U.S. patent application number 11/470845 was filed with the patent office on 2008-01-17 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 | 20080010930 11/470845 |
Document ID | / |
Family ID | 36678182 |
Filed Date | 2008-01-17 |
United States Patent
Application |
20080010930 |
Kind Code |
A1 |
Mao; Chen-chi |
January 17, 2008 |
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 top surface, 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,
TW) |
Correspondence
Address: |
DUANE MORRIS LLP;IP DEPARTMENT
30 SOUTH 17TH STREET
PHILADELPHIA
PA
19103-4196
US
|
Assignee: |
ZAXXON USA, INC.
3511 Silverside Road Suite 105
Wilmington
DE
|
Family ID: |
36678182 |
Appl. No.: |
11/470845 |
Filed: |
September 7, 2006 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
11036907 |
Jan 14, 2005 |
|
|
|
11470845 |
Sep 7, 2006 |
|
|
|
Current U.S.
Class: |
52/403.1 |
Current CPC
Class: |
B32B 2307/554 20130101;
E04F 15/22 20130101; Y10T 156/10 20150115; B32B 3/30 20130101; E04F
15/225 20130101; E04F 15/185 20130101; E04F 15/0215 20130101; B32B
2419/04 20130101; B32B 2307/102 20130101; B32B 2250/03 20130101;
B32B 2607/02 20130101; E04F 15/02172 20130101 |
Class at
Publication: |
052/403.1 |
International
Class: |
E04F 15/22 20060101
E04F015/22 |
Claims
1. A floor covering comprising: a top surface; a cushion layer
arranged below said top surface and having a bottom-most embossed
surface defining a plurality of channels that are separated one
from another by a plurality of lands; and a repositionable,
pressure sensitive adhesive layer having an initial tack that is
applied onto said bottom-most surface so that said cushion layer
(i) adheres to a surface thereby to hold said cushion layer in
place after application of a pressure, and (ii) allows removal of
said cushion layer from said surface absent a substantial
diminution of said initial tack.
2. A self-adhesive, loose-lay floor tile according to claim 1
wherein said cushion layer is divided so as to define a plurality
of removable pad segments.
3. A floor covering according to claim 1 wherein said cushion layer
is divided by a grid of intersecting incisions so as to form a
plurality of removable pad segments.
4. A floor covering according to claim 3 wherein said grid of
intersecting incisions provides for the separation and discrete
removal of at least one of said removable pad segments.
5. A floor covering according to claim 4 comprising a backing layer
disposed below said top surface that defines a bottom-most surface
and said a cushion layer defines a top surface and a bottom surface
wherein said top surface is adhered to said bottom-most surface of
said backing layer with a cured adhesive having an initial
tack.
6. A floor covering according to claim 4 wherein each of said pad
segments comprises a plurality of lands that are located between
and separate a plurality of channels that are arranged in regular
intervals.
7. A floor covering according to claim 1 wherein said cushion layer
is about 0.1 mm to 1.0 mm thick.
8. A floor covering according to claim 7 wherein said cushion layer
is divided by a grid of intersecting incisions so as to form a
plurality of removable pad segments each including a plurality of
lands that are located between and separate a plurality of channels
that are arranged in regular intervals with those portions of said
cushion that define said channels having a thickness of no more
than one millimeter.
9. A floor covering according to claim 1 wherein said curable
adhesive layer is pressure-sensitive and selected from the group
consisting of rubber-type adhesives, acrylic adhesives, including
e-beam curable acrylic adhesives, vinyl acetate-type adhesives,
urethane-type adhesives, and combinations thereof.
10. A floor covering comprising: a top surface; a divided cushion
layer arranged below said top surface and having a bottom-most
embossed surface defining a plurality of intersecting channels that
are separated one from another by a plurality of lands wherein each
of said lands comprises a top surface; and a repositionable,
pressure sensitive adhesive layer having an initial tack that is
applied said top surface so that said divided cushion layer (i)
adheres to a surface thereby to hold said cushion layer in place
after application of a pressure, and (ii) allows removal of said
cushion layer from said surface absent a substantial diminution of
said initial tack.
11. A floor covering according to claim 10 comprising a backing
layer disposed below said top surface that is selected from the
group consisting of polyvinyl chloride, rubber, linoleum,
reinforced resins, vinyl composite, or other resilient materials,
carpet, stones, ceramic, metals, glass, textiles, wood, composites,
mineral composites, veneers, laminates, and polymeric resins.
12. A floor covering according to claim 10 wherein said divided
cushion comprises a foamable material selected from the group
consisting of 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.
13. A floor covering according to claim 10 wherein said adhesive
comprises a adhesive material made of at least one of PVC-type
adhesives, rubber-type adhesives, acrylic adhesives, including
e-beam curable acrylic adhesives, vinyl acetate-type adhesives, and
urethane-type adhesives.
14. A floor covering according to claim 10 wherein said adhesive is
curable.
15. A floor covering according to claim 10 wherein said adhesive is
noncurable.
16. A method for adjusting a surface contour of a self-adhesive,
loose-lay tile comprising the steps of; (A) forming a divided
cushion layer on a bottom surface of a self-adhesive, loose-lay
tile so as to define a plurality of removable pad segments; and (B)
removing at least one of said pad segments thereby forming a void
in said divided cushion layer.
17. A method for adjusting a surface contour of a self-adhesive,
loose-lay tile comprising the steps of; (A) forming a divided
cushion layer on a bottom surface of a self-adhesive, loose-lay
tile so as to define a plurality of removable pad segments; (B)
removing at least one of said pad segment thereby forming a void in
said divided cushion layer; and (C) positioning said at least one
pad segment atop a portion of said divided cushion layer.
18. A method for adjusting a surface contour of a self-adhesive,
loose-lay tile comprising the steps of; (A) forming a divided
cushion layer on a bottom surface of a self-adhesive, loose-lay
tile so as to define a plurality of removable pad segments; and (B)
positioning said at least one pad segment atop a portion of said
divided cushion layer.
19. A floor covering comprising: a top surface; a cushion layer
arranged below said backing layer and having a bottom-most plane
surface; and a repositionable, pressure sensitive adhesive layer
having an initial tack that is applied onto said bottom-most
surface so that said cushion layer (i) adheres to a surface thereby
to hold said cushion layer in place after application of a
pressure, and (ii) allows removal of said cushion layer from said
surface absent a substantial diminution of said initial tack.
20. A floor covering according to claim 19 wherein said adhesive is
curable.
21. A floor covering according to claim 19 wherein said adhesive is
noncurable.
22. A floor covering comprising: a ceramic layer; a cushion layer
arranged below said ceramic layer and having a bottom-most plane
surface wherein said cushion layer is 0.2 millimeters thick; and a
repositionable, pressure sensitive adhesive layer having an initial
tack that is applied onto said bottom-most surface so that said
cushion layer (i) adheres to a surface thereby to hold said cushion
layer in place after application of a pressure, and (ii) allows
removal of said cushion layer from said surface absent a
substantial diminution of said initial tack.
23. A floor covering comprising: a wood layer; a cushion layer
arranged below said wood layer and having a bottom-most plane
surface wherein said cushion layer is 0.2 millimeters thick; and a
repositionable, pressure sensitive adhesive layer having an initial
tack that is applied onto said bottom-most surface so that said
cushion layer (i) adheres to a surface thereby to hold said cushion
layer in place after application of a pressure, and (ii) allows
removal of said cushion layer from said surface absent a
substantial diminution of said initial tack.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of, and claims
priority from, co-pending patent application Ser. No. 11/036,907,
filed Jan. 14, 2005, and entitled Removable And Relayable Floor
Covering.
FIELD OF THE INVENTION
[0002] The present invention generally relates to floor coverings
and their installation and, more particularly to a removable and
repositionable tile floor coverings.
BACKGROUND OF THE INVENTION
[0003] There is always a need for efficiency, economy and speed in
the construction industry. The surface-covering portion of the
construction industry has also had the challenge of escalating
costs incurred by the labor, material, and time associated with
flooring installation and removal procedures. This waste of time,
labor, and materials is particularly evident in the flooring
industry where the need for durability and replaceability are
constant conflicting requirements. Conventional flooring is
traditionally installed on sub-floors by either pre-glue or glue
applications, interlocking mechanisms, or underlayment systems. For
any floor to be durable and slip-resistant, it needs to be securely
installed on the sub-floor. However, the more solidly it is secured
to the sub-floor, the more difficult and costly it will be to
install or remove the flooring.
[0004] Prior to a conventional flooring installation, much labor,
time and material is wasted in the removal of existing flooring and
the return of the damaged sub-floor to ideal conditions for the
installation of the new floor. The removal of existing flooring
often causes glue residue to remain on the top surface of the
sub-floor. The process of removal of existing flooring or the
residual, hardened glue also often damages the sub-floor. When the
removal is complete, additional labor, time and material are
required to install the new floor securely to the sub-floor.
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.
[0005] Self-adhesive tiles, produced with or without release paper,
are known in the art and may help to eliminate the re-application
of glue when installing new flooring materials. Interlocking
flooring systems have also been developed to eliminate the
application of glue altogether by making the adjacent tiles
interlock. Underlayment systems have been developed in the art to
eliminate faulty sub-floor conditions and enable new flooring to be
fastened onto the underlayment systems directly instead of on to a
sub-floor.
[0006] For example, in U.S. Pat. No. 6,129,967 a system for
securing brittle ceramic tiles to a sub-floor without a supporting
adhesive substrate is disclosed. A liner is used to provide
structural support and an energy absorbent layer is present which
allows the tile to withstand greater forces of abrasion without
breaking. The liner is adhered to a sub-floor and the tiles are
placed inside and are anchored to the liner and an impact resistant
ceramic layer.
[0007] U.S. Pat. No. 6,694,689 discloses a modular flooring system
which utilizes a free-lay support base plate into which replaceable
wear surface tiles fit. The base plate provides for a level floor
surface when placed over a preexisting worn floor and for the
removal and replacement of flooring within the base plate
superstructure. The composite base plate structure permits
independent temporary displacement of each of the tiles.
[0008] U.S. Pat. No. 4,654,244 discloses a loose-lay floor
structure including two layers of reinforced material that are
suitable for use over stable and unstable sub-floors. 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.
[0009] U.S. Pat. No. 6,751,917 discloses a floor tile structure
without an adhesive coating at the bottom. Each tile surface layer
and bottom layer are attached respectively, on the upper and the
lower surfaces of 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.
[0010] 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.
[0011] 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 an 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.
[0012] U.S. Pat. No. 6,769,217 discloses an interconnecting
disengageable flooring system. The system includes two or more
flooring panels including 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.
[0013] 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.degree. F. but has
tack at about 20 psi at 75.degree. 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.
[0014] U.S. Pat. No. 6,905,100 discloses an adhesive sheet strip,
single-sidedly or double-sidedly pressure-sensitively adhering,
redetachable by extensive stretching/pulling on a grip tab in the
direction of the bond plane, where the grip tab is such that it has
a static frictional force of at least 170 cN.
[0015] U.S. Published Patent Application No. 20040129365 discloses
a pre-glued 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 on the adhesive
layer.
[0016] None of the foregoing prior art flooring systems and methods
are completely satisfactory. There remains a need for a flooring
systems that is durable and slip-resistant against foot traffic
when adhered to a sub-floor, but that can be installed and removed
readily without additional investment in time, labor, cost, tools
or energy. In addition, there is a need in the art for a flooring
system with a nearly 100% clean removeability (i.e., that will not
damage a sub-floor, leave appreciable 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 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. Also, 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 sub-floor. 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. Furthermore, 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.
SUMMARY OF THE INVENTION
[0017] The present invention relates to removable flooring and
surface coverings that are 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, all of which are hereinafter referred to as a "floor
section, floor covering, or floor tile".
[0018] More particularly, the present invention provides a floor
covering having a dual backing layer comprising a foam layer coated
with a repositionable, pressure sensitive adhesive layer. This dual
backing layer allows the floor covering to be installed directly to
a sub-floor surface with only a slight application of pressure, and
without any additional application of glue or underlayment systems.
Significantly, this dual backing layer-enhanced floor covering can
be removed readily from the sub-floor without any glue residue or
any damage done to the sub-floor or to the flooring substrate.
Additionally, that very same floor covering may be reinstalled
again without losing the effectiveness of its original tack. Thus,
a loose-lay floor covering is provided that is self-adhering,
removable and relayable, otherwise referred to as, "stick, peel,
stick."
[0019] In one embodiment, a floor covering is provided including a
top surface or wear layer often having a backing layer arranged
below the wear layer. A cushion layer is arranged below the backing
layer which includes a bottom-most embossed surface that defines a
plurality of channels that are separated one from another by a
plurality of lands. A repositionable, pressure sensitive adhesive
that has an initial tack is applied onto the bottom-most surface of
the cushion layer so that the cushion layer (i) adheres to a
surface thereby to hold the cushion layer in place after
application of a pressure, but (ii) allows removal of the cushion
layer from the surface absent a substantial diminution of the
initial tack so that the floor covering may be repositioned on the
sub-floor.
[0020] In another embodiment, floor covering is provided that
includes a top surface or wear layer. A divided cushion layer is
located below the backing layer which has a bottom-most embossed
surface that defines a plurality of intersecting channels that are
separated one from another by a plurality of lands wherein each of
the lands comprises a top surface. A repositionable, pressure
sensitive adhesive that has an initial tack is applied to the top
surface of the lands so that the divided cushion layer (i) adheres
to a surface thereby to hold the cushion layer in place after
application of a pressure, and (ii) allows removal of the cushion
layer from the surface absent a substantial diminution of the
initial tack so that the floor covering may be repositioned on the
sub-floor.
[0021] A method for adjusting the surface contour of a floor
covering is also provided in which a divided cushion layer is
formed on a bottom surface of a self-adhesive, loose-lay tile so as
to define a plurality of removable pad segments. In order to
compensate for a prominence or depression on a sub-floor, e.g., a
nail or portion of a floor board or a hole or low spot, at least
one of the pad segment is removed from its position of the
bottom-most surface of the floor covering thereby forming a void in
the divided cushion layer that is suitable for accepting and
receiving the prominence.
[0022] In another method for adjusting the surface contour of a
floor covering, a divided cushion layer is formed on a bottom
surface of a self-adhesive, loose-lay tile so as to define a
plurality of removable pad segments. In order to compensate for a
prominence or depression on a sub-floor, e.g., a nail or portion of
a floor board or a hole or low spot, at least one of the pad
segment is removed from its position of the bottom-most surface of
the floor covering thereby forming a void in the divided cushion
layer that is suitable for accepting and receiving the prominence,
and the removed pad segment is positioned atop a portion of the
divided cushion layer that corresponds to the position of the
depression in the sub-floor.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] These and other features and advantages of the present
invention will be more fully disclosed in, or rendered obvious by,
the following detailed description of the preferred embodiments of
the invention, which are to be considered together with the
accompanying drawings wherein like numbers refer to like parts and
further wherein:
[0024] FIG. 1 is a perspective view of a floor covering without
moisture-release channels according to the present invention;
[0025] FIG. 2 is a cross-sectional view of a floor covering without
moisture-release channels according to the present invention;
[0026] FIG. 3 is a perspective view of a floor covering with
moisture-release channels according to the present invention;
[0027] FIG. 4 is a cross-sectional view of a floor covering with
moisture-release channels according to the present invention;
[0028] FIG. 5 is a flowchart of one typical production process
according to the invention;
[0029] FIG. 6 is a perspective view of an alternative embodiment of
floor covering formed in accordance with the present invention.
[0030] FIG. 7 is a bottom perspective view of the floor covering
shown in FIG. 6;
[0031] FIG. 8 is a broken-away and enlarged view of a corner
portion of the floor covering shown in FIG. 7;
[0032] FIG. 9 is a cross-sectional view of a portion of the floor
covering shown in FIG. 7; a floor covering formed in accordance
with the alternative embodiment of the present invention;
[0033] FIG. 10 is a broken-away and enlarged view of the floor
covering shown in FIGS. 7, 8, and 9, showing an individual pad
segment, lands, and channels in accordance with the present
invention;
[0034] FIG. 11 is a broken-away perspective view showing the top
surfaces of pad segments on the bottom-most surface of a floor
covering formed in accordance with the present invention;
[0035] FIGS. 12 and 13 are a broken-away perspective views similar
to that of FIG. 11, showing a pad segment being removed from the
floor covering;
[0036] FIG. 14 is a perspective view of a portion of a workman's
hand holding a pad segment formed in accordance with the present
invention;
[0037] FIG. 15 is a broken-away illustration of a floor covering
formed in accordance with the present invention being applied to a
sub-floor;
[0038] FIG. 16 is a perspective view of a broken-away corner
portion of a floor covering showing a first pad segment being
applied over top of a second pad segment so as to increase the
thickness of the floor covering in that region;
[0039] FIG. 17 is a perspective view of a bottom of a floor
covering formed in accordance with the present invention showing an
edge strip with pad segments removed to accommodate a prominence on
a sub-floor;
[0040] FIG. 18 is a perspective view of a bottom of a floor
covering formed in accordance with the present invention showing a
central void formed by the selective removal of pad segments so as
to accommodate a prominence on a sub-floor and portion of the floor
covering bottom having additional pad segments added so as to
compensate for unevenness or depressions in the sub-floor;
[0041] FIG. 19 is a perspective view of a bottom of a floor
covering formed in accordance with the present invention showing a
corner pad segment removed to accommodate a prominence on a
sub-floor and a corner having a doubled pad segment to compensate
for a corresponding depression in the sub-floor;
[0042] FIG. 20 is a broken-away, perspective view of a corner
portion of a floor covering formed in accordance with the present
invention showing a double-thickness of pad segments on the bottom
portion of a floor section acting to compensate for a depression in
the sub-floor;
[0043] FIGS. 21 and 22 are cross-sectional views of a pair of
side-by-side floor tiles formed in accordance with the present
invention where a portion of one of the floor tiles sits atop a
recess in a sub-floor; and
[0044] FIGS. 23 and 24 are cross-sectional views of floor tiles
formed in accordance with the present invention where a portion of
the floor tile sits atop a prominence in a sub-floor.
DETAILED DESCRIPTION OF THE INVENTION
[0045] This description of preferred embodiments is intended to be
read in connection with the accompanying drawings, which are to be
considered part of the entire written description of this
invention. The drawing figures are not necessarily to scale and
certain features of the invention may be shown exaggerated in scale
or in somewhat schematic form in the interest of clarity and
conciseness. In the description, relative terms such as
"horizontal," "vertical," "up," "down," "top" and "bottom" as well
as derivatives thereof (e.g., "horizontally," "downwardly,"
"upwardly," etc.) should be construed to refer to the orientation
as then described or as shown in the drawing figure under
discussion. These relative terms are for convenience of description
and normally are not intended to require a particular orientation.
Terms including "inwardly" versus "outwardly," "longitudinal"
versus "lateral" and the like are to be interpreted relative to one
another or relative to an axis of elongation, or an axis or center
of rotation, as appropriate. Terms concerning attachments, coupling
and the like, such as "connected" and "interconnected," refer to a
relationship wherein structures are secured or attached to one
another either directly or indirectly through intervening
structures, as well as both movable or rigid attachments or
relationships, unless expressly described otherwise.
[0046] The term "operatively connected" is such an attachment,
coupling or connection that allows the pertinent structures to
operate as intended by virtue of that relationship. In the claims,
means-plus-function clauses, if used, are intended to cover the
structures described, suggested, or rendered obvious by the written
description or drawings for performing the recited function,
including not only structural equivalents but also equivalent
structures.
[0047] Referring to FIGS. 1-5, a floor section 10 that is formed in
accordance with a first embodiment of the present invention may be
formed, at least in part from any one of the following floor
covering material types 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, all of which are
referred to hereinafter as a "floor section".
[0048] Floor section 10 often comprises a self-adhesive, loose-lay
installed floor covering which may have multiple layers or be
homogenous, i.e., natural stone or wood, including an upper wear
surface 11 and an internal adhesive layer 12 that secures upper
wear surface 11 to a cushion material layer 13. Another adhesive
layer 14 is provided by a backing coating of cured or non-cured
adhesive. More particularly, upper wear surface 11 is preferably
formed from polyvinyl chloride (PVC), ceramic, stone, or other
suitable surface materials, and can be of varying width, thickness,
density and edge shape design, color, pattern, chemistry, or
composition dependent on the specific material of which it is made.
Upper wear surface 11 is defined by its upper surface 11a, which
forms the uppermost wear surface of floor section 10, and its lower
surface 11b, the bottommost surface of floor section 10.
[0049] Cushion material layer 13 is defined by its upper surface
13a and lower surface 13b. Cushion material layer 13 often
comprises a variety of soft, resilient materials including, but not
limited to foamable polymers, and in particular, 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 is
foamed or non-foamed may also be employed. The thickness of cushion
material layer 13 is often about 0.1 mm to 1.0 mm, with about 0.2
mm often preferred. Cushioned material layer 13 provides for an
evenly distributed contact between floor section 10 and a
sub-floor. This, in-turn, significantly increases the degree of
leveling adhesion of floor section 10, and enhances the acoustic
absorption of floor section 10 while making the finished floor more
comfortable to walk on and more shock-absorbent.
[0050] Upper wear surface 11 is adhered to cushion material layer
13 by an internal adhesive layer 12. Internal adhesive layer 12
adheres lower surface 11b to an uppermost surface 13a of cushion
material layer 13. A repositionable, pressure sensitive adhesive
layer 14 is often formed or applied as a coating of cured or
non-cured adhesive that adheres onto the sub-floor with very slight
pressure, but allows lifting, removal, and repositioning of floor
section 10 with its original "tack" substantially unaffected, and
without glue residue or delaminating the sub-floor. The
repositionable, pressure sensitive adhesive that comprises internal
adhesive layer 14 may include many of the adhesives that are
non-curable or 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. Lower surface 14b of repositionable, pressure
sensitive adhesive layer 14 must provide sufficient adhesive
properties to maintain floor section 10 in place during use, but
also be releasable so that floor section 10 can be removed and
repositioned, sometimes repeatedly. In other words, repositionable,
pressure sensitive adhesive layer 14 advantageously adheres to a
surface with an initial tack that holds the cushion layer in place
after application of a pressure, but allows for the removal of the
cushion layer from the surface (e.g., sub-floor) absent a
substantial diminution of its initial tack. One adhesive that has
been found to provide adequate results is made of modified
acrylate, with a viscosity of 3000-5000 cps/25.degree. C., a
density of 1.0-1.1 g/cm.sup.3, and a curing speed greater than 10
M/min/Lamp (80 Wcm.sup.-1) with 80% active component. The coating
method for this particular adhesive can be either a reverse roll
coater, a forward roll coater, a doctor blade, an air knife, or
other similar coating apparatus. Of course, repositionable,
pressure sensitive adhesives that do not need to be cured, as are
well known in the art, may also be used in connection with the
present invention.
[0051] Lower surface 13b adheres to a backing coating of cured
adhesive layer 14. In one embodiment, the criteria for the
repositionable, pressure sensitive adhesive layer applied on foam
layer lower surface 13b, 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
sub-floor, (3) be non-stringing and relatively resistant to
penetration or compression of particles, (4) about 0.03 mm to 0.05
mm thick average, but can be less than 0.03 mm or greater than 0.05
mm depending on the adhesive used. Cushioned material layer 13 may
have about 0.5 mm to 3.0 mm thickness, but could vary depending on
the foam material used. The repositionable, pressure sensitive
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] Referring to FIGS. 3 and 4, another embodiment of the
invention comprises a floor section 20 that includes a
moisture-releasing channel layer 24. More particularly, floor
section 20 comprises multiple layers, including a wear surface
layer 21 that forms the uppermost layer that is seen and is the
contact and wear surface. Wear surface layer 21 is defined by its
upper surface 21a which is the uppermost contact and wear surface
of sample floor section member 20 and its bottom surface 21b. An
internal adhesive layer 22 is adhered to a lower surface 21b of
wear surface layer 21. Wear surface layer 21 is preferably formed
from polyvinyl chloride (PVC), ceramic, stone, or other suitable
surface materials, and can be of varying width, thickness, density
and edge shape design, color, pattern, chemistry, or composition
dependent on the specific material of which it is made. Wear
surface layer 21 is often applied to cushion material layer 23 with
an internal adhesive layer 22. Internal adhesive layer 22 adheres
to bottom surface 21b and surface 23a which is the uppermost
surface of cushion material layer 23.
[0053] When cushion material layer 23 is positioned below wear
surface layer 21, the lowermost portion of it defines
moisture-releasing channel layer 24. Moisture-releasing channel
layer 24 comprises a plurality of lands 26 that are located between
and separate a plurality of troughs or channels 27 that are
arranged in regular intervals across the bottom of floor section
20. Moisture-releasing channel layer 24 is preferably formed by
pressing or embossing the bottom-most surface of cushion material
layer 23 so as to compress portions of cushion material layer 23 to
form troughs or channels 27 while maintaining the portions of
cushion material layer 23 adjacent to troughs or channels 27 at or
near to their original thickness so as to define lands 26.
Additionally, depending upon embossing conditions, lands 26 can
also be compressed to less than their original thickness.
Repositionable, pressure sensitive adhesive layer 14b is applied to
lower surface 23b of cushion material layer 23. In one embodiment,
(FIG. 3) lands 26 and channels 27 may extend parallel to each other
for the length and width of floor section 20. Repositionable,
pressure sensitive adhesive layer 14b advantageously adheres to a
surface with an initial tack that holds the cushion layer in place
after application of a pressure, but allows for the removal of the
cushion layer (i.e., the tile) from the surface (e.g., sub-floor)
absent a substantial diminution of the initial tack.
[0054] Cushion material layer 23 may comprise any one or
combination of soft, resilient materials including, but not limited
to foamable polymers or foam 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, so long as they are
susceptible to taking a set after being compressed or other wise
embossed in accordance with that aspect of the invention.
Additionally, any soft, resilient or cushioned material which is
foamed or non-foamed may also be employed. The thickness of cushion
material layer 23 and lands 26 is often about 0.1 mm to 1.0 mm,
with about 0.2 mm being often preferred, with those portions of
cushion material layer 23 that define troughs or channels 27 having
an embossed thickness of about 0.2 mm or less.
[0055] Repositionable, pressure sensitive adhesive layer 14b is
applied over the bottom-most surface of moisture-releasing channel
layer 24, and functions as a releasable glue to hold floor section
20 in place on a sub-floor, while advantageously allowing floor
section 20 to be removed, repositioned, and then relayed onto the
sub-floor. Repositionable, pressure sensitive adhesive layer 14b
may be formed 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 pressure sensitive adhesives that are curable or
non-curable as are well known in the art.
[0056] Moisture-releasing channel layer 24 molds to the sub-floor
upon which it is laid and reinforces the surface tension of the
floor section's adhesion on the sub-floor. Such molding resists
horizontal or diagonal pull forces and movement on the sub-floor.
Floor section 20 is best removed from a sub-floor with a pull
parallel to the vertical structural lining on the cushion material
layer 23 as a result of the provision of channels 27. Floor section
20 remains intact and cannot be easily displaced with a horizontal
or diagonal pull. Moisture releasing channel layer 24 allows water
to evaporate from its point of contact with the sub-floor, helping
to maintain the floor section's adhesion to the sub-floor and to
maintain the aesthetic value of floor section 20. This arrangement
also prevents unwanted particles from collecting and soiling floor
section 20 or distressing the point of contact of
moisture-releasing channel layer 24 with the sub-floor.
[0057] Referring to FIG. 5, a flowchart is provided of a typical
production process for a floor section 20 in the form of a vinyl
tile formed in accordance with the present invention. 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 also include
a printed design. The polyvinyl chloride film is then extruded into
a tile by heat lamination according to 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 tile by a crushing
machine. The tile surface may then be embossed, cooled, and
annealed. Glue is then applied to the tile back. The foam layer,
the first layer of the current invention is then combined to the
tile material in accordance with the invention. 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.
[0058] As referenced in schematic 41, after the foam is adhered
onto the tile's backing and formed, the back surface of the tile is
smoothed, embossed to yield lands 26 and channels 27, and then the
adhesive is applied onto the foam layer and followed, in some
embodiments, by drying/curing with ultraviolet light. The
production process is then complete, and the tile is ready for
packing.
[0059] Referring to FIGS. 6-24, a further embodiment of the present
invention provides for removal and readjustment of a cushion layer
to accommodate unevenness in the sub-floor. More particularly, a
floor section 50 comprises multiple layers including wear surface
layers 52, a backing layer 54 and a dividable cushion material
layer 56. Wear surface layers 52 include an upper-most clear film
surface 58 and often a print film layer 60 that form the uppermost
layers that are seen and that form the contact and wear portion of
floor section 50. Backing layer 54 may be formed from polyvinyl
chloride (PVC), ceramic, stone, or other suitable support
materials, and can be of varying width, thickness, density and edge
shape design. An internal adhesive layer 62 is adhered to a lower
layer surface of wear surface layers 52 so as to adhere an
uppermost surface of backing layer 54 and another internal adhesive
layer 63 (a repositionable, pressure sensitive adhesive layer, such
as adhesive layer 14b) is adhered to a bottom surface of backing
layer 54 so as to adhere an uppermost surface of dividable cushion
material layer 56. Internal adhesive layer 63 advantageously
adheres to the bottom surface of backing layer 54 with an initial
tack that holds dividable cushion material layer 56 in place after
application of a pressure, but allows for the removal of dividable
cushion material layer 56 from the bottom surface of backing layer
54 absent a substantial diminution of an initial tack.
[0060] Dividable cushion material layer 56 comprises a plurality of
removable pad segments 70, i.e., cushion material layer 56 is
arranged and constructed so as to be separated or split into a
plurality of separate and discrete segments. Each pad segment 70 is
separated from its adjacent pad segments by score lines 72 that
allow for removal of individual pad segments 70 from floor section
50 (FIG. 12) i.e., a grid of intersecting incisions or cuts through
the thickness of cushion material 56 so as to render it capable of
being split into a plurality of separate and discrete pad segments.
The bottom-most surface of each pad segment 70 is also pressed or
embossed so as to define a plurality of lands 76 that are located
between and separate a plurality of troughs or channels 77 that are
arranged in regular intervals across the bottom surface of floor
section 50. In particular, bottom-most surface of each pad segment
70 is preferably formed by pressing or embossing the bottom-most
surface of so as to compress portions of dividable cushion material
layer 56 to form troughs or channels 77 while maintaining the
portions of dividable cushion material layer 56 adjacent to troughs
or channels 77 at or near to their original thickness so as to
define lands 76. Dividable cushion material layer 56 may
additionally comprise a repositionable, pressure sensitive adhesive
layer 80 substantially similar to repositionable, pressure
sensitive adhesive layer 14b (FIG. 10) that is applied to the
bottom-most surface of each pad segment 70. Depending upon process
conditions, repositionable, pressure sensitive adhesive layer 80
can be applied to the bottom surface of lands 26 as shown in FIGS.
8-24, or it can be applied to the entire bottom surface of cushion
layer 56, including the surface that defines the bottom of channels
77. Repositionable, pressure sensitive adhesive layer 80
advantageously adheres to a sub-floor surface with an initial tack
that holds each pad segment 70 in place after application of a
pressure, but allows for the removal of any one or more of pad
segments 70 from the surface of the sub-floor absent a substantial
diminution of an initial tack (FIGS. 12, 13, 14, and 16).
[0061] Dividable cushion material layer 56 may comprise any one or
a combination of soft, resilient materials including, but not
limited to foamable polymers or foam 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 is foamed or non-foamed
may also be employed. The thickness of dividable cushion material
layer 56 and lands 76 is often about 0.5 mm to 3.0 mm, with those
portions of dividable cushion material layer 56 that define troughs
or channels 77 having an embossed thickness of about 1 mm or
less.
[0062] Repositionable, pressure sensitive adhesive layer 80 is
applied over the bottom-most surface of dividable cushion material
layer 56 and is often curable, and functions as a releasable glue
to hold floor section 50 in place on the sub-floor, while
advantageously allowing floor section 50 (or one or more pad
segments 70) to be removed, repositioned, and relayed onto the
sub-floor. Repositionable, pressure sensitive adhesive layer 80 may
be formed 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
pressure sensitive adhesives that are curable or non-curable as are
well known in the art.
[0063] Floor section 50 may be applied to a sub-floor 85 in the
following manner. Referring to FIGS. 11-24, floor section 50 is
applied to sub-floor 85 by first arranging dividable cushion
material layer 56 in spaced confronting relation to the top surface
of sub-floor 85. Once in this position, floor section 50 is moved
toward the top surface of sub-floor 85 until adhesive layer 80
engages the sub-floor. If sub-floor 85 is uneven, i.e., there are
both depressions 87 (FIGS. 21 and 22) and prominences 90 (FIGS. 23
and 24) within the sub-floor surface to be covered by floor section
50, one or more pad segments 70 may be removed and/or stacked one
atop another so as to compensate for the uneven surface features of
the sub-floor. Of course, pad segments 70 would be removed from
floor section 50 to form a complementary void 92 on its back
surface so as to compensate for a prominence 90 that projects from
the surface of sub-floor 85. Alternatively, pad segments 70 from
the same or any other floor section 50, or as provided separately
packaged, may be applied over top of other pad segments 70 on the
back surface of floor section 50 so as to compensate for
depressions 87 that are formed in the surface of sub-floor 85
(FIGS. 17, 18, 19, and 20).
[0064] More particularly, one or more individual pad segments 70
may be peeled from backing layer 54 (FIGS. 12, 13, and 14) thereby
creating a void 92 defined by the surrounding, remaining pad
segments 70 adjacent to that section of dividable cushion material
layer 56. The number of pad segments 70 to be removed will
correspond to the amount of surface area required to accept
prominence 90 to be compensated for on the surface of sub-floor 85
(FIGS. 23 and 24). In addition, the removed pad segments 70 may be
stacked one atop another so as to build up the thickness in any
region of dividable cushion material layer 56 so as to compensate
for corresponding depressions 87 located on sub-floor 85.
[0065] It is to be understood that the present invention is by no
means limited only to the particular constructions herein disclosed
and shown in the drawings, but also comprises any modifications or
equivalents within the scope of the claims.
* * * * *