U.S. patent application number 11/036907 was filed with the patent office on 2006-07-20 for removable and relayable floor covering.
This patent application is currently assigned to Zaxxon USA, Inc.. Invention is credited to Chen-chi Mao.
Application Number | 20060156663 11/036907 |
Document ID | / |
Family ID | 36678182 |
Filed Date | 2006-07-20 |
United States Patent
Application |
20060156663 |
Kind Code |
A1 |
Mao; Chen-chi |
July 20, 2006 |
Removable and relayable floor covering
Abstract
A removable interior building surface-covering section member
such as a floor tile, sheet, or plank is provided that can be laid
without the use of adhesives and which can be removed and relayed
repeatedly. The removable floor section member has multiple layers
including an upper wear layer, an intermediate cushion layer and a
lower adhesive layer. The lower adhesive layer may have alternating
raised and lowered channels to increase adhesion moisture
conditions.
Inventors: |
Mao; Chen-chi; (Taipei,
CN) |
Correspondence
Address: |
DUANE MORRIS LLP;IP DEPARTMENT
30 SOUTH 17TH STREET
PHILADELPHIA
PA
19103-4196
US
|
Assignee: |
Zaxxon USA, Inc.
|
Family ID: |
36678182 |
Appl. No.: |
11/036907 |
Filed: |
January 14, 2005 |
Current U.S.
Class: |
52/403.1 ;
156/60 |
Current CPC
Class: |
E04F 15/225 20130101;
E04F 15/22 20130101; B32B 2250/03 20130101; B32B 2419/04 20130101;
B32B 2307/102 20130101; E04F 15/02172 20130101; E04F 15/0215
20130101; B32B 2607/02 20130101; E04F 15/185 20130101; Y10T 156/10
20150115; B32B 2307/554 20130101; B32B 3/30 20130101 |
Class at
Publication: |
052/403.1 ;
156/060 |
International
Class: |
E04F 15/22 20060101
E04F015/22 |
Claims
1. A self-adhesive, loose-lay installed floor surface covering
comprising; an upper wear surface layer; a cushioned backing
adhered to the upper wear surface layer to increase the surface
covering's evenly distributed contact with a sub-floor, and thereby
increase the leveling adhesion of the tile onto the sub-floor; and
a cured adhesive applied onto the cushioned backing's lower surface
that adheres to a sub-floor to hold the floor in place during use
and that adheres onto a surface with very slight pressure on its
own and that allows removal and repositioning with its original
tack in place, without additional glue residue, damage done to the
subfloor or delaminating of the substrate so that it can be removed
and relayed repeatedly.
2. The floor surface covering of claim 1 wherein the upper surface
may be comprised of floor tile, sheet, or plank material types
including those made from polyvinyl chloride, rubber, linoleum,
reinforced resins, vinyl composite, or other resilient materials,
carpet, stones, ceramic, metals, glass, textiles, wood, composites,
veneers, and laminates and polymeric resins
3. The floor surface covering of claim 1 wherein the cushioned
backing may be comprised of a soft material layer including
foamable material such as chemically blown polyvinyl chloride
plastisols/organosols, acrylics, polyurethane foams, rubber foams,
froth foams such as polyvinyl chloride plastisol, acrylics, melt
processed foams such as polyvinyl chloride, polyethylene, ethylene
vinyl acetate, metallocene polyolefins, elastomeric polyolefin
copolymers.
4. The floor surface covering of claim 1 wherein the lower surface
may comprise a curable or cross-linked adhesive material made of
PVC-type adhesives, rubber-type adhesives, acrylic adhesives,
including e-beam curable acrylic adhesives, vinyl acetate-type
adhesives, urethane-type adhesives, and combinations thereof.
5. The floor surface covering of claim 1 wherein the lower adhesive
layer has moisture release grid channels onto the backing layer to
enhance its adhesion to a sub-floor and provide moisture-release
enhancement.
6. The floor surface covering of claim 1 wherein the lower adhesive
layer includes vertical indentations and protrusions to reinforce
the surface tension of the floor surface covering's adhesion on the
sub-floor.
7. The floor surface covering of claim 1 wherein the lower adhesive
layer comprises a self-adhesive surface covering that can be
removed from a subflooring surface with a pull parallel to the
vertical structural lining on the foam backing layer because of the
air channels on the grids and which stays intact and is not easily
displaced with a horizontal or diagonal pull force.
8. The floor surface covering of claim 1 wherein the flooring can
be removed and cleaned with water and still retain its original
tack for repositionability and reinstallation.
9. A method of forming a self-adhesive, loose-lay installed floor
surface covering comprising the steps of; applying a cushioned
backing adhered to an upper wear surface to increase the surface
covering's evenly distributed contact with a sub-floor, and thereby
increase the leveling adhesion of the tile onto the floor; and
applying a cured adhesive onto the thin cushioned backing to
increase the surface tension of the floor adhesion and hold it in
place during use and that adheres onto a surface with very slight
pressure and that allows repositioning with its original tack in
place, without additional glue residue or delaminating of the
substrate so that it can be removed and relayed repeatedly.
10. The method of claim 9 including the step of applying the
cushion backing includes applying it to the lower surface of floor
tiles, sheets, and planks or sections of varying sizes and shapes
and surface types including those made from polyvinyl chloride,
rubber, linoleum, polymeric resins, reinforced resins, vinyl
composite, or other resilient materials, carpet, stones, ceramic,
metals, glass, textiles, wood, composites thereof, veneers thereof,
and laminates thereof.
11. The method of claim 9 including the step of applying the
cushion backing includes applying a cushion backing comprised of
soft material layer including foamable material.
12. The method of claim 11 wherein the step of applying the cushion
backing includes applying chemical blown polyvinyl chloride
plastisols/organosols, acrylics, rubber foams, polyurethane foams,
froth foams such as polyvinyl chloride plastisol, acrylics, melt
processed foams such as polyvinyl chloride, polyethylene, ethylene
vinyl acetate, metallocene polyolefins, or elastomeric polyolefin
copolymers.
13. The method of claim 9 including the step of applying the lower
surface comprises applying a curable or cross-linked adhesive
material made of PVC-type adhesives, rubber-type adhesives, acrylic
adhesives, including e-beam curable acrylic adhesives, vinyl
acetate-type adhesives, urethane-type adhesives, and combinations
thereof.
14. The method of claim 9 including the step of applying the lower
surface comprises applying a lower adhesive layer that has moisture
release grid channels onto the backing layer to enhance its
adhesion to a sub-floor and provide moisture-release
enhancement.
15. The method of claim 9 including the step of applying the lower
surface comprises applying a lower layer that includes vertical
indentations and protrusions to reinforce the surface tension of
the floor surface covering's adhesion on the sub-floor.
16. The method of claim 9 including the step of applying the lower
surface comprises applying a self-adhesive surface covering that
can be removed from the surface with a pull parallel to the
vertical structural lining on the foam backing layer because of the
air channels on the grids and which stays intact and is not easily
displaced with a horizontal or diagonal pull force.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] N/A
STATEMENTS REGARDING FEDERALLY SPONSORED RESEARCH OR
DEVELOPMENT
[0002] NA
REFERENCE TO A MICROFICHE APPENDIX
[0003] NA
BACKGROUND OF THE INVENTION
[0004] 1. Field of the Invention
[0005] The present invention relates to removable surface
coverings. In particular, this invention is a structural
improvement of floor tiles, sheets, or planks, including floor
tiles, sheets, and planks or sections of varying sizes and shapes
and surface types including those made from polyvinyl chloride,
rubber, linoleum, polymeric resins, reinforced resins, vinyl
composite, or other resilient materials, carpet, stones, ceramic,
metals, glass, textiles, wood, composites thereof in desired
combinations, veneers thereof in desired combinations, and
laminates thereof in desired combinations. More specifically, the
invention is the enabling of loose-lay application, via the
addition onto the conventional floor tiles, sheets or planks, a
dual backing layer comprised of a foam layer and a cured adhesive
layer. This dual layer, when added onto the back of a conventional
floor tile, sheet, or plank, allows the flooring to be installed
directly only with a slight application of pressure, without any
additional application of glue or underlayment systems. In the
meantime, this dual backing layer-enhanced flooring can be removed
readily from the subfloor without any glue residue or any damage
done to the subfloor or to the flooring substrate. Because of this
backing-enhancement, the very same flooring tile, sheet, or plank
may be reinstalled again without losing the effectiveness of its
original tack. The current invention thereby makes possible a
loose-lay flooring that is "stick, peel, stick", or that is
self-adhesive, removeable and relayable.
[0006] In the need for efficiency, economy and speed in our
accelerated construction industry, the surface-covering business
has witnessed the challenge of escalating cost incurred by the
labor, material, and time associated with installation and removal
procedures. The waste of time, labor, and material is particularly
evident in the flooring industry where the needs for durability and
replaceability co-exist as constantly conflicting demands. For any
floor to be durable and slip-resistant, it needs to be securely
installed onto the earth. But the more solidly it is secured onto
the earth, the harder and more costly it is to install the flooring
and the harder and more costly it is to remove it and replace it
with something else.
[0007] Prior to a conventional flooring installation, much labor,
time and material is wasted in the removal of existing flooring and
the recovery of the damaged subfloor to ideal conditions for the
re-installation of the new floor. The removal of existing flooring
causes residue of glue to be stuck on the subfloor. It also damages
the subfloor itself and the old flooring substrate, yielding the
old flooring material to be no longer re-useable after removal.
When the removal is complete, additional labor, time and material
are required to install the new floor securely onto the earth.
Unnecessary environmental cost is also incurred in the wasteful
discarding of the old flooring material, and in the repeated use of
another new set of the cement, adhesive or underlayment system
required for the new flooring.
[0008] So far, the surface-covering industry, in particular, the
flooring industry, has seen innovations developed to increase the
efficiency and reduce the cost of the conventional installation
process. Self-adhesive tiles, produced with or without release
paper, have been developed to eliminate the re-application of glue
when installing the flooring material. Interlocking flooring
systems have been developed to eliminate the application of glue
altogether by making the adjacent tiles interlock through built-in
features. Underlayment systems have been developed to eliminate the
faulty subfloor conditions altogether and enable the new flooring
to be fastened onto the underlayment systems directly instead of
the subfloor. However, all of the existing developments, while
being improvements, retain certain defects and create new ones in
course. It is also notable that none of the existing solutions in
the field make significant progress on removal segment of the use
cycle.
[0009] Existing self-adhesive tiles in the industry make progress
by way of a pressure-sensitive glue that bonds the flooring to the
earth with only a slight use of pressure, and without any
additional glue application on the job site. In removal, however,
the self-adhesive tile damages the subfloor easily via glue residue
and delaminates and destroys the substrate of the flooring
material, yielding it no longer useable. The cost of renovation and
upkeep is thereby increased significantly.
[0010] The existing solution of Interlocking flooring systems,
especially those commonly found in laminates, create the defects of
its own. After installation, the interlocked floor becomes a
unitary and leveled surface that is locked in place against the
seams of each tile or plank. As a result, an interlocked floor
installed wall-to-wall cannot tolerate the contraction and
expansion of each of the plank or tile. Over time, a severe
campering problem inevitably results. In addition, interlocked
flooring also suffers from an increased level of noise pollution
due to the noticeable space left to echo traffic sounds between the
subfloor and the interlocked floor. In removal, the interlocked
flooring solutions create extra environmental burdens and incur
more material and labor cost since a significant portion of it must
be destroyed in order for the entire floor to be removed.
[0011] There have been floating floors developed with
interconnected panels or sections to form a single unitary floor
that can contract and expand as a unit. This typically requires
that there be a space between the periphery of the unit and the
walls of a room. The interconnected panels may be tongue and groove
and glued. The interconnected panel may utilize a self locking
joint that does not require the use of glue. However, such types of
flooring are not ideal in aesthetics due to the gaps between the
floor and the walls of the room. Their floating nature also make
them limited and suitable for only temporary usages.
[0012] Underlayment systems, pre-glued or not, are also limited in
their benefits. While eliminating the need for subfloor preparation
by acting as a medium between the new flooring material and the
subfloor, underlayment systems are in and of itself a complicated
assembly. It is costly to produce, cumbersome and complicated to
install. The extra labor in applying fasteners, stables, and or
other forms of structural support elements to hold the flooring in
place actually end up creating additional cost in the installation
process. For most underlayment systems, specialized tools are also
needed in the installation.
[0013] Aside from the limitations mentioned above, all of the
existing solutions in the market create extra environmental burdens
in the installation and removal procedures (i.e. the material waste
as a by-product, the messy clean-up process, and the inability to
recycle the used flooring after it is removed).
[0014] There remains, therefore, a need for a flooring solution
that is durable and slip-resistant against foot traffic in its
adhesion on the subfloor, but that can be installed and removed
readily without additional investment in time, labor, cost, tools
or energy. There remains also a need for a flooring solution with a
100% clean removeability (will not damage the subfloor, leave any
glue residue, nor become delaminated or damaged in its removal) and
that retains all of its beneficial features and original adhesion
tack in place so that it can be repositioned or reused after
repeated installations and removals. It is also likewise
advantageous and desirable to provide a method of flooring
installation and replacement that is efficient and clean without
the burden of glue residue removal and the creation of material
waste in course.
[0015] Similarly, it is desirous to provide a moisture release
enhancement as an additional feature in the flooring to minimize
the dirt and grime collection in and under the tile seams and to
release the pressure built-up due to moisture in the subfloor.
[0016] Additionally, it is desirous to provide a method of floor
adhesion that is not "tacky" or "sticky" to the touch, does not
leave a glue residue, is slip resistant and suitable for both
permanent and temporary tile installations.
[0017] At last, it is desirous to provide a solution in flooring
that can be installed, removed, and re-installed with a
Do-It-Yourself "Stick, Peel, Stick" ease so the flooring can be
transferred intact from one place to another by an untrained
person, much like a piece of furniture.
[0018] 2. Description of the Related Art
[0019] U.S. Pat. No. 6,623,840 discloses a rubber-surfaced
protective flooring tile and method of manufacturing the same which
provides a covering over hard floor surfaces. The tile consists of
two layers. The top has a bottom surface which has voids which
extend from the bottom surface towards the top surface. The bottom
layer is of granulated rubber and has a prepolymer material that
binds to the voids in the top layer during the manufacture of the
tile. The rubber tile provides cushion on hard surfaces to minimize
injury in playgrounds, factory floors, fitness rooms, and physical
therapy facilities.
[0020] U.S. Pat. No. 6,129,967 discloses a system for securing
brittle ceramic tiles to the sub-floor without a supporting
adhesive substrate. A liner is used to provide structural support
and an energy absorbent layer is present which allows for the tile
to withstand greater forces of abrasion without breaking. The liner
is adhered to the sub-floor and the tiles are placed inside and are
anchored to the liner and an impact resistant ceramic layer.
[0021] U.S. Pat. No. 6,694,689 discloses a modular flooring system
which utilizes a free-lay support baseplate. Replaceable wear
surface tiles fit within the baseplate. The baseplate allows for
the maintenance of a level floor surface when placed over a
preexisting worn floor and for the removal and replacement of
flooring within the baseplate superstructure. The composite
baseplate structure permits independent temporary displacement of
each of the tiles.
[0022] U.S. Pat. No. 4,654,244 discloses a loose-lay and adhered to
floor structure comprised of two layers of reinforced material
suitable for use over stable and unstable sub-floors. The rigidity
in the flooring is achieved by two layers of reinforced material
sandwiching a cushion layer. Surface layers are placed on the
outside of the reinforced layers. This reinforcement is designed to
prevent buckling, curling and doming under a rolled load. As an
alternative, the reinforcing layer may be pre-modified such that,
when used to provide a surface covering the covering will have
acceptable buckling characteristics.
[0023] U.S. Pat. No. 6,751,917 discloses a floor tile structure
without an adhesive coating at the bottom. Each tiles surface layer
and bottom layer are attached respectively on the upper and the
lower surfaces of the soft double sided adhesive tape with pressure
sensitivity. The surface layer is possibly made of rock, metal, or
other hard material and the periphery is a smooth cross-section.
Tiles are joined by placing the adhesive on the middle protruding
convex layer of one tile onto the convex edge of the adjoining one
and bonding the two together in the middle, leaving no need for
bottom adhesion.
[0024] U.S. Pat. No. 6,751,912 discloses a modular interlocking
tile and flooring system. Each tile is adapted to be coupled to
another interlocking tile. Each tile includes a body having a
playing surface and two male and two female interlocking sides. The
interlocking mechanism is adapted to allow the modular interlocking
tiles to connect together in a staggered fashion.
[0025] U.S. Pat. No. 6,802,159 discloses a roll-up tile system.
Individual tiles lock together in a manner to form a plurality of
non-bendable tile joints. The tile includes a hinge or fold line
along a second axis. The hinges allow the multi-tile surface to be
rolled up into a hollow tube from any direction along one of the
axes. The rolled up floor panel consists of a plurality of tile
panels.
[0026] U.S. Pat. No. 6,769,217 discloses an interconnecting
disengageable flooring system. The system includes two or more
flooring panels comprised of a top wear surface and a bottom
surface for contact with the support structure. The panels have at
least three edges and all edges have recesses formed therein. The
system also comprises a connector having a base and a projection
extending vertically from the base. The projection extending from
the base is shaped to be received in a disengageable vertical
connected fashion into the recesses of the panels.
[0027] U.S. Pat. No. 6,803,099 discloses a self-adhering surface
covering having a wear surface and a pressure-sensitive adhesive
layer on the lower surface of the wear surface and a barrier layer
disposed on the adhesive layer. The surface covering has
substantially no tack at about 10 psi at 140 degrees F. but has
tack at about 20 psi at 75 degrees F. An adhesive which is
substantially non-stringing may also be employed in the adhesive
layer. The barrier layer includes substantially non-adhesive
particles which have a crash resistance of at least about 10 psi
while disposed on the adhesive layer. The method of making the
self-adhering surface covering includes applying an adhesive to a
substrate to form an adhesive layer having an adhesive surface, and
applying a barrier layer comprising substantially non-adhesive
particles to the adhesive surface to form the surface covering. The
particles have a crush resistance of at least about 10 psi while
disposed on the adhesive layer.
[0028] U.S. published patent application No. 20040129365 discloses
a preglued underlayment assembly for a floor covering system having
a substantially rigid underlayment. The underlayment has an upper
and a lower surface and a pressure sensitive adhesive layer
disposed on the upper surface and a release layer disposed on the
adhesive layer.
BRIEF SUMMARY OF THE INVENTION
[0029] The present invention is a structural improvement of a
removable and relayable surface covering, preferably flooring,
including but not limited to floor tiles, sheets, and planks or
sections of varying sizes and shapes and surface types including
those made from polyvinyl chloride, rubber, linoleum, polymeric
resins, reinforced resins, vinyl composite, or other homogeneous or
heterogeneous resilient materials, in-laid floors, cushioned
floors, carpet, stones, ceramics, metals, glass, textiles, wood,
composites thereof in desired combinations, veneers thereof in
desired combinations, and laminates thereof in desired
combinations. The present invention makes such a structural
improvement possible via the addition of an innovative backing
layer onto any such flooring types. The backing layer may come in
at least two varieties: without moisture-release channels and with
moisture-release channels.
[0030] The structure of this backing without moisture-release
channels to be affixed onto any variety of floor-covering tile,
sheet, or planks is comprised of two layers. The top layer, which
is adhered onto the conventional floor tile, sheet, or planks via
any conventional glue used in flooring is composed of a soft,
resilient, or foam material about 0.5 mm to 3.0 mm in thickness.
The bottom layer of this backing, or the side that faces the earth
in installation, is composed of any type of curable adhesive that
has undergone curing or cross-linked process.
[0031] The soft, resilient, cushioned or foam material of the
present invention can be any conventional foam layer used in
surface covering, such as a foam layer used in flooring. In
particular, the foam layer can be any suitable material known in
the art for producing foam layers such as chemical blown polyvinyl
chloride plastisols/organosols, acrylics, polyurethane foams, froth
foams such as polyvinyl chloride plastisol, acrylics, melt
processed foams such as polyvinyl chloride, polyethylene, ethylene
vinyl acetate, metallocene polyolefin's, elastomeric polyolefin
copolymers. Additionally, any soft, resilient or cushioned material
which are non-foamed may also be employed. The method of foaming
via blowing agents and the specification of soft, cushioned or foam
material required for the use in flooring is well-known in the
art.
[0032] Various curable adhesives are known and can be utilized in
the present invention. There is no specific limitations to the
chemistry or composition of the adhesive, as long as the adhesive
is curable and provided sufficient adhesion and slip resistance and
can be removed and relayed. A common variety would be rubber-type
adhesives, PVC-type adhesives, acrylic adhesives, e-beam curable
acrylic adhesives, vinyl acetate-type adhesives, urethane-type
adhesives, and combinations thereof. The curable adhesive, after
the curing process, may be applied onto the foam layer by a
conventional coating apparatus such as a reverse roll coater, a
forward roll coater, a doctor blade, an air knife, or other similar
apparatus. The thickness of the adhesive may be conventionally
determined. In view of adhesion strength and economy, the adhesive
layer is typically around 0.1 mm in thickness but can be less or
more depending on the adhesive employed.
[0033] When this dual backing comprised of the foam layer and the
curable adhesive is affixed onto a conventional floor tile, sheet,
or plank made of any material composition, the floor is made into a
loose-lay flooring system with the ease of "stick-peel-stick"
features as mentioned above.
[0034] Additional features of this current invention is that the
embedded foam layer increases the tile's evenly distributed contact
with the sub-floor and thereby increases the leveling adhesion of
the tile onto the floor. The foam layer also makes the floor more
comfortable and warm to walk on, being more shock-absorbent and
acoustically sound.
[0035] The curable adhesive, in the meantime, has the additional
feature of being non-stringing and non-sticky to the touch before
installation and after removal. All of its original tack remains in
place after the flooring removal and even more significantly, after
the removed flooring is cleaned with water or a damp cloth.
[0036] The backing structure with moisture-release channels remains
the same as the version without the moisture-release channels
except that the soft, resilient, cushion or foam layer is molded
with regular intervals of indented and protruded channels. This
interval layer overrides a layer of cured adhesive. Strips of
protruding and indented foam channels with cured adhesive follow
and allow for moisture release. They also reinforce the surface
tension of the tile's adhesion onto the subfloor and make the
flooring only removeable from the sub-floor surface with a pull
parallel to the vertical structural lining on the foam backing
layer, but un-removeable when pulled with a horizontal or diagonal
pull force.
[0037] By this construction each tile, sheet, or plank of any
variety of flooring material as listed above is capable of being
installed by a loose lay application which requires no glue,
release paper, underlayment systems, interlocking mechanisms and
with manual and clean removeability that allows the transferals and
repositioning of such a floor with all of its original tack and
features in place. The vertical lines of the cushion layer on the
backing resist horizontal or diagonal pull force of tile removal
from floor creating a 100% recyclable, slip resistant loose lay
tile.
[0038] More specific features and advantages will become apparent
with reference to the DETAILED DESCRIPTION OF THE INVENTION,
appended claims, and the accompanying drawing figures.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0039] FIG. 1 is a perspective view of a polyvinyl chloride floor
tile without moisture-release channels according to the present
invention.
[0040] FIG. 2 is a cross-sectional view of a polyvinyl chloride
floor tile without moisture-release channels according to the
present invention.
[0041] FIG. 3 is a perspective view of a polyvinyl chloride floor
tile with moisture-release channels according to the present
invention.
[0042] FIG. 4 is a cross-sectional view of a polyvinyl chloride
floor tile with moisture-release channels according to the present
invention.
[0043] FIG. 5 is a flowchart of the production process for the
invention onto a vinyl tile.
DETAILED DESCRIPTION OF THE INVENTION
[0044] As previously stated, conventional flooring is traditionally
installed on sub-floors by either pre-glue or glue applications,
interlocking mechanisms, or underlayment systems. This invention is
an improved method upon removeable and relayable flooring as well
as other advantages that will be more fully discussed below.
[0045] Floor section member 10 shown in FIGS. 1 and 2 represents
one section of a floor system that may take the form of a vinyl
tile or other flooring material types including but not limited to
from polyvinyl chloride, rubber, linoleum, polymeric resins,
reinforced resins, vinyl composite, or other resilient materials,
carpet, stones, ceramic, metals, glass, textiles, wood, composites
thereof in desired combinations, veneers thereof in desired
combinations, and laminates thereof in desired combinations The
embodiment of FIGS. 1 and 2 describe a section without
moisture-releasing channels. Floor section member 10 is a
self-adhesive, loose-lay installed floor surface covering which may
have multiple layers: an upper wear surface 11 which is seen. An
internal adhesive layer 12 secures the surface layer to a cushion
material layer 13. Another internal adhesive layer 14 is provided
by the backing coating of cured adhesive 14. The surface layer 11
in FIG. 1 and 2 may be made of polyvinyl chloride (PVC) or other
suitable surface material. The present invention is applicable to
other surface layers of a variety of materials, including polymeric
resins, rubber, linoleum, reinforced resin, in-aid floors, all
resilient flooring, carpet, stone, ceramic, wood, wood parquet,
composites, veneers, and laminates or combinations thereof. The
surface layer can be of varying width, thickness, density and edge
shape design, color, pattern, chemistry, or composition dependent
on the specific material of which the surface layer is made.
[0046] The surface layer 11 is adhered to the thin cushioned
backing of cushion material layer 13 by an adhesive layer 12.
Surface layer 11 is defined by its upper surface 11a, the uppermost
surface of tile, and its lower surface 11b, the bottommost surface
of layer 11. Internal adhesive layer 12 adheres surface 11b to
surface 13a which is the uppermost surface of cushion layer 13.
Cushion material layer 13 is defined by its upper surface 13a and
lower surface 13b. Surface 13b adheres to a backing coating of
cured adhesive like material 14. Layer 14 is defined by its upper
surface 14a and lower 14b. Layer 14 is the bottommost layer of
sample floor section member 10 with a lower surface 14b.
[0047] The surface layer 11 is any type of flooring material which
may include but is not limited to polyvinyl chloride, rubber,
linoleum, polymeric resins, reinforced resins, vinyl composite, or
other resilient materials, carpet, stones, ceramic, metals, glass,
textiles, wood, composites thereof in desired combinations, veneers
thereof in desired combinations, and laminates thereof in desired
combinations thereof. The cushion material layer 13 may be
comprised of a variety of soft material layer including but not
limited to foamable material in particular, the foam layer can be
any suitable material known in the art for producing foam layers
such as chemical blown polyvinyl chloride plastisols/organosols,
acrylics, rubber foams, polyurethane foams, froth foams such as
polyvinyl chloride plastisol, acrylics, melt processed foams such
as polyvinyl chloride, polyethylene, ethylene vinyl acetate,
metallocene polyolefins, elastomeric polyolefin copolymers.
Additionally, any soft, resilient or cushioned material which are
foamed or non-foamed may also be employed. The thickness of the
cushion material layer is about 0.5 mm to 3.0 mm. The soft
cushioned layer 13 increases the tile's evenly distributed contact
with the sub-floor, and thereby increases the leveling adhesion of
the tile onto the floor. It also enhances the acoustic absorption
of the floor while making the floor more comfortable to walk on and
more shock-absorbent.
[0048] The bottom layer 14 is a coating of cured-adhesive that
adheres onto the sub-surface with very slight pressure and allows
removal and repositioning with its original tack in place without
glue residue or delaminating the substrate. The cured-adhesive that
comprises layer 14 may be made of any adhesive that is curable,
including rubber-type adhesives, PVC-type adhesives, acrylic
adhesives, e-beam curable acrylic adhesives, vinyl acetate-type
adhesives, urethane-type adhesives, and combinations thereof. The
bottom layer must provide sufficient adhesive properties to
maintain the floor section member in place during use. It should
also be releasable so the floor section member can be removed and
relayed repeatedly.
[0049] A common adhesive is made of modified acrylate, with
viscosity of 3000-5000 cps/25 degrees Celsius, with density of
1.0-1.1 g/cm 3, with curing speed greater than 10 M/min/Lamp (80
Wcm-1) with 80% of active component. The coating method for this
adhesive can be either a reverse roll coater, a forward roll
coater, a doctor blade, an air knife, or other similar coating
apparatus.
[0050] The criteria for the lower adhesive layer applied on the
foam layer and exposed to the subfloor would be any curable
adhesive which: (1) has undergone curing or cross-linked
processing; (2) has initial tack that's sufficient to bond or hold
the particles to the adhesive surface and maintain the back layer
in contact with the subfloor, (3) be non-stringing and relatively
resistant to penetration or compression of particles, (4) about 1
to 2 mil but can be less than 1 mil or greater than 2 mils
depending on the adhesive used; (5) retains strong adhesion on
subfloor when flooring is pulled vertically upwards.
[0051] The foam layer may have about 0.5 mm to 3.0 mm thickness but
could vary depending on the foam material used. The curable
adhesive thickness can be conventionally determined, typically
between 0.01 mm to 0.3 mm, but preferably lower than a thickness of
0.1 mm.
[0052] Another embodiment of the invention shown in FIGS. 3 and 4
is the floor section member 20 which represents a tile with the
present invention with moisture-releasing channels. Floor section
member 20 has multiple layers: A surface layer 21 is the uppermost
layer that is seen and is the contact and wear surface. An internal
adhesive layer 22 is adhered to the lower surface 21a. A cushion
material layer 23 is positioned below the wear surface layer 22.
The lowermost layer includes the raised and lower alternation
molding channels in regular intervals. Layer 24 may be a curable
adhesive layer that functions as the glue that holds the floor
section member in place and allows it to be removed and relayed.
The layer 24 is preferably pressure-sensitive and may be made of
rubber-type adhesives, acrylic adhesives, including e-beam curable
acrylic adhesives, vinyl acetate-type adhesives, urethane-type
adhesives, and combinations thereof, or any other adhesives
commonly used that can be curable. Layer 24 is comprised of
alternating raised and lowered protruding channels members 27 and
indented channels 26.
[0053] Surface layer 21 in FIGS. 3 and 4 may be made of polyvinyl
chloride (PVC), however, the present invention can be applied
tinder a surface layer of a variety of materials including but not
limited to polyvinyl chloride, rubber, linoleum, polymeric resins,
reinforced resins, vinyl composite, or other resilient materials,
carpet, stones, ceramic, metals, glass, textiles, wood, composites
thereof in desired combinations, veneers thereof in desired
combinations, and laminates thereof in desired combinations. The
surface layer can be of varying width, thickness, density and edge
shape design, color, chemistry, or composition, dependent on the
specific material of which the surface layer is made.
[0054] Surface layer 21 is adhered to the cushion material layer 23
by the internal adhesive layer 22. Surface layer 21 is defined by
its upper surface 21a which is the uppermost contact and wear
surface of sample tile 20 and its bottom surface 21b. Internal
adhesive layer 22 adheres to surface 21b and surface 23a which is
the uppermost surface of cushion layer 23. Cushion layer 23 is
comprised of a variety of ethylene vinyl acetate foam, polyethylene
foam, rubber foam, polyvinyl foam or any other soft, cushioned,
resilient foam material. The thickness of the cushion material
layer is 0.5 mm to 3.0 mm. The soft cushioned layer 23 increases
the floor section member's evenly distributed contact with the
sub-floor, and thereby increases the leveling adhesion of the floor
section member onto the floor.
[0055] Layer 23 is defined by its upper surface 23a and lower
surface 23b. Molding layer 24 may be comprised of a curable
adhesive layer 25 that is adhered or glued to the bottommost
surface 23b of cushion layer 23. Layer 24, the bottommost layer of
floor section member 20 may comprise a plurality of vertical
protruding channels 26 alternated with adjacent vertical indented
channels 27. As shown in FIG. 3 which is a bottom view of the floor
section member 20, channels 26 and 27 extend parallel to each other
for the length and width of the floor section member.
[0056] Molding layer 24 molds to the sub-floor upon which it is
laid and reinforces the surface tension of the tile's adhesion on
the sub-floor. Such molding resists horizontal and diagonal pull
forces and movement on the sub-floor. The floor section member can
only be removed from the floor with a pull parallel to the vertical
structural lining oil the foam backing-layer 23 because of air
channels on the grids. The floor section member remains intact and
cannot be easily displaced with a horizontal or diagonal pull. The
moisture releasing channel layer 24 allows water to evaporate from
its point of contact with the sub-floor. Allowing for such
evaporation helps to maintain the floor section member's adhesion
to the sub-floor and to maintain the aesthetic value of the floor
section member. Moisture in the floor section member collects
unwanted particles soiling the floor section member and distressing
the point of contact of layer 24 with the sub-floor.
[0057] FIG. 5 is a flowchart of a typical production process for a
floor section member in the form of a vinyl tile. The production
process follows generally conventional means of tile manufacturing
either via extrusion, calendar or heat pressure lamination. With
reference to schematic 41, the process may begin with a top layer
that may be a polyvinyl film that may be design printed. The
polyvinyl chloride tile is then extruded into the tile by heat
lamination and the process shown in schematic 42. The process
referenced in schematic 42 begins with a polyvinyl chloride
compound mixed with calcium carbonate and processed via a bumberly
and extruded into the tile by a crushing machine. The tile surface
may then be embossed, cooled, and annealed. Glue may then be
applied to the tile back.
[0058] The foam layer, the first layer of the current invention is
then combined to the tile material described above. Schematic 43
shows the process for incorporation of the foam layer. Schematic 43
begins with a foamable material compound processed via a bumberly,
extruded, and cut to fit the tile material already produced.
[0059] As referenced in schematic 41, after the foam layer is
adhered onto the tile's backing and formed, the back surface of the
tile is smoothed, and an optional ultraviolet coating may be added.
The tile is then dried with ultraviolet lighting. The cured
adhesive is then applied onto the foam layer and followed by drying
with ultraviolet lighting. The production process is then complete,
and the tile is ready for packing.
[0060] It is believed that the primary use of the invention would
be with standard flooring. However, it also has application in
analogous environment that call for the properties of the preferred
embodiments. Flooring is used as a covering on surfaces other than
floors.
[0061] Although the foregoing specific details describe various
embodiments of the invention, persons reasonably skilled in the art
will recognize that various changes may be made in the details of
the apparatus of this invention without departing from the spirit
and scope of the invention as defined in the appended claims.
Therefore, it should be understood that, unless otherwise
specified, this invention is not to be limited to the specific
details shown and described herein.
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