Dimensionally-Stabilized Cushioned Carpet Tile and Methods of Manufacture Thereof

1 . A carpet tile comprising:

a face fabric having a top surface and a base; and

a dimensionally-stabilized non-woven cushion material having a stabilizing material incorporated therein, incorporated thereonto, or a combination thereof, wherein the dimensionally-stabilized non-woven cushion material is attached to the base if the face fabric such that the dimensionally-stabilized non-woven cushion material provides dimensional stability to the face fabric.

2 . The carpet tile of claim 1 , wherein the stabilizing material comprises non-woven PET, polyamide, polypropylene or a blend thereof.

3 . The carpet tile of claim 1 , wherein the cushion material comprises a needle-punched fiber pad.

4 . The carpet tile of claim 1 , wherein the stabilizing material is arranged in regular or irregular patterns throughout the non-woven fiber pad.

5 . The carpet tile of claim 1 , wherein the dimensionally-stabilized non-woven cushion provides sufficient dimensional stability to prevent shrinkage, growth, or curling of the carpet tile.

6 . The carpet tile of claim 1 , wherein the dimensionally-stabilized non-woven cushion provides sufficient dimensional stability to prevent shrinkage, growth, or curling of the carpet tile without requiring the use of additional stabilizing material.

7 . A carpet tile comprising:

a primary carpet base having a face fabric side and an opposed back side;

a polymer adhesive layer attached to the back side of the primary carpet base; and

a dimensionally stabilized non-woven cushion material layer attached to the primary carpet base by the polymer adhesive layer, the dimensionally stabilized non-woven cushion material having a stabilizing material incorporated therein, incorporated thereonto, or a combination thereof.

8 . The carpet tile of claim 7 , wherein the stabilizing material comprises non-woven PET, polyamide, polypropylene or a blend thereof.

9 . The carpet tile of claim 7 , wherein the cushion material comprises a needle-punched fiber pad.

10 . The carpet tile of claim 7 , wherein the stabilizing material is arranged in regular or irregular patterns throughout the non-woven fiber pad.

11 . The carpet tile of claim 7 , wherein the dimensionally-stabilized non-woven cushion provides sufficient dimensional stability to prevent shrinkage, growth, or curling of the carpet tile.

12 . The carpet tile of claim 7 , wherein the dimensionally-stabilized non-woven cushion provides sufficient dimensional stability to prevent shrinkage, growth, or curling of the carpet tile without requiring the use of additional stabilizing material.

13 . A method of manufacturing a carpet tile comprising:

integrating a stabilizing material with a cushion material to form a dimensionally-stabilized cushion material; and

attaching the dimensionally-stabilized cushion material to a face fabric.

14 . The method of claim 13 , wherein the cushion material is attached to the face fabric with a polymer adhesive.

15 . The method of claim 13 , wherein the stabilizing material is incorporated into the cushion material before the cushion material is attached to the face fabric.

16 . The method of claim 13 , wherein the stabilizing material comprises non-woven PET, polyamide, polypropylene, or a blend thereof.

17 . The method of claim 13 , wherein the cushion material comprising a needle-punched fiber pad, a spunbound fiber pad, a fusion-bonded fiber pad, or a combination thereof.

18 . The method of claim 13 , wherein stabilizing material is integrated with the stabilizing material by needle-punching, spunbounding, or fusion-bonding.

19 . A carpet tile produced by the method of claim 13 .

20 . A method of manufacturing a carpet tile comprising:

producing a face fabric comprising a plurality of pile extending from a primary carpet base;

producing a dimensionally-stabilized cushion pad comprising a non-woven cushion material and a stabilizing material incorporated therewith;

laminating the dimensionally-stabilized cushion pad to the face fabric with a polymer adhesive; and

curing the polymer adhesive such that it locks the plurality of pile to the primary carpet base and bonds the dimensionally-stabilized cushion pad to the face fabric.