation from a planar/flat/level/even) state, for
example, doming or curling, which also often indicates a change in
z-directional thickness).
[0017] Linear stability may generally be characterized as
exhibiting a change in length or width of the carpet tile of less
than about 0.15%, for example, less than about 0.14%, less than
about 0.13%, less than about 0.12%, less than about 0.11%, less
than about 0.10%, less than about 0.09%, less than about 0.08%,
less than about 0.07%, less than about 0.06%, less than about
0.05%, less than about 0.04%, less than about 0.03%, less than
about 0.02%, or less than about 0.01%, after exposure to adverse
conditions, as measured using ISO 2551 or any other suitable test
method. This corresponds to a change in less than about 0.027 in.
for an 18 in..times.18 in. tile (i.e., no more than +/-0.027 in.),
less than about 0.036 in. for an 24 in..times.24 in. tile (i.e., no
more than +/-0.036 in.), or less than about 0.054 in. for an 36
in..times.36 in. tile (i.e., no more than +/-0.054 inch), for
example, as measured using ISO 2551 or any other suitable test
method.
[0018] Planar stability may generally be characterized exhibiting a
planar deviation of less than about 0.078 in., less than about
0.075 in., less than about 0.070 in., less than about 0.065 in.,
less than about 0.060 in., less than about 0.055 in., less than
about 0.050 in., less than about 0.045 in., less than about 0.040
in., less than about 0.035 in., less than about 0.030 in., less
than about 0.025 in., less than about 0.020 in., less than about
0.015 in., or less than about 0.010 in., as measured for example,
before and/or after heating according to ISO 2551 or other suitable
test method.
[0019] The present inventors have recognized that the
characteristics of the backing (i.e., secondary backing) of the
carpet tile may substantially determine whether a particular carpet
tile is dimensionally stable, even in adverse conditions. More
particularly, the present inventors have discovered that a backing
that is somewhat flexible tends to lie more flat on the
installation surface, which assists with resisting dimensional
changes when exposed to adverse conditions.
[0020] In one aspect, the backing may comprise a polymer having an
amorphous content of at least about 50%. While not wishing to be
bound by theory, it is believed that having at least 50% amorphous
polymer content in the backing allows the polymer in the backing to
"flow" and adapt more readily to the conditions of the installation
environment. In each of various examples, the polymer of the
backing may have an amorphous content of at least about 50 wt %, at
least about 55 wt %, at least about 60 wt %, at least about 65 wt
%, at least about 70 wt %, at least about 75 wt %, at least about
80 wt %, at least about 85 wt %, at least about 90 wt %, at least
about 95 wt %. In another example, the polymer of the backing may
have an amorphous content of 100%.
[0021] In one example, the polymer of the backing may comprise
polyvinyl butyral (PVB). The present inventors have discovered that
a backing comprising PVB may be particularly suitable for use for
providing stability in a modular carpet system, even in adverse
conditions. While not wishing to be bound by theory, it is believed
that the completely amorphous (i.e., 100% amorphous) nature of PVB
imparts an inherent flexibility to the backing. Additionally, it is
believed that the molecular weight of the PVB polymer is
sufficiently high to resist attack by moisture, plasticizers, and
caustic environments. Still other possibilities are contemplated.
One example of a commercially available backing including a polymer
that is at least 50% amorphous is ETHOS.RTM. tile backing,
commercially available from Tandus Flooring, Inc. The Ethos.RTM.
carpet tile, which comprises PVB, has been found to be
dimensionally stable in adverse conditions, as will be discussed
further below.
[0022] In other examples, the polymer of the backing may comprise
modified polycarbonate, ultra high molecular weight polyethylene
(UHMWPE), atactic polypropylene (a-PP), silicone elastomers,
thermoplastic polyolefins, thermoplastic elastomers, bitumen, or
any combination thereof. All of such polymers may be at least 50%
amorphous.
[0023] If desired, the backing may include a filler in an amount of
from about 40 to about 75 wt % of the backing. While not wishing to
be bound by theory, it is believed that the presence of filler at
this level imparts a degree of dimensional stability to the backing
that allows the tile to remain substantially flat, even in adverse
conditions. Further, it is believed that the filler also assists
with stabilizing the amorphous polymer, which can sometimes exhibit
poor cold flow performance (i.e., the distortion, deformation, or
dimensional change that takes place in materials under continuous
load at ambient temperatures). Accordingly, the backing may be
better able to maintain its shape and dimensional stability, even
in adverse conditions.
[0024] Thus, in each of various independent examples, the backing
may comprise, for example, from about 42 to about 65 wt %, from
about 44 to about 60 wt %, from about 45 to about 55 wt %, for
example, about 48%, or about 48.5 wt % filler, with the remainder
comprising polymer or polymeric materials, such as the at least 50%
amorphous polymers described above. Any filler may be used, for
example, calcium carbonate, coal fly ash, barium sulfate, talc, any
other suitable material, or any combination thereof.
[0025] Further, if desired, the backing may include a plasticizer
(i.e., may be externally plasticized). While countless plasticizers
may be suitable, in one example, the plasticizer may comprise a C8
(eight carbons) or greater alcohol based ester plasticizer.
[0026] In other examples, the backing may comprise a polymer that
may be less than 50% amorphous. For example, the polymer may be
less than 40% amorphous, less than 30% amorphous, less than 20%
amorphous, or less than 10% amorphous. Stated alternately, the
polymer may be at least about 10% amorphous, at least about 20%
amorphous, at least about 30% amorphous, or at least about 40%
amorphous. Examples of such polymers may include, but are not
limited to, polyethylene terephthalate, thermoplastic polyurethane,
poly(trimethylene terephthalate), polylactic acid, polyvinylidene
chloride, ethylene vinyl acetate, thermoplastic polyolefin or other
polyolefin, thermoplastic elastomer,
acrylonitrile-styrene-butadiene, nylon, styrene-butadiene,
styrene-butadiene-styrene, styrene-butadiene-rubber, acrylic, vinyl
acrylic, styrene acrylic, vinyl acetate ethylene copolymer, cork,
or rubber. Still countless other possibilities are contemplated.
Fillers may also be used with such materials, as described
above.
[0027] Numerous adhesives may likewise be suitable for use with the
modular carpet system, provided that the adhesive is stable, even
when exposed to adverse installation conditions, as set forth
above. The adhesive may also be suitable for use with externally
plasticized backings.
[0028] In one exemplary embodiment, the adhesive may be
silicone-based (e.g., may comprise a silicone-based polymer,
silicone elastomer, modified silicone elastomer, silicone-based
elastomer, etc.). Some examples of suitable silicone-based
adhesives have been evaluated in connection with various
commercially available adhesive tapes including, but not limited to
SR336R release coated polyester silicone tape (commercially
available from Specialty Tapes Manufacturing, Franksville, Wis.),
Tesa 50600 polyester tape with silicone-based adhesive
(commercially available from Tesa SE), ARclad 6370 polyester tape
with silicone-based adhesive (commercially available from Adhesives
Research, Glen Rock, PA), and SC-4075 polyester tape with
silicone-based adhesive (commercially available from Custom
Adhesive Products, Racine, Wis.), each of which is described in
greater detail below. Countless other silicone-based adhesives may
also be suitable.
[0029] In another exemplary embodiment, the adhesive may be
urethane-based (e.g., may comprise polyurethane, castor oil based
urethane, urethane hot melt, polyurethane reactive, etc.). Examples
of urethane-based adhesives that may be suitable for use with the
modular carpet system are Hauthane L2183 and Hauthane L3378, both
commercially available from Hauthaway Corporation, Lynn, Mass.).
However, countless others may be suitable.
[0030] In still other exemplary embodiments, the adhesive may be
acrylic-based, modified acrylic, styrene-based (e.g.,
styrene-butadiene, styrene-butadiene-styrene,
styrene-butadiene-rubber, styrene-acrylic), hot melt based (e.g.,
rubber based hotmelt, EVA, EVA based hotmelt, urethane based
hotmelt), butadiene-based (e.g., styrene-butadiene,
styrene-butadiene-styrene, styrene-butadiene-rubber), epoxy-based,
rubber based (e.g., natural or synthetic rubber), modified rubber,
cyanoacrylate, PVB, biopolymer-based (e.g., vinyl acetate ethylene
copolymers or castor oil based urethane). Further, any combination
or copolymer of any of the above adhesives (including the
silicone-based and urethane adhesives) may be suitable.
[0031] Prior to being exposed to adverse conditions (e.g., as set
forth above), the adhesive may generally have an adhesive tack that
is greater than 2.3 lb-f, for example, at least about 2.5 lb-f, for
example, at least about 3 lb-f, at least about 3.5 lb-f, at least
about 4 lb-f, at least about 4.5 lb-f, at least about 5 lb-f, at
least about 5.5, at least about 6 lb-f, at least about 6.5 lb-f, at
least about 7 lb-f, at least about 7.5 lb-f, at least about 8 lb-f,
at least about 8.5 lb-f, at least about 9 lb-f, at least about 9.5
lb-f, at least about 10 lb-f, or at least about 10.6 lb-f, as
measured using ASTM D2979 or any other suitable test method. (To
convert the adhesive tack values throughout this specification into
lb-f/sq. in, the value can be divided by the probe area of 0.66 sq.
in.).
[0032] After about one day, about 7 days, or about 14 of exposure
to one or more adverse conditions, as set forth above, the adhesive
tack may generally be greater than 1.3 lb-f, for example, at least
about 1.5 lb-f, at least about 2 lb-f, at least about 2.5 lb-f, at
least about 3 lb-f, at least about 3.5 lb-f, at least about 4 lb-f,
at least about 4.5 lb-f, at least about 5 lb-f, at least about 5.5
lb-f, at least about 6 lb-f, at least about 6.5 lb-f, at least
about 7 lb-f, at least about 7.5 lb-f, at least about 8 lb-f, at
least about 8.5 lb-f, at least about 9 lb-f, at least about 9.5
lb-f, or at least about 10 lb-f, as measured using ASTM D2979 or
any other suitable test method. However, other adhesive tack values
and ranges thereof are contemplated, depending on the adhesive used
and the conditions to which the adhesive is exposed.
[0033] For example, after about 1 day, about 7 days, or about 14
days of being immersed in water, the adhesive tack may be greater
than 1.3 lb-f, for example, at least about 1.5 lb-f, at least about
2 lb-f, at least about 2.4 lb-f, at least about 2.5 lb-f, at least
about 3 lb-f, at least about 3.5 lb-f, at least about 3.6 lb-f, at
least about 4 lb-f, at least about 4.1 lb-f, at least about 4.5
lb-f, at least about 5 lb-f, at least about 5.3 lb-f, at least
about 5.5 lb-f, at least about 6 lb-f, at least about 6.5 lb-f, at
least about 7 lb-f, at least about 7.5 lb-f, or at least about 8
lb-f, as measured using ASTM D2979 or any other suitable test
method.
[0034] After being immersed in water for about 1 day, about 7 days,
or about 14 days, the decrease in adhesive tack may be less than
about 42.8% or less than about 43%, for example, less than about
40%, less than about 35%, less than about 30%, less than about 28%,
less than about 27.6%, less than about 25%, less than about 20%,
less than about 15%, less than about 11%, less than about 11.3%,
less than about 10%, less than about 7%, less than about 6.6%, or
less than about 5%. In some examples, there may be no loss of
adhesion or there may be an increase in adhesion after immersion in
water for the specified period of time.
[0035] After about 1 day, about 7 days, or about 14 days of being
immersed in a pH 12 solution, the adhesive tack may be greater than
1.5 lb-f, for example, at least about 1.6 lb-f, at least about 2
lb-f, at least about 2.5 lb-f, at least about 2.7 lb-f, at least
about 3 lb-f, at least about 3.2 lb-f, at least about 3.5 lb-f, at
least about 3.6 lb-f, at least about 4 lb-f, at least about 4.1
lb-f, at least about 4.5 lb-f, at least about 5 lb-f, at least
about 5.5 lb-f, at least about 6 lb-f, at least about 6.5 lb-f, at
least about 7 lb-f, at least about 7.5 lb-f, or at least about 8
lb-f, as measured using ASTM D2979 or any other suitable test
method.
[0036] Prior to being exposed to adverse conditions (e.g., as set
forth above), the adhesive may generally have a shear (i.e., lap
shear) strength of from about 130 to about 200 lb-f, for example,
from about 140 to about 170 lb-f, for example, about 150 lb-f, when
adhered to various surfaces and measured using ASTM D3654 (as
modified herein) or any other suitable test method. (To convert the
lap shear adhesion values throughout this specification into
lb-f/sq. in, the value can be divided by the contact area of 6 sq.
in.). In other embodiments, the shear strength of the adhesive may
be at least about 130 lb-f, for example, at least about 140 lb-f,
at least about 150 lb-f, at least about 160 lb-f, at least about
163 lb-f, at least about 170 lb-f, at least about 180 lb-f, at
least about 190 lb-f, or at least about 200 lb-f, as measured using
ASTM D3654 (as modified herein) or any other suitable test method,
prior to exposure to adverse conditions.
[0037] After about one day of exposure to one or more adverse
conditions, as set forth above, the shear strength of the adhesive
may be greater than 98 lb-f, for example, at least about 100 lb-f,
at least about 110 lb-f, at least about 120 lb-f, at least about
130 lb-f, at least about 140 lb-f, at least about 150 lb-f, at
least about 160 lb-f, at least about 170 lb-f, at least about 180
lb-f, at least about 190 lb-f, or at least about 200 lb-f, as
measured using ASTM D3654 (as modified herein) or any other
suitable test method. After about 7 days of exposure to one or more
adverse conditions, as set forth above, the shear strength of the
adhesive may be greater than 84 lb-f, for example, at least about
90 lb-f, for example, at least about 100 lb-f, at least about 110
lb-f, at least about 120 lb-f, at least about 130 lb-f, for
example, at least about 140 lb-f, at least about 150 lb-f, at least
about 160 lb-f, at least about 170 lb-f, or at least about 180
lb-f, as measured using ASTM D3654 (as modified herein) or any
other suitable test method. After about 14 days of exposure to one
or more adverse conditions, as set forth above, the shear strength
of the adhesive may be greater than 106 lb-f, for example, at least
about 110 lb-f, at least about 120 lb-f, at least about 130 lb-f,
for example, at least about 140 lb-f, at least about 150 lb-f, at
least about 160 lb-f, at least about 170 lb-f, or at least about
180 lb-f, as measured using ASTM D3654 (as modified herein) or any
other suitable test method. However, other shear strength values
and ranges thereof are contemplated, depending on the adhesive used
and the conditions to which the adhesive is exposed. For example,
after about one day of being immersed in water, the shear strength
may be greater than 109 lb-f, for example, at least about 110 lb-f,
at least about 120 lb-f, at least about 130 lb-f, at least about
140 lb-f, at least about 150 lb-f, at least about 158 lb-f, at
least about 160 lb-f, at least about 170 lb-f, at least about 180
lb-f, at least about 190 lb-f, or at least about 200 lb-f, as
measured using ASTM D3654 (as modified herein) or any other
suitable test method. After about one day of being immersed in
water, the shear strength may decrease less than 27.4%, for
example, less than about 27%, less than about 25%, for example,
less than about 20%, less than about 15%, less than about 10%, less
than about 6.9%, less than about 5.1%, less than about 5%, or less
than about 4%. In some examples, there may be no loss of adhesion
or there may be an increase in adhesion after being immersed in
water for about one day. After about 7 days of being immersed in
water, the shear strength may be greater than 84 lb-f, for example,
at least about 90 lb-f, at least about 100 lb-f, at least about 110
lb-f, at least about 120 lb-f, at least about 122 lb-f, at least
about 130 lb-f, at least about 140 lb-f, at least about 150 lb-f,
at least about 158 lb-f, at least about 160 lb-f, at least about
170 lb-f, at least about 180 lb-f, at least about 184 lb-f, at
least about 190 lb-f, or at least about 200 lb-f, as measured using
ASTM D3654 (as modified herein) or any other suitable test method.
After about 7 days of being immersed in water, the shear strength
may decrease less than 43.9%, for example, less than about 43%,
less than about 40%, less than about 35%, less than about 30%, less
than about 25%, less than about 20%, less than about 18.9%, less
than about 15%, less than about 10%, or less than about 5%. In some
examples, there may be no loss of adhesion or there may be an
increase in adhesion after being immersed in water for about 7
days.
[0038] After about 14 days of being immersed in water, the shear
strength may be greater than 112 lb-f, for example, at least about
120 lb-f, at least about 130 lb-f, at least about 140 lb-f, at
least about 143 lb-f, at least about 150 lb-f, at least about 160
lb-f, at least about 170 lb-f, at least about 180 lb-f, at least
about 187 lb-f, at least about 190 lb-f, or at least about 200
lb-f, as measured using ASTM D3654 (as modified herein) or any
other suitable test method. After about 14 days of being immersed
in water, the shear strength may decrease less than 25.6%, for
example, less than about 25%, less than about 20%, less than about
15%, less than about 10%, or less than about 5%. In some examples,
there may be no loss of adhesion or there may be an increase in
adhesion after being immersed in water for about 14 days.
[0039] As another example, after about one day of being immersed in
a high pH solution (e.g., about 12), the shear strength of the
adhesive may be greater than 98 lb-f, for example, at least about
100 lb-f, at least about 110 lb-f, at least about 120 lb-f, at
least about 130 lb-f, at least about 140 lb-f, at least about 150
lb-f, at least about 158 lb-f, at least about 160 lb-f, at least
about 170 lb-f, at least about 177 lb-f, at least about 180 lb-f,
at least about 190 lb-f, or at least about 200 lb-f, as measured
using ASTM D3654 (as modified herein) or any other suitable test
method. After about one day of being immersed in a high pH solution
(e.g., about 12), the decrease in shear strength may be less than
35.1%, for example, less than about 35%, less than about 30%, less
than about 25%, less than about 20%, less than about 18.9%, less
than about 15%, less than about 10%, less than about 8.7%, less
than about 5.4%, or less than about 5%. In some examples, there may
be no loss of adhesion or there may be an increase in adhesion
after being immersed in a high pH solution for about one day.
[0040] After about 7 days of being immersed in a high pH solution
(e.g., about 12), the shear strength of the adhesive may be greater
than 89 lb-f, for example, at least about 90 lb-f, at least about
100 lb-f, at least about 110 lb-f, at least about 120 lb-f, at
least about 124 lb-f, at least about 130 lb-f, at least about 140
lb-f, at least about 150 lb-f, at least about 160 lb-f, at least
about 170 lb-f, at least about 180 lb-f, at least about 190 lb-f,
at least about 194 lb-f, or at least about 200 lb-f, as measured
using ASTM D3654 (as modified herein) or any other suitable test
method. After about 7 days of being immersed in a high pH solution
(e.g., about 12), the decrease in shear strength may be less than
41.1%, for example, less than about 41%, less than about 40%, less
than about 35%, less than about 30%, less than about 25%, less than
about 20%, less than about 18.7%, less than about 17.8%, less than
about 15%, less than about 10%, or less than about 5%. In some
examples, there may be no loss of adhesion or there may be an
increase in adhesion after being immersed in a high pH solution for
about 7 days.
[0041] After about 14 days of being immersed in a high pH solution
(e.g., about 12), the shear strength of the adhesive may be greater
than 106 lb-f, for example, at least about 110 lb-f, at least about
117 lb-f, at least about 120 lb-f, at least about 130 lb-f, at
least about 140 lb-f, at least about 150 lb-f, at least about 160
lb-f, at least about 170 lb-f, at least about 180 lb-f, at least
about 188 lb-f, at least about 190 lb-f, at least about 200 lb-f,
as measured using ASTM D3654 (as modified herein) or any other
suitable test method. After about 14 days of being immersed in a
high pH solution (e.g., about 12), the decrease in shear strength
may be less than 29.5%, for example, less than about 29%, less than
about 25%, less than about 22.1%, less than about 20%, less than
about 15.3%, less than about 15%, less than about 10%, or less than
about 5%. In some examples, there may be no loss of adhesion or
there may be an increase in adhesion after being immersed in a high
pH solution for about 14 days.
[0042] As another example, after about one day of exposure to water
vapor (e.g., 100% relative humidity), the shear strength of the
adhesive may be greater than 155 lb-f, for example, at least about
at least about 160 lb-f, at least about 170 lb-f, at least about
177 lb-f, at least about 180 lb-f, at least about 190 lb-f, or at
least about 200 lb-f, as measured using ASTM D3654 (as modified
herein) or any other suitable test method. After about 7 or 14 days
of exposure to water vapor (e.g., 100% relative humidity), the
shear strength of the adhesive may be at least about 90 lb-f, for
example, at least about 100 lb-f, at least about 106 lb-f, at least
about 111 lb-f, at least about 110 lb-f, at least about 120 lb-f,
at least about 130 lb-f, at least about 140 lb-f, or at least about
150 lb-f, as measured using ASTM D3654 (as modified herein) or any
other suitable test method. After about one day, about 7 days, or
about 14 days of exposure to water vapor (e.g., 100% relative
humidity), the decrease in shear strength may less than about 35%,
for example, less than about 30%, less than about 29.8%, less than
about 25.9%, less than about 25%, less than about 20%, less than
about 15%, less than about 10%, or less than about 5%. In some
examples, there may be no loss of adhesion or there may be an
increase in adhesion after being exposed to water vapor for the
specified amount of time.
[0043] As another example, after about one day of exposure to high
alkaline vapor (e.g., pH of 12), the shear strength of the adhesive
may be at least about 150 lb-f, at least 154 lb-f, at least 155
lb-f, at least about 160 lb-f, at least about 170 lb-f, at least
about 180 lb-f, at least about 190 lb-f, or at least about 200
lb-f, as measured using ASTM D3654 (as modified herein) or any
other suitable test method. After about 7 or 14 days of exposure to
high alkaline vapor (e.g., pH of 12), the shear strength of the
adhesive may be at least about 90 lb-f, for example, at least about
100 lb-f, at least about 110 lb-f, at least about 114 lb-f, at
least about 117 lb-f, at least about 120 lb-f, at least about 130
lb-f, at least about 140 lb-f, or at least about 150 lb-f, as
measured using ASTM D3654 (as modified herein) or any other
suitable test method. After about one day, about 7 days, or about
14 days of exposure to high alkaline vapor (e.g., pH of 12), the
decrease in shear strength may less than about 35%, for example,
less than about 30%, less than about 25%, less than about 24.1%,
less than about 22%, less than about 20%, less than about 15%, less
than about 10%, or less than about 5%. In some examples, there may
be no loss of adhesion or there may be an increase in adhesion
after being exposed to water vapor for the specified amount of
time.
[0044] The adhesive component of the system may be provided in a
variety of different ways and/or may be provided using various
carriers or vehicles, some of which are described herein.
[0045] In one embodiment, the adhesive may comprise a portion of a
fastener, for example, an adhesive tape. The fastener, for example,
tape, may generally be operative for maintaining the tiles in a
connected or joined condition, even when the tiles are installed in
an adverse installation environment, as described above.
[0046] The tape may generally include a plurality of layers in a
superposed, facing relationship with one another. The tape may have
a first side (e.g., face or surface) of the tape is for being in
contact with the bottom surface (i.e., underside) of one or more
tiles, and a second side (e.g., face or surface) of the tape is for
being proximate to the floor (e.g., in contact with the floor or
any underlayment disposed on the floor).
[0047] For example, in a first embodiment, the tape may comprise a
single-sided adhesive tape, in which the adhesive (e.g., adhesive
material) is disposed or supported on one side (e.g., a first, tile
contacting side) of a substrate. In use, the tape may be positioned
so that adhesive side of the tape is facing upwardly with the
adhesive in contact with the underside (i.e., the backing) of the
tiles. The tape may generally span across at least one seam between
two or more tiles (or at the abutting corners of two or more tiles,
for example, four tiles) to connect or join the tiles to one
another to provide sufficient stability to withstand normal foot
traffic without adhering the tile to the underlying surface. The
adjoined tiles generally serve as a unitary textile or "rug" that
"floats" on the floor, such that the adjoined tiles may be
collectively repositioned on the floor. Further, when needed or
desired, one or more individual tiles may be repositioned,
replaced, reconfigured, or otherwise altered without causing damage
to the surface of the floor.
[0048] The adhesive may comprise any suitable adhesive, such as
those described above. The level of adhesion may be semi-permanent
(releasable with some effort) or non-permanent (i.e., readily
releasable), such that the adhesive is sufficiently strong to
adhere the tape to the backing of the tile, but not so strong that
the tape cannot be separated from the tile and/or repositioned
without destruction or delamination of the tape (i.e., the loss of
adhesion between the adhesive and the substrate). In other
embodiments, the level of adhesion may be permanent (not
releasable).
[0049] The adhesive material may be a substantially continuous
layer, or may be a discontinuous layer (e.g., a random or
non-random pattern of adhesive). In this and other embodiments, the
adhesive may have any suitable coat weight or thickness, for
example, from about 0.25 mil to about 5 mil, for example, from
about 1 mil to about 4 mil, for example, from about 2.5 mil to
about 3.5 mil. However, other suitable thicknesses and ranges
thereof may be used.
[0050] In this and other embodiments, the substrate may generally
comprise a polymer film, paper, foil, or any other suitable
material. In one exemplary embodiment, the substrate may comprise a
polyester film (e.g., polyethylene terephthalate). In other
embodiments, the substrate may comprise thermoplastic polyurethane,
polyvinyl butyral, poly(trimethylene terephthalate), polystyrene,
polylactic acid, ethylene vinyl acetate, polyvinyl chloride,
thermoplastic polyolefin or other polyolefin, polyvinylidene
chloride, and/or polypropylene. Countless other possibilities are
contemplated. Further, the substrate may have any suitable
thickness, for example, from about 0.25 mil to about 7 mil, for
example, from about 1 mil to about 5 mil, for example, from about 3
mil to about 4 mil, for example, about 3.5 mil. However, other
suitable thicknesses and ranges thereof are contemplated.
[0051] Thus, in one exemplary embodiment, the tape may comprise
about 2.5 mil silicone adhesive disposed on an about 4 mil
polyester film substrate. In another exemplary embodiment, the tape
may comprise about 3.5 mil silicone adhesive disposed on an about 4
mil polyester film substrate. However, numerous variations are
contemplated.
[0052] In general, the substrate should have a tensile strength
that is sufficient to resist stretching under typical loads. In one
example, the substrate may have a tensile strength of from about
20.times.10.sup.3 (or 20,000) lb/sq. in to about 40.times.10.sup.3
(or 40,000) lb/sq. in, for example, from about 25.times.10.sup.3(or
25,000) lb/sq. in to about 32.times.10.sup.3 (or 32,000) lb/sq. in,
for example, about 27.times.10.sup.3 (or 27,000) lb/sq. in of force
as measured using ASTM D882. However, other possibilities are
contemplated.
[0053] In another exemplary embodiment, the tape of the first
embodiment may include a slip resistant material on a second,
floor-contacting side of the tape. The slip resistant material may
generally be operative for preventing movement of the tape (and any
carpet tiles joined to the tape) on the installation surface, so
the carpet tiles remain substantially in position without the need
for a permanent adhesive, even in adverse installation conditions.
While the weight of the carpet tiles (and any items placed on the
tiles) may provide sufficient resistance to undesired movement of
the adjoined tiles, it is contemplated that additional slip
resistance may desirable in some installations.
[0054] The slip resistant material may have any suitable
composition. Suitable slip resistant materials may generally be
characterized as having a sufficiently high coefficient of friction
so that a carpet tile positioned on a flooring surface resists
lateral movement when subjected to foot traffic, but also does not
substantially adhere to the flooring surface. For example, suitable
slip resistant materials may have a coefficient of friction of at
least about 0.5, at least about 0.6, at least about 0.7, or at
least about 0.8. The slip resistant material should also generally
resist picking up dirt or other substances from the flooring
surface that may impede the slip resistance of the carpet tile. In
this manner, the carpet tiles remain in position during normal use,
but can be readily lifted from the flooring surface and
repositioned repeatedly without a substantial decrease in slip
resistance. Further, in some embodiments, the slip resistant
coating may be able to be wiped off or rinsed to remove any minimal
debris or particulate before drying and replacing the carpet
tile.
[0055] Examples of materials that may be suitable include, but are
not limited to, a low-tack, non-permanent adhesive (such as those
described above), a natural or synthetic polymeric material having
a sufficiently high coefficient of friction (such as, for example,
polyolefin coatings, natural rubber coatings, acrylic coatings, any
other suitable material, or any combination thereof), a protective
material, a foam or other cushioning material, any other suitable
material, or any combination of materials. Any such material
ideally should also be able to withstand any adverse conditions in
which the tape is installed.
[0056] The slip resistant material may be continuous or
discontinuous and may be disposed on all or a portion of the
backing. In some embodiments, a primer (where needed) may be
disposed between the slip resistant material and the backing.
[0057] In yet another exemplary embodiment, the adhesive may be
disposed on the second, floor contacting side of the tape, and the
slip resistant (e.g., non-skid or similar material) may be disposed
on the first, tile-contacting side of the tape. The slip resistant
material may comprise any suitable material operative for
restricting the motion of the tile relative to the tape and to any
other tile that the tape is in contact with (i.e., any adjoined
tile), such as those described in connection with the second
embodiment. Any such material ideally should also be able to
withstand any adverse conditions in which the tape is installed. In
this example, the tape could be positioned along the seams or may
be spaced from the seams beneath the tile.
[0058] In still another exemplary embodiment, the tape may comprise
a double-sided adhesive tape, in which adhesive is disposed on both
the first side and the second side of the substrate. The adhesive
on each side may be the same or may differ, as needed for a
particular application. For example, the peel strength and/or shear
strength of the adhesive in contact with the tile may be greater
than the peel strength and/or shear strength of the adhesive in
contact with the floor. As another example, the peel strength
and/or shear strength of the adhesive in contact with the tile may
be less than the peel strength and/or shear strength of the
adhesive in contact with the floor. The adhesive in contact with
the floor may be permanent, semi-permanent, or may be
non-permanent, so that the tiles can be removed and/or repositioned
without damaging the floor. The tape may be positioned along the
seams or may be spaced from the seams beneath the tile.
[0059] It will be appreciated that the above embodiments are
exemplary only, and that various other embodiments contemplated by
this disclosure may have fewer or more layers, as needed for a
particular application.
[0060] Examples of tapes that may be suitable in forming any of the
above embodiments include, but are not limited to (the values of
noted properties being approximate): [0061] SR336R release coated
polyester silicone tape (2.5 mil silicone-based adhesive on 3 mil
release coated polyester film) (commercially available from
Specialty Tapes Manufacturing, Franksville, Wis.), [0062] Tesa
50600 polyester tape with silicone-based adhesive (3.1 mils total
thickness, 36.5 oz/in. 180 degree peel to steel, 110% elongation,
41.1 lb/in tensile strength, as provided by the manufacturer)
(commercially available from Tesa SE) (to express the tensile
strength in lb/sq. in, divide 41.1 lb/in. by the thickness of the
film in inches), [0063] ARclad 6370 polyester tape with
silicone-based adhesive (2.7-3 mil silicone-based adhesive on 1 mil
polyester film, for a total thickness of 3.7-4 mil) (commercially
available from Adhesives Research, Glen Rock, PA), and [0064]
SC-4075 polyester tape with silicone-based adhesive (1.5 mil
silicone-based adhesive on 2 mil polyester film, for a total
thickness of 3.5 mil, having 40 oz/in. 180 degree peel to steel,
170% elongation, 55 lb/in tensile strength, as provided by the
manufacturer) (commercially available from Custom Adhesive
Products, Racine, Wis.) (to express the tensile strength in lb/sq.
in, divide 55 lb/in. by the thickness of the film in inches).
[0065] If desired, the tape may be provided with a release liner on
one or both sides of the tape, for example, where one or both of
layers comprise an adhesive or tacky material. Although countless
materials may be used for such liners, in one exemplary embodiment,
one or both liners may comprise a coated paper, for example, a
polyolefin or fluoropolymer coated paper. In still other examples,
one or both of release liners may comprise a polymer film with or
without a release coating, for example, a PET film coated with a
fluoropolymer. Alternatively still, one or both of release liners
may be omitted in some embodiments.
[0066] The tape may be provided in any suitable manner or
configuration. In one embodiment, the tape may be wound into a
roll. The tape may be provided with one or more release layers, as
described above, or may be self-wound, such that no release layer
is used. In one example, the tape may be self-wound using an
untreated polyester film substrate. In another example, the tape
may be self-wound using a release treated polymer film
substrate.
[0067] The tape may be provided with areas of weakening, for
example, lines of perforation or scoring that facilitate separation
of pieces of tape having predetermined dimensions.
[0068] In another embodiment, the tape may be provided in the form
of a sheet. The sheet may include one or more release layers, as
described above. The sheet may be provided with areas of weakening
in the tape and/or release layer(s), for example, lines of
perforation or scoring that facilitate separation of the sheet into
pieces of tape having predetermined dimensions.
[0069] In still another embodiment, the tape may be pre-cut into
pieces having specified dimensions. Such pieces may have any
suitable shape, for example, circles, rectangles, squares, crosses,
and so on. The tape pieces may be provided with one or more release
layers, as described above, or may be configured without a release
layer.
[0070] In yet another embodiment, the tape may be at least
partially pre joined to the carpet tiles. For example, sheets or
disks of tape may be at least partially attached to a modular
flooring tile using pressure, adhesive, ultrasonic frequency
welding, radio frequency welding, heat, electron beam radiation, UV
radiation, laser, or plasma treatment.
[0071] In still another embodiment, the substrate may be provided
in any wound, sheet, pre-cut, and/or pre-attached form, and the
adhesive and/or slip resistant material(s) may be applied or formed
in situ using a brush, roller, spray bottle, squeeze tube,
hand-held mixing unit, gun, or any suitable device or technique, as
the carpet tiles are installed.
[0072] In another embodiment, the adhesive may be self-supporting
or self-supported (i.e., unsupported), such that it does not need
to be supported or mounted on a polymer film or other substrate in
use (the adhesive may be provided on a temporary carrier sheet as a
means of providing it to the user). The self-supported adhesive
fastener may generally comprise a double-sided adhesive, with one
side or portion that contacts the underside of the carpet tile, and
one side or portion that contacts the installation. Any suitable
adhesive may be used, such as those described above. Both sides of
the unsupported adhesive fastener may comprise the same material or
different materials and/or may have different levels of tackiness
or adhesion.
[0073] The self-supported adhesive fastener may have a rectangular
shape, circular or "dot" shape, oval shape, zigzag shape, or any
other suitable shape or configuration. The self-supported adhesive
may be for use with one tile or more than one tile, so that the
self-supported adhesive may be used to join the carpet tile to the
installation surface, and optionally to one another (e.g., by
extending across the seams or corners of adjacent carpet tiles).
Any number and/or configuration of such fasteners may be used,
depending on the size and shape of the fastener. In one example,
the adhesive may comprise dots having a diameter of from about 0.25
to about 2 in., for example, from about 0.5 to about 1 in. However,
countless other possibilities are contemplated. A release liner may
be provided to protect the adhesive.
[0074] In still another embodiment, the adhesive may be provided as
a pre-applied coating on all or a portion of the tile backing. Any
suitable adhesive may be used, such as those described above. While
countless possibilities are contemplated, in some embodiments, the
dry coat weight may be from 0.25 oz/sq yd to 5 oz/sq yd, for
example, from about 1.5 to 2 oz/sq yd. If desired, a release liner
may be provided to protect the adhesive.
[0075] The present invention may be understood further in view of
the following examples, which are not intended to be limiting in
any manner. All values are approximate unless noted otherwise. When
a sample was not tested, the data is represented in the tables with
"NT". When a product could not be tested due to failure or
otherwise, the data is represented in the tables with an asterisk
(*).
EXAMPLE 1
[0076] The dimensional stability of various carpet tile backings
was evaluated under various adverse conditions. Three types of
backings were evaluated: (1) Ethos.RTM. PVB carpet tile backing
(Tandus Flooring, Inc.), (2) ER3.RTM. PVC carpet tile backing
(Tandus Flooring, Inc.), and (3) modified ER3.RTM. PVC carpet tile
backing (made with alternate recycled carpet content) (Tandus
Flooring, Inc.).
[0077] The backings were cut into about 2 in..times.2 in. squares.
The weight and thickness of each sample was recorded. The
experimental samples were subjected to the Water Immersion Test
n=5), Water Vapor Exposure Test (n=4), High Alkaline Immersion Test
(n=4), and High Alkaline Vapor Exposure Test (n=4), as follows:
[0078] High Alkaline Immersion Test/Water Immersion Test: Samples
were placed into an about 12.75 in..times.11.5 in..times.5 in.
container. The container was filled with about 2 in. of either (1)
a solution having a pH of about 12 (prepared by dissolving sodium
hydroxide in tap water) (for the high alkaline immersion test), or
(2) water (for the water immersion test). The container was filled
with sufficient liquid to cover the samples. The samples were
weighed down using an about 9.75 in..times.1.75 in..times.0.16 in.
piece of aluminum. The container was then covered tightly with
plastic wrap. The container was kept at ambient temperature during
testing.
[0079] High Alkaline Vapor Exposure Test/Water Vapor Exposure Test:
Large sponges (about 7.5 in..times.5 in..times.2 in.) were placed
inside an about 12.75 in..times.11.5 in..times.5 in. container. The
container was filled with about 2 in. of either (1) a solution
having a pH of 12 (prepared by dissolving sodium hydroxide in tap
water) (for the high alkaline vapor exposure test), or (2) water
(for the water vapor exposure test). Samples were placed on top of
the sponges to prevent any direct contact with the liquid. The
container was then covered tightly with plastic wrap. The container
was kept at ambient temperature during testing. Due to the large
amount of condensation on the plastic covering film, the relative
humidity within the container is believed to be 100%.
[0080] The control samples (n=2) were maintained at ambient
conditions. The weight of each sample was measured after 1, 7, and
14 days of exposure, after which the sample was returned to its
respective test environment for further evaluation. The results
(averages) are presented in Tables 1-3. Comparative date for the
various backings after exposure to each adverse condition is
presented in Tables 4-7. In general, dimensionally stable materials
may exhibit no more than about 10% loss in mass, and no more than
about 5% gain in mass. However, it is contemplated that some
materials may fall outside of this range and still be dimensionally
stable.
TABLE-US-00001 TABLE 1 Dimensional stability of Ethos .RTM. PVB
carpet tile backing Initial 1 day 7 days 14 days Test g g % .DELTA.
g % .DELTA. g % .DELTA. Control 7.6 7.7 1.2 7.7 2.1 7.7 2.2 Water
immersion 8.7 8.8 1.5 9.0 2.7 8.9 2.5 Water vapor 7.7 7.8 1.2 7.9
2.1 7.8 1.5 pH 12 immersion 7.8 7.9 1.5 8.0 3.0 8.1 3.7 pH 12 vapor
7.6 7.7 1.2 7.7 2.1 7.7 2.2
TABLE-US-00002 TABLE 2 Dimensional stability of ER3 .RTM. PVC
carpet tile backing Initial 1 day 7 days 14 days Test g g % .DELTA.
g % .DELTA. g % .DELTA. Control 8.6 8.6 0.0 8.7 0.1 8.6 -0.1 Water
immersion 8.5 8.7 1.7 8.9 4.7 9.1 6.7 Water vapor 8.4 8.5 0.8 8.6
2.0 8.5 1.0 pH 12 immersion 8.4 8.5 2.0 8.8 5.6 9.0 7.8 pH 12 vapor
8.5 8.5 0.6 8.7 2.6 8.8 3.8
TABLE-US-00003 TABLE 3 Dimensional stability of modified ER3 .RTM.
PVC carpet tile backing Initial 1 day 7 days 14 days Test g g %
.DELTA. g % .DELTA. g % .DELTA. Control 9.1 8.8 -3.7 9.1 0.1 9.1
-0.1 Water immersion 9.0 9.2 2.3 9.6 7.3 9.9 10.8 Water vapor 9.1
9.2 1.0 9.4 2.8 9.3 2.1 pH 12 immersion 9.4 9.7 2.8 10.2 8.0 10.6
12.0 pH 12 vapor 9.3 9.4 1.1 9.6 3.1 9.7 4.2
TABLE-US-00004 TABLE 4 Dimensional stability of various backings
after immersion in water Initial 1 day 7 days 14 days Backing g g %
.DELTA. g % .DELTA. g % .DELTA. Ethos .RTM. PVB 8.7 8.8 1.5 9.0 2.7
8.9 2.5 ER3 .RTM. PVC 8.5 8.7 1.7 8.9 4.7 9.1 6.7 Modified ER3
.RTM. 9.0 9.2 2.3 9.6 7.3 9.9 10.8 PVC
[0081] As shown in Table 4, the PVB backing showed some initial
increase in mass after 7 days of immersion in water, but leveled
out afterwards. In sharp contrast, the PVC backings continued to
increase in mass over time, which typically leads to curling of the
backing, and subsequent failure of the installation.
TABLE-US-00005 TABLE 5 Dimensional stability of various backings
after immersion in pH 12 solution Initial 1 day 7 days 14 days
Backing g G % .DELTA. g % .DELTA. g % .DELTA. Ethos .RTM. PVB 7.8
7.9 1.5 8.0 3.0 8.1 3.7 ER3 .RTM. PVC 8.4 8.5 2.0 8.8 5.6 9.0 7.8
Modified ER3 .RTM. 9.4 9.7 2.8 10.2 8.0 10.6 12.0 PVC
[0082] As indicated in Table 5, the PVB backing showed very little
initial increase in mass after 14 days of immersion in water. In
sharp contrast, the PVC backings showed a sharp increase in mass
after 7 days and continued to increase in mass at 14 days. Overall,
the PVB sample absorbed significantly less pH 12 solution than the
PVC samples.
TABLE-US-00006 TABLE 6 Dimensional stability of various backings
after exposure to water vapor Initial 1 day 7 days 14 days Backing
g g % .DELTA. g % .DELTA. g % .DELTA. Ethos .RTM. PVB 7.7 7.8 1.2
7.9 2.1 7.8 1.5 ER3 .RTM. PVC 8.4 8.5 0.8 8.6 2.0 8.5 1.0 Modified
ER3 .RTM. 9.1 9.2 1.0 9.4 2.8 9.3 2.1 PVC
[0083] As shown in Table 6, the percent change in mass was similar
for each of the three samples. This is not entirely unexpected due
to the relatively short duration of the test and the relatively low
mass of water vapor the samples were exposed to. However, it is
noted that even with this relatively low increase in mass, the PVC
samples curled upwardly, while the PVB backing samples remained
flat.
TABLE-US-00007 TABLE 7 Dimensional stability of various backings
after exposure to pH 12 vapor Initial 1 day 7 days 14 days Backing
g g % .DELTA. g % .DELTA. g % .DELTA. Ethos .RTM. PVB 7.6 7.7 1.2
7.7 2.1 7.7 2.2 ER3 .RTM. PVC 8.5 8.5 0.6 8.7 2.6 8.8 3.8 Modified
ER3 .RTM. 9.3 9.4 1.1 9.6 3.1 9.7 4.2 PVC
[0084] As indicated in Table 7, the PVB backing showed very little
initial increase in mass after 14 days of immersion in water. The
PVC backings exhibited a greater increase in mass after 14 days.
The PVC samples also curled upwardly during the test, while the PVB
backing samples remained flat.
EXAMPLE 2
[0085] The dimensional stability of various carpet tiles was
evaluated using International Standard ISO 2551 ("Machine made
textile floor coverings--Determination of dimensional changes due
to the effects of varied water and heat conditions") (also referred
to as the "Aachen test"), in which the samples are heated in a
140.degree. F. oven for 2 hours, submerged in water for 2 hours,
then heated in a 140.degree. F. oven again for 2 hours. Before and
after testing according to ISO 2551, the samples were also
evaluated for planar stability, which entails taking eight
measurements of the distance the tile is offset from a horizontal
surface, averaging the results, and rating the results according to
the following scale: [0086] 0=flat [0087] 0.001-0.078=4 curl/6 dome
[0088] 0.079-0.156=3 curl/7 dome [0089] 0.157-0.234=2 curl/8 dome
[0090] 0.235 or more=1 curl/9 dome The target for the planar
stability test is less than or equal to 0.078 in.
[0091] Ethos.RTM. PVB backed carpet tile (Tandus Flooring, Inc.)
(n=100) was evaluated. The results were averaged, as presented in
Table 8. The Ethos.RTM. PVB backed carpet tile samples remained
substantially flat, even after being subjected to adverse
conditions.
TABLE-US-00008 TABLE 8 Dimensional changes and planar stability of
Ethos .RTM. PVB backed carpet tile Planar stability ISO 2551
(.DELTA. in.) Before After MD CD heating in a 140.degree. F. oven
heating in a 140.degree. F. oven East Center West East Center West
Planar Dome/curl Planar Dome/curl 0.01 0.007 0.002 0 -0 -0.01 0.071
6.39 0.031 5.08 Avg = 0.01 Avg = 0
EXAMPLE 3
[0092] The dimensional stability of various carpet tile backings
was evaluated under high humidity conditions using a controlled
humidity chamber in which the relative humidity both below and
above the sample is controlled. The samples (n=2) were exposed to
both about 90 and about 97% relative humidity below the tile (in
different tests) and about 50% relative humidity above the tile for
at least 6 months.
[0093] Two types of carpet tiles were evaluated: (1) Ethos.RTM. PVB
backed carpet tile (Tandus Flooring, Inc.), and (2) ER3.RTM. PVC
backed carpet tile (Tandus Flooring, Inc.). The Ethos.RTM. PVB
backed carpet tile exhibited no planar curling, while the ER3.RTM.
PVC backed carpet tile began to show planar curling (e.g., curl of
greater than 0.078 in. per the planar stability test set forth in
Example 2) after 3 to 7 days.
EXAMPLE 4
[0094] The dimensional stability of various carpet tile backings
was evaluated using a simulated wet floor test in which a metal
tray is filled with tap water and sponges are placed in the water
bath so that they are about half submerged. The samples are seated
on the wet sponge, but are not in contact with the water bath so
that the relative humidity was about 100%. The water level is
refilled daily to the same level to overcome loss by evaporation.
The samples (n=2) are observed over a period of 134 days.
[0095] Three types of carpet tiles were evaluated: (1) Ethos.RTM.
PVB backed carpet tiles (Tandus Flooring, Inc.), (2) ER3.RTM. PVC
backed carpet tiles (Tandus Flooring, Inc.), and (3) GlasBac.RTM.
PVC backed carpet tiles. The Ethos.RTM. PVB backed carpet tiles
exhibited no planar curling after 134 days. In sharp contrast, the
ER3.RTM. PVC backed carpet tiles began to curl within 4 to 30 days
and the GlasBac.RTM. PVC backed carpet tile began to show planar
curling within 2 days.
EXAMPLE 5
[0096] The adhesive tack of various adhesive tapes was evaluated
after exposure to various adverse conditions. Two adhesive tapes
were evaluated: (1) SR336R release coated polyester silicone tape
(2.5 mil silicone-based adhesive on 3 mil release coated polyester
film) (commercially available from Specialty Tapes Manufacturing,
Franksville, Wis.), and (2) Tactiles.TM. carpet tile tape pieces
(believed to be an acrylic adhesive on a polyester film)
(commercially available from Interface, Inc.). Additionally,
Hauthane L2183 urethane-based adhesive with 1.5 wt % XR 5508
crosslinker (commercially available from Stahl, Peabody, Mass.) was
coated directly onto the back of Ethos.RTM. PVB with a #15 Meyer
rod and evaluated.
[0097] The samples were subjected to the Water Immersion Test
(n=3), Water Vapor Exposure Test (n=3), High Alkaline Immersion
Test (n=3), and High Alkaline Vapor Exposure Test (n=3), as
described above in Example 1. The control samples (n=3) were
maintained at ambient conditions. To prevent the contact of the
adhesive layer of tape with any surface, the tape was bent into a
cylindrical shape with adhesive layer inside, and the extreme outer
edge was adhered to the inside of a tongue depressor (about 6
in..times.0.75 in).
[0098] After 1, 7, and 14 days of exposure, the adhesive tack of
each sample was measured according to ASTM D2979-01(2009) and the
results were averaged. For the tape samples, the Instron probe was
set to compress at a rate of 10 mm/sec until a force of 0.001 KN
was reached. The resultant pressure was held constant for 1.0 sec,
and the probe was then extended away from the sample at a rate of
10.008 mm/sec. For the Hauthane L2183, the Instron probe was set to
compress at a rate of 10 mm/sec until a force of 0.45 KN. The
resultant pressure was held constant for 10 sec, and the probe was
then extended away from the sample at a rate of 10.008 mm/sec. The
results are presented in lb-f. (To convert to lb-f/sq. in, divide
lb-f by 0.66 sq in., which was the area of the probe. For example,
an adhesive tack of about 1.3 lb-f corresponds to about 2.0 lb-f/sq
in., an adhesive tack of about 1.5 lb-f corresponds to about 2.7
lb-f/sq in., an adhesive tack of about 2.3 lb-f corresponds to
about 3.5 lb-f/sq in., and an adhesive tack of about 5 lb-f
corresponds to about 7.6 lb-f/sq in.)
[0099] The effect of plasticizer migration was also evaluated for
the Hauthane L2183 sample by placing the sample in a 140.degree. F.
oven for 1 day.
[0100] The results are presented in Tables 9-11. Any observations
regarding edge crawl (i.e., the progressive weakening of the
adhesive from the outer edges of the adhesive tape inwardly
and/oozing from the weakened areas) were also noted.
TABLE-US-00009 TABLE 9 Adhesive tack of SR336R tape Initial 1 day 7
days 14 days Test lb-f lb-f % .DELTA. lb-f % .DELTA. lb-f % .DELTA.
Control 5.0 7.6 53.5% 5.9 18.7% 6.5 30.8% Water immersion 5.0 5.5
11.3% 5.3 6.6% 3.6 -27.6% Water vapor 5.0 7.7 54.9% 5.1 2.6% 5.4
8.7% pH 12 immersion 5.0 3.2 -34.8% 5.0 0.6% 1.6 -67.8% pH 12 vapor
5.0 5.0 0.6% 6.4 28.8% 5.3 6.6%
TABLE-US-00010 TABLE 10 Adhesive tack of Hauthane L2183 adhesive on
Ethos .RTM. PVB tile Initial 1 day 7 days 14 days Test lb-f lb-f %
.DELTA. lb-f % .DELTA. lb-f % .DELTA. Control 10.6 8.1 -23.6 8.5
19.8 NT NT Water immersion 10.6 2.4 -77.4 4.1 61.3 NT NT Water
vapor 10.6 9.1 -14.2 6.1 42.5 NT NT pH 12 immersion 10.6 2.7 -74.5
4.1 61.3 NT NT pH 12 vapor 10.6 8.8 -17.0 8.2 22.6 NT NT
140.degree. F. oven 10.6 5.4 49.1 NT NT NT NT
TABLE-US-00011 TABLE 11 Adhesive tack of Tactiles .TM. tape Initial
1 day 7 days 14 days Test lb-f lb-f % .DELTA. lb-f % .DELTA. lb-f %
.DELTA. Control 2.3 2.4 6.6 NT NT NT NT Water immersion 2.3 1.3
-42.8 * * * * Water vapor 2.3 2.2 -3.9 NT NT NT NT pH 12 immersion
2.3 1.5 -32.8 * * * * pH 12 vapor 2.3 2.4 6.1 NT NT NT NT
[0101] No edge crawl was observed for any of the SR336R tape tests.
Thus, it would be expected that the SR336R tape would withstand
adverse conditions over time. However, the Tactiles.TM. tape
samples exhibited substantial edge crawl and were not able to be
tested using the water immersion test or pH 12 immersion test after
1 day because the adhesive delaminated from the backing.
EXAMPLE 6
[0102] The lap shear strength of various modular carpet (i.e.,
carpet tile) systems was evaluated after exposure to various
adverse conditions. Two systems were evaluated: (1) SR336R release
coated polyester silicone tape (2.5 mil silicone-based adhesive on
3 mil release coated polyester film) (commercially available from
Specialty Tapes Manufacturing, Franksville, Wis.) joined to
Ethos.RTM. PVB backed carpet tile (Tandus Flooring, Inc.), and (2)
Tactiles.TM. carpet tile tape pieces (believed to be an acrylic
adhesive on a polyester film) (commercially available from
Interface, Inc.) joined to a PVC backing (commercially available
from Tandus Asia). (PVC backing was used in this instance because
it is believed that the Tactiles.TM. tape pieces are sold in
connection with PVC-backed tiles.) The SR336R release coated
polyester silicone tape and Tactiles.TM. carpet tile tape pieces
were also evaluated on steel plates.
[0103] To prepare the tape-steel samples, a steel plate (3.5
in..times.6 in.) was cleaned with isopropyl alcohol. An about 3
in..times.4 in. tape sample was then placed on the steel so that
about 2 in. of the tape was in contact with the steel, and the
remainder of the tape was not in contact with any surface. Pressure
was applied (about 1.75 lb) to the area in which the tape was in
contact with the substrate. The tape-carpet samples were prepared
in a similar manner, except that an about 3 in..times.4 in. piece
of carpet was used instead of a steel plate. The tape was adhered
to the backing of the carpet.
[0104] The samples were subjected to the Water Immersion Test
(n=3), Water Vapor Exposure Test (n=3), High Alkaline Immersion
Test (n=3), and High Alkaline Vapor Exposure Test (n=3), as
described above in Example 1. The control samples (n=3) were
maintained at ambient conditions. After 1, 7, and 14 days of
exposure, the lap shear strength of each sample was measured
according to ASTM D3654/D3654M-06(2011), except that the force to
failure (in lb-f) was recorded instead of time to failure. The
results were averaged and are presented in Tables 12 and 13. The
results are presented in lb-f. (To convert to lb-f/sq. in, divide
lb-f by 6 sq in. (the contact area with the sample). For example, a
lap shear value of about 130 lb-f corresponds to about 21.7 lb-f/sq
in., a lap shear value of about 150 lb-f corresponds to about 25
lb-f/sq in., a lap shear value of about 163 lb-f corresponds to
about 27.2 lb-f/sq in., and a lap shear value of about 200 lb-f
corresponds to about 33.3 lb-f/sq in.) Any observations regarding
edge crawl were also noted.
TABLE-US-00012 TABLE 12 Lap shear strength of SR336R tape/Ethos
.RTM. backing Initial 1 day 7 days 14 days Test lb-f lb-f % .DELTA.
lb-f % .DELTA. lb-f % .DELTA. Control 150 151 0.6 146 -3.1 142 -5.7
Water immersion 150 158 5.1 122 -18.9 143 -4.7 Water vapor 150 157
4.5 111 -25.9 106 -29.8 pH 12 immersion 150 158 5.4 124 -17.8 117
-22.1 pH 12 vapor 150 154 2.3 117 -22.0 114 -24.1
[0105] As will be evident from Table 12, the SR336R /Ethos.RTM.
backing system showed virtually no loss in lap shear strength after
being immersed in water for 14 days.
[0106] Although there was some loss in lap shear strength under the
remaining tests, it will be appreciated that the nature of these
tests is far more extreme than typical adverse installation
conditions. (However, it will be noted that even in these extreme
conditions, no edge crawl was observed.) Further, these tests may
exhibit a high degree of variability under some circumstances.
Finally, it will also be noted that even where there is a loss in
adhesion under these extreme tests, such loss in adhesion may not
be considered an adhesive failure that would render the tape or
system unsuitable for use. Thus, while the absolute values of the
data might not be directly indicative of actual performance, this
data may be highly useful for comparison with the performance of
other systems (see Tables 13-17).
TABLE-US-00013 TABLE 13 Lap shear strength of Tactiles .TM.
tape/PVC backing Initial 1 day 7 days 14 days Test lb-f lb-f %
.DELTA. lb-f % .DELTA. lb-f % .DELTA. Control 150 NT NT NT NT NT NT
Water immersion 150 109 -27.4 84 -43.9 112 -25.6 Water vapor 150
155 3.9 NT NT NT NT pH 12 immersion 150 98 -35.1 89 -41.1 106 -29.5
pH 12 vapor 150 197 31.4 NT NT NT NT
[0107] The Tactiles.TM. tape samples exhibited substantial edge
crawl after 1 day. Accordingly, the tests were aborted because it
was believed that the samples would delaminate (Table 13).
TABLE-US-00014 TABLE 14 Lap shear strength for various systems
after immersion in water Initial 1 day 7 days 14 days System lb-f
lb-f % .DELTA. lb-f % .DELTA. lb-f % .DELTA. SR336R/Ethos .RTM. 150
158 5.1 122 -18.9 143 -4.7 Tactiles .TM./PVC 150 109 -27.4 84 -43.9
112 -25.6 SR336R/steel 163 170 4.0 184 12.8 187 14.5 Tactiles
.TM./steel 195 181 -6.9 211 8.4 214 9.8
[0108] As will be evident from Table 14, the Tactiles.TM./PVC
backing system showed significantly more loss in lap shear strength
than the SR336R/Ethos.RTM. backing system.
[0109] As regards the steel plate tests, the lap shear strength
values set forth above were recorded when the film substrate of the
tape broke, rather than when there was an adhesive failure. Since
the initial adhesion of both tapes was significantly stronger, as
compared with their respectively evaluated carpet backings, it is
believed that it would have taken a significantly longer period of
time than 14 days to achieve an adhesive failure. Since the SR336R
tape had a backing thickness of 3 mils, and the Tactiles.TM. tape
had a backing of 4 mils, it is not surprising that that the
Tactiles.TM./steel system appeared to outperform the SR336R/steel
system. However, due to the level of edge crawl exhibited by the
Tactiles.TM. tape (as compared with none observed with the SR336R
tape), it is believed that the Tactiles.TM. tape would have
eventually failed, while the SR336R tape would not have.
[0110] Similar observations can be made with respect to the pH 12
immersion test, as set forth in Table 15 below.
TABLE-US-00015 TABLE 15 Lap shear strength for various systems
after immersion in pH 12 solution Initial 1 day 7 days 14 days
System lb-f lb-f % .DELTA. lb-f % .DELTA. lb-f % .DELTA.
SR336R/Ethos .RTM. 150 158 5.4 124 -17.8 117 -22.1 Tactiles
.TM./PVC 150 98 -35.1 89 -41.1 106 -29.5 SR336R/steel 163 177 8.7
194 18.7 188 15.3 Tactiles .TM./steel 195 182 -6.6 227 16.6 218
12.1
[0111] As shown in Tables 16 and 17 below, the SR336R /Ethos.RTM.
backing system exhibited no edge crawl and was able to be tested
even after 14 days.
TABLE-US-00016 TABLE 16 Lap shear strength for various systems
after exposure to water vapor Initial 1 day 7 days 14 days System
lb-f lb-f % .DELTA. lb-f % .DELTA. lb-f % .DELTA. SR336R/Ethos
.RTM. 150 157 4.5 111 -25.9 106 -29.8 Tactiles .TM./PVC 150 155 3.9
NT NT NT NT
TABLE-US-00017 TABLE 17 Lap shear strength for various systems
after exposure to pH 12 vapor Initial 1 day 7 days 14 days System
lb-f lb-f % .DELTA. lb-f % .DELTA. lb-f % .DELTA. SR336R/Ethos
.RTM. 150 154 2.3 117 -22.0 114 -24.1 Tactile .RTM./PVC 150 197
31.4 NT NT NT NT
EXAMPLE 7
[0112] The plasticizer migration resistance of various modular
carpet (i.e., carpet tile) systems was evaluated. The following
tapes were evaluated: (1) SR336R release coated polyester silicone
tape (2.5 mil silicone-based adhesive on 3 mil release coated
polyester film) (commercially available from Specialty Tapes
Manufacturing, Franksville, Wis.), (2) Hauthane L2183
urethane-based adhesive plus 1.5 wt % X5800 crosslinker
(commercially available from Stahl, Peabody, Mass.) (coated
directly onto the back of Ethos.RTM. PVB tile), (3) Tactiles.TM.
carpet tile tape pieces (believed to be an acrylic adhesive on a
polyester film) (commercially available from Interface, Inc.), (4)
Ecosticker (commercially available from Carpet Tiles 1, Australia),
(5) China White (acrylic adhesive based tape, commercially
available from Shanghai ZhengHuan Adhesive Products Co., Ltd.,
Shanghai, China), and (6) China Yellow (acrylic adhesive based
tape, commercially available from Shanghai ZhengHuan Adhesive
Products Co., Ltd., Shanghai, China). Each tape was evaluated in
connection with two backings: 1) Ethos.RTM. PVB carpet tile backing
(Tandus Flooring, Inc.), and (2) PVC carpet tile backing (Tandus
Asia).
[0113] A sample of each tape was placed on each backing. A control
sample was left at room temperature, while the experimental sample
was placed into an oven at 180.degree. F. After two hours, the
experimental sample was removed from the oven and allowed to cool
to room temperature. The tape was then pulled away by hand from the
backing. The composition of the adhesive and tape was evaluated
using the following scale (where "legs" refer to strings of
adhesive): [0114] 0-No change [0115] 1-Slight difference adhesive
has not softened and no legs are noticeable [0116] 2-Noticable
change legs have begun to form [0117] 3-Legs are present and some
adhesive has transferred from the film to the carpet [0118]
4-Adhesive transfer and delamination from film, adhesive has
softened [0119] 5-Severly compromised, complete adhesive
delamination, long legs, very soft adhesive For the Hauthane L2183
sample, which was coated directly onto the back of Ethos.RTM. PVB
with a #15 Meyer rod, the sample was evaluated by dragging a finger
across the sample. The results are presented in Table 18.
TABLE-US-00018 [0119] TABLE 18 Plasticizer migration resistance of
various adhesive tapes Plasticizer migration resistance Immediate
Aged 1 month Tape Backing Control Oven Control Oven SR336R tape PVC
0 1 0 1 Ethos .RTM. PVB 1 1 1 1.5 Hauthane L2183 Ethos .RTM. PVB 0
1 NT NT Tactiles .TM. tape PVC 1 4 2 5 Ethos .RTM. PVB 0 5 0 5
Ecosticker PVC 0 3.5 NT NT Ethos .RTM. PVB 1 4 NT NT China White
PVC 0 4 3 4 Ethos .RTM. PVB 0 5 1 4 China Yellow PVC 0 2 0 2 Ethos
.RTM. PVB 0 1 0 1
[0120] Notably, the Tactiles.TM., Ecosticker, and China White tapes
all exhibited rather immediate plasticization of the adhesive when
attached to both PVC and PVB backed carpets. The SR336R tape
exhibited virtually no plasticization, even after one month of
aging in an oven.
EXAMPLE 8
[0121] The plasticizer migration resistance of various modular
carpet (i.e., carpet tile) systems was evaluated. The following
systems were evaluated: (1) SR336R release coated polyester
silicone tape (2.5 mil silicone-based adhesive on 3 mil release
coated polyester film) (commercially available from Specialty Tapes
Manufacturing, Franksville, Wis.) joined to Ethos.RTM. PVB carpet
tile backing, and (2) Tactiles.TM. carpet tile tape pieces
(believed to be an acrylic adhesive on a polyester film)
(commercially available from Interface, Inc.) joined to a PVC
carpet tile backing (commercially available from Tandus Asia).
[0122] A sample of each tape was placed on each backing. A control
sample was left at room temperature, while the experimental sample
was placed into an oven at 140.degree. F. The samples were observed
every 2-3 days until failure, i.e., until the adhesive is softened
and the tape is readily removed from the backing. The Tactiles.TM.
tape on PVC backing failed after about 5 days. In sharp contrast,
the SR336R tape on PVB was stable for 45 days, after which the test
was discontinued.
EXAMPLE 9
[0123] The adhesive tack of various tapes used in connection with
various backings was evaluated after exposure to high pH and
moisture.
[0124] The following tapes were evaluated: (1) SR336R release
coated polyester silicone tape (2.5 mil silicone-based adhesive on
3 mil release coated polyester film) (commercially available from
Specialty Tapes Manufacturing, Franksville, Wis.), (2) Tactiles.TM.
carpet tile tape pieces (believed to be an acrylic adhesive on a
polyester film) (commercially available from Interface, Inc.), (3)
Ecosticker (commercially available from Carpet Tile 1, Australia),
(4) China White (acrylic adhesive based tape, commercially
available from Shanghai ZhengHuan Adhesive Products Co., Ltd.,
Shanghai, China), and (5) China Yellow (acrylic adhesive based
tape, commercially available from Shanghai ZhengHuan Adhesive
Products Co., Ltd., Shanghai, China). Each tape was evaluated in
connection with two backings: 1) Ethos.RTM. PVB carpet tile backing
(Tandus Flooring, Inc.), and (2) PVC carpet tile backing (Tandus
Asia).
[0125] A piece of tape was placed on a 4 in..times.4 in. square
piece of tile so that only about half of the tape was on the tile
(the other half was not in contact with anything). The samples were
then soaked in a pH 11.5 solution for 4 days. Control samples were
maintained at ambient conditions. The adhesive tack of each sample
was then measured according to ASTM D2979-01(2009) and the results
were averaged. The results are presented in Table 19. Any
observations regarding edge crawl was also noted.
TABLE-US-00019 TABLE 19 Adhesive tack of various adhesive
tapes/backings Adhesive tack (lb-f) Experi- Edge Tape Backing
Control mental .DELTA. (%) crawl SR336R tape PVC 98.2 54.7 44.3
none Ethos .RTM. 150.5 147.9 1.7 none PVB Tactiles .TM. tape PVC
149.5 82.3 44.9 severe Ethos .RTM. 167.6 147.9 11.8 slight PVB
Ecosticker PVC 110.2 76.9 30.2 some Ethos .RTM. 158.1 141.4 10.6
some PVB China White PVC 137.9 85 38.4 some Ethos .RTM. 199.7 146.8
26.5 some PVB China Yellow PVC 133.7 61.4 54.1 some Ethos .RTM.
176.6 159.1 9.9 some PVB
[0126] The SR336R tape samples exhibited virtually no edge crawl,
while the Tactiles.TM. tape samples exhibited severe (PVC) or
slight (Ethos.RTM. PVB) edge crawl, indicating that the
Tactiles.TM. tape would likely fail over time. Similarly, the
Ecosticker, China White, and China Yellow tapes all exhibited some
edge crawl. Thus, such tapes would also likely fail over time.
EXAMPLE 10
[0127] Various tapes were used to secure Tandus Flooring, Inc.
Ethos.RTM. PVB-backed tile to a concrete floor under adverse
installation conditions (about 2.2 lb/24 hr/1000 sq. ft. MVER,
about 11-11.5 pH, and about 65.5% RH) in an environment subject to
electric pallet jacks carrying a full payload and heavy foot
traffic. Prior to installation, the floor was primed with C56
Primer, available from Tandus Flooring, Inc. The following tapes
from Specialty Tapes Manufacturing were used to join the tiles to
one another (with the adhesive facing upwardly): [0128] about 2.5
mil silicone adhesive on one side of about 4 mil polyester (PET)
film; [0129] about 3.5 mil silicone adhesive on one side of about 4
mil polyester (PET film; [0130] about 3.5 mil silicone adhesive on
one side of about 3 mil polyester (PET) film; and [0131] about 1.5
mil silicone adhesive on about 2 mil polyester (PET) film.
[0132] All of the tapes were used to install the tiles
successfully. The performance of the tape was monitored for about
one year with no visible movement of tiles or loss of tape
adhesion.
EXAMPLE 11
[0133] Tape was used to secure Tandus Flooring, Inc. Ethos.RTM.
PVB-backed tile on a concrete floor under adverse installation
conditions (about 2.4 lb/24 hr/1000 sq. ft. MVER, about 9.5-10 pH,
and about 86.5% RH). Prior to installation, the floor was primed
with C56 Primer, available from Tandus Flooring, Inc.
[0134] The tape (obtained from Specialty Tape Manufacturers)
comprised about 3.5 mil silicone adhesive on one side of an about 4
mil polyester (PET) film. The tape was provided as a 3 in. wide
roll with perforations about every 3.875 in. The tape pieces were
applied to the corners of adjacent tiles with the adhesive facing
up. 24 in..times.24 in. square tiles were used.
[0135] Tiles were kicked with standard foot pressure after the
installation was complete to look for movement. Little to no
movement was noted across the installation. The installation was
observed for about one year with no visible movement of tiles or
loss of tape adhesion.
EXAMPLE 12
[0136] Tape was used to secure Tandus Flooring, Inc. Ethos.RTM.
PVB-backed tile on a residential concrete floor under adverse
installation conditions (about 5.1 lb/24 hr/1000 sq. ft. MVER and
about 10.5 pH).
[0137] The tape was obtained from Specialty Tape Manufacturers and
comprised about 3.5 mil silicone adhesive on one side of an about 4
mil PET film The tape was supplied as a 3 in. wide roll with
perforations about every 3.875 in. The tape pieces were applied to
the corners of adjacent tiles with the adhesive facing up. 24
in..times.24 in. square tiles were used. The installation was
observed for about three months with no visible movement of tiles
or loss of tape adhesion.
EXAMPLE 13
[0138] Tape was used to secure Tandus Flooring, Inc. Ethos.RTM.
PVB-backed tile on a concrete floor under varying and unpredictable
adverse conditions (about 2.3 lb/24 hr/1000 sq. ft. MVER, about
8.5-9 pH, and about 79.3% RH). The tape was SR336R release coated
polyester silicone tape (2.5 mil silicone-based adhesive on 3 mil
release coated polyester film) (commercially available from
Specialty Tapes Manufacturing, Franksville, Wis.). The tape was
supplied as a 3 in. wide roll with perforations about every 3.875
in. The tape pieces were applied to the corners of adjacent tiles
with the adhesive side facing up. 24 in..times.24 in. square tiles
were used. The installation was observed for about 3 months with no
visible movement of the tiles or loss of tape adhesion. The
installation area was in a semi-covered outdoor exposed area
subject to rain and drastic swings in humidity typical of the
climate in Dalton, Ga., USA.
EXAMPLE 14
[0139] Tape was used to secure Tandus Flooring, Inc. Ethos.RTM.
PVB-backed tile on a concrete floor under varying and unpredictable
adverse conditions (about 2.4 lb/24 hr/1000 sq. ft. MVER, about
9.5-10 pH, and about 86.5% RH). The tape was 50600 Tesa release
coated polyester silicone tape (commercially available from Tesa SE
Tape). The tape was supplied as a 2 in wide roll. Strips were cut
every 4 in. and were applied to the corners of adjacent tiles with
the adhesive side facing up. 36 in..times.36 in. square tiles were
used. The installation was observed for about 11 months with no
visible movement of the tiles or loss of tape adhesion. The
installation area was subjected to heavy foot traffic during the
evaluation time.
[0140] It will be readily understood by those persons skilled in
the art that the present invention is susceptible of broad utility
and application. It will also be recognized by those skilled in the
art that various elements discussed with reference to the various
embodiments may be interchanged to create entirely new embodiments
coming within the scope of the present invention. While the present
invention is described herein in detail in relation to specific
aspects and embodiments, it is to be understood that this detailed
description is only illustrative and exemplary of the present
invention and is made merely for purposes of providing a full and
enabling disclosure of the present invention and to set forth the
best mode of practicing the invention known to the inventors at the
time the invention was made. The detailed description set forth
herein is illustrative only and is not intended, nor is to be
construed, to limit the present invention or otherwise to exclude
any such other embodiments, adaptations, variations, modifications,
and equivalent arrangements of the present invention. All
directional references (e.g., upper, lower, upward, downward, left,
right, leftward, rightward, top, bottom, above, below, vertical,
horizontal, clockwise, and counterclockwise) are used only for
identification purposes to aid the reader's understanding of the
various embodiments of the present invention, and do not create
limitations, particularly as to the position, orientation, or use
of the invention unless specifically set forth in the claims.
Joinder references (e.g., joined, attached, coupled, connected, and
the like) are to be construed broadly and may include intermediate
members between a connection of elements and relative movement
between elements. As such, joinder references do not necessarily
imply that two elements are connected directly and in fixed
relation to each other. Further, various elements discussed with
reference to the various embodiments may be interchanged to create
entirely new embodiments coming within the scope of the present
invention. Many adaptations of the present invention other than
those herein described, as well as many variations, modifications,
and equivalent arrangements will be apparent from or reasonably
suggested by the present invention and the above detailed
description without departing from the substance or scope of the
present invention. Accordingly, the detailed description set forth
herein is not intended nor is to be construed to limit the present
invention or otherwise to exclude any such other embodiments,
adaptations, variations, modifications, and equivalent arrangements
of the present invention.
* * * * *