LOOP-BACKED CARPET TILES AND METHODS OF MANUFACTURE
Loop backed carpet tiles and methods of producing a carpet tile having a loop backing are provided. In one embodiment, the method includes applying a precoat adhesive, such as a latex, to the base of a carpet substrate; curing the precoat adhesive onto the carpet substrate; applying a lamination adhesive, which may be an ethyl vinyl acetate or a styrene-acrylate adhesive, onto the precoated carpet substrate, the lamination adhesive having an activation temperature at which the lamination adhesive is operable for lamination; and applying and laminating a backing fabric comprising loops to the precoated carpet substrate via the lamination adhesive after the lamination adhesive applied to the precoated carpet substrate is heated to the activation temperature.
1 . A method of producing a carpet tile having a loop backing comprising:
applying a precoat adhesive to the base of a carpet substrate;
curing the precoat adhesive onto the carpet substrate;
applying a lamination adhesive onto the precoated carpet substrate, the lamination adhesive having an activation temperature at which the lamination adhesive is operable for lamination; and
applying and laminating a backing fabric comprising loops to the precoated carpet substrate via the lamination adhesive after the lamination adhesive applied to the precoated carpet substrate is heated to the activation temperature.
2 . The method of claim 1 , wherein the precoat adhesive comprises a latex.
3 . The method of claim 1 , wherein the lamination adhesive comprises a frothed adhesive.
4 . The method of claim 1 , wherein the lamination adhesive comprises ethylene vinyl acetate or a styrene-acrylate polymer.
5 . The method of claim 3 , wherein the lamination adhesive comprises ethylene vinyl acetate or a styrene-acrylate polymer.
6 . The method of claim 1 , wherein the activation temperature is in the range of about 210° F. to about 230° F.
7 . The method of claim 1 , wherein lamination adhesive is heated after the lamination adhesive is applied to the precoated carpet substrate.
8 . The method of claim 7 , wherein the backing fabric is not directly exposed to a source of heat used to heat the lamination adhesive to its activation temperature.
9 . The method of claim 1 , wherein the backing fabric comprises polypropylene.
10 . The method of claim 1 , wherein the lamination comprises using a pressurized lamination roller.
11 . A method of producing a carpet tile having a looped backing comprising:
applying a precoat of latex to a carpet substrate; and
laminating a loop covered secondary fabric to the latex precoated carpet substrate with an adhesive compound which comprises ethyl vinyl acetate or a styrene-acrylate polymer.
12 . The method of claim 11 , wherein the adhesive compound is frothed.
13 . A carpet tile made by the method of claim 1 .
14 . A carpet tile made by the method of claim 11 .
15 . A carpet tile product comprising:
a fabric face having a layer of latex coating cured thereonto; and
a loop-covered secondary fabric affixed to the layer of latex coating via a lamination adhesive.
16 . The carpet tile product of claim 15 , wherein the lamination adhesive comprises ethyl vinyl acetate or a styrene-acrylate polymer.