U.S. patent application number 13/052499 was filed with the patent office on 2012-09-27 for floating, groutable vinyl floor tile.
Invention is credited to Steven Wilson, Frank Yoo.
Application Number | 20120240502 13/052499 |
Document ID | / |
Family ID | 46876118 |
Filed Date | 2012-09-27 |
United States Patent
Application |
20120240502 |
Kind Code |
A1 |
Wilson; Steven ; et
al. |
September 27, 2012 |
FLOATING, GROUTABLE VINYL FLOOR TILE
Abstract
A vinyl-based floor tile is disclosed for constructing a
floating and groutable floor covering. The vinyl-based floor tile
has a decorative upper surface and a lower surface for support the
floor tile. On one edge of the floor tile is a male coupling member
having a vertical insert and an opposing edge has a female coupling
member that has two or more grooves for accepting the vertical
insert of a male coupling member of an adjacent floor tile. The
grooves determine the width of a grouting channel that is formed
between the edges of the adjacent tiles and a grout-accepting
surface on the top surface of either the male or female coupling
member. The decorative upper surface of the tile can have a
removable protective layer that protects the vinyl tile during the
installation and grouting process.
Inventors: |
Wilson; Steven; (Brampton,
CA) ; Yoo; Frank; (North York, CA) |
Family ID: |
46876118 |
Appl. No.: |
13/052499 |
Filed: |
March 21, 2011 |
Current U.S.
Class: |
52/416 |
Current CPC
Class: |
E04F 2201/01 20130101;
E04F 15/14 20130101; E04F 15/02172 20130101; E04F 2201/07
20130101 |
Class at
Publication: |
52/416 |
International
Class: |
E04F 15/022 20060101
E04F015/022; E04F 15/14 20060101 E04F015/14 |
Claims
1. A vinyl-based floor tile for making a floating and groutable
floor covering, the floor tile comprising: a decorative upper
surface and a lower surface for supporting the floor tile; a first
edge of the floor tile between the decorative upper surface and the
lower surface, the first edge having a male coupling member having
a vertical insert; a second edge of the floor tile between the
decorative upper surface and the lower surface, the second edge
opposite the first edge, the second edge having a female coupling
member extending from the second edge wherein a top surface of at
least one of the male coupling member and the female coupling
member define a grout accepting surface, the female coupling member
defining at least two grooves, wherein at least one of the two
grooves receives the vertical insert from the male coupling member
of an adjacent floor tile thereby forming a grouting channel
between the second edge, the grout accepting surface and the first
edge of the adjacent floor tile, and wherein a width of the
grouting channel between the first edge of the adjacent tile and
second edge is determined by one of the at least two grooves that
receives the vertical insert from the adjacent floor tile.
2. The vinyl-based floor tile of claim 1 wherein the decorative
upper surface has a removable protective layer for protecting the
decorative surface during installation.
3. The vinyl-based floor tile of claim 2 wherein the protective
layer defines a top edge of the grouting channel to allow for
precise placement of grouting material in the grouting channel.
4. The vinyl-based floor tile of claim 1 further comprising a glass
filament layer, wherein the glass filament layer extends into at
least one of the male coupling member and the female coupling
member to provide increased rigidity to the corresponding coupling
member.
5. The vinyl-based floor tile of claim 1 wherein the grouting
channel is configured to receive grouting material to chemically
bond the floor tile with the adjacent floor tile.
6. The vinyl-based floor tile of claim 1 wherein a first groove of
the at least two grooves determines the width of the grouting
channel to be 3 millimeters and a second groove of the at least two
grooves determines the width of the grouting channel to be 5
millimeters.
7. A vinyl-based floor tile for making a floating and groutable
floor covering, the floor tile comprising: a decorative upper
surface and a lower surface for supporting the floor tile; at least
one edge of the floor tile between the decorative upper surface and
the lower surface; and a beveled edge between the at least one edge
and the decorative upper surface, wherein the beveled edge forms a
grout accepting groove when the at least one edge is abutted to an
adjacent floor tile.
8. The vinyl-based floor tile of claim 7 wherein the decorative
upper surface has a removable protective layer for protecting the
decorative surface during installation.
9. The vinyl-based floor tile of claim 8 wherein the protective
layer defines a top edge of the grouting channel to allow for
precise placement of grouting material in the grouting channel.
10. The vinyl-based floor tile of claim 7 wherein the lower surface
has a non-slip backing applied thereon.
11. The vinyl-based floor tile of claim 10 wherein the non-slip
backing is patterned.
Description
FIELD
[0001] The present disclosure relates generally to a vinyl floor
tile. More particularly, the disclosure relates to a floating
luxury vinyl tile floor product that can be grouted.
BACKGROUND
[0002] Groutable vinyl tiles are becoming an increasingly popular
low-cost alternative to real ceramic tiles. A luxury vinyl tile can
have the look and feel of a ceramic tile without the cost and
installation of real ceramic tiles that can be prone to cracking or
chipping. Luxury vinyl tiles are manufactured to have a durable and
decorative surface and can replicate the look of natural stone,
ceramic, marble or concrete. Current groutable vinyl tiles on the
market typically either include a recessed edge around the tile to
form a shallow grout channel or have a rounded edge that requires
spacing the tiles to form the grout channel.
[0003] Currently available vinyl floor tile products rely on using
an adhesive that can be prone to bonding failures due to
temperature and moisture. Many products are required to be fully
glued down to the subfloor by using an adhesive applied to the
subfloor or a pre-applied adhesive backing on the tile. These
products require additional labor and materials, such as floor
patch and adhesive, to adequately prepare the subfloor and install
the tile. Floating vinyl floor tile products (i.e. those not glued
or fastened to the subfloor) do not require as much subfloor
preparation, but floating products also typically rely on using
glue to adhere overlapping edges of the tiles in order to connect
adjacent floor tiles. Since both of these products rely on
adhesive, the floor covering can be prone to damage due to
expansion and contraction from heat and also moisture. Installation
using vinyl flooring adhesive can also be messy and is not
particularly environmentally friendly.
[0004] Although groutable vinyl tiles are a practical alternative
to ceramic, installing and grouting these tiles can prove to be
challenging and labor intensive process. Both the adhesive and
floating vinyl tiles require using a spacer to provide a standard
grout width between all of the tiles. Using a spacer increases the
time required to install the floor since it requires careful
placement of the spacers to maintain a uniform grout channel width
between all of tiles and the spacers must be removed prior to
grouting.
[0005] Applying the grout into the channel is also a difficult and
labor intensive process. It can be difficult to align the grout
into the channel and maintain even grout edges between all of the
tiles. This can be especially challenging for the inexperienced
do-it-yourself installer. Current installation of groutable vinyl
tiles typically requires working with around 15 square feet at a
time to remove excess grout and clean each tile surface. Grouting
material that dries on the vinyl tile surface is a common problem
with groutable vinyl products and produces what is commonly
referred to as a "haze" that diminishes the visual appeal of the
decorative surface of the tile.
SUMMARY
[0006] According to a first aspect, a vinyl-based floor tile is
provided for making a floating and groutable floor covering where
the vinyl-based floor tile joins with an adjacent floor tile to
define one of at least two possible grouting channel widths without
the use of spacers. The floor tile comprises a decorative upper
surface and a lower surface for supporting the floor tile; a first
edge of the floor tile between the decorative upper surface and the
lower surface, the first edge having a male coupling member having
a vertical insert; a second edge of the floor tile between the
decorative upper surface and the lower surface, the second edge
opposite the first edge, the second edge having a female coupling
member extending from the second edge wherein a top surface of at
least one of the male coupling member and the female coupling
member define a grout accepting surface, the female coupling member
defining at least two grooves, wherein at least one of the two
grooves receives the vertical insert from the male coupling member
of an adjacent floor tile thereby forming a grouting channel
between the second edge, the grout accepting surface and the first
edge of the adjacent floor tile, and wherein a width of the
grouting channel between the first edge of the adjacent tile and
second edge is determined by one of the at least two grooves that
receives the vertical insert from the adjacent floor tile.
[0007] According to another aspect, a vinyl-based floor tile is
provided that has a removable protective layer that covers the
decorative surface of the vinyl-based floor tile during
installation. According to yet another aspect, the vinyl-based
floor tile further comprises a glass filament layer, wherein the
glass filament layer extends into at least one of the male coupling
member and the female coupling member to provide increased rigidity
to the corresponding coupling member.
[0008] According to another aspect, a vinyl-based floor tile is
provided for making a floating and groutable floor covering, the
floor tile comprising a decorative upper surface and a lower
surface for supporting the floor tile; at least one edge of the
floor tile between the decorative upper surface and the lower
surface; and a beveled edge between the at least one edge and the
decorative upper surface, wherein the beveled edge forms a grout
accepting groove when the at least one edge is abutted to an
adjacent floor tile.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] For a better understanding of the various embodiments
described herein and to show more clearly how they may be carried
into effect, reference will now be made, by way of example only, to
the accompanying drawings which show at least one exemplary
embodiment, and in which:
[0010] FIG. 1 is a side cross-sectional view of a groutable vinyl
tile 100 according to one embodiment;
[0011] FIG. 2 is a side cross-sectional view of a narrow grouting
channel between adjoining groutable vinyl tiles according to the
embodiment shown in FIG. 1;
[0012] FIG. 3 is a side cross-sectional view of a wide grouting
channel between adjoining groutable vinyl tiles according to the
embodiment shown in FIG. 1;
[0013] FIG. 4 is side cross-sectional view illustrating the
composition of layers of an embodiment of a groutable vinyl
tile;
[0014] FIG. 5 is a top plan view of a groutable vinyl tile
according to the embodiment shown in FIG. 1;
[0015] FIG. 6 is a side cross-sectional view of an adjoining
groutable vinyl tile according to an alternative embodiment;
[0016] FIG. 7 is a side cross-sectional view of adjoining groutable
vinyl tile according to another alternative embodiment having a
fixed grout width;
[0017] FIG. 8 is a side cross-sectional view of adjoining groutable
vinyl tile according to another alternative embodiment having a
variable grout width illustrating a narrow grouting channel;
[0018] FIG. 9 is a side cross-sectional view of adjoining groutable
vinyl tile according to the embodiment of FIG. 8 illustrating a
wide grouting channel;
[0019] FIG. 10 is a side cross-sectional view of groutable vinyl
tile having beveled top edges that define the grouting channel
according to another embodiment
[0020] FIG. 11 is a side cross-sectional view of abutting groutable
vinyl tile having beveled top edges that define the grouting
channel.
DESCRIPTION OF VARIOUS EMBODIMENTS
[0021] It will be appreciated that for simplicity and clarity of
illustration, where considered appropriate, numerous specific
details are set forth in order to provide a thorough understanding
of the exemplary embodiments described herein. However, it will be
understood by those of ordinary skill in the art that the
embodiments described herein may be practiced without these
specific details. In other instances, well-known methods,
procedures and components have not been described in detail so as
not to obscure the embodiments described herein. Furthermore, this
description is not to be considered as limiting the scope of the
embodiments described herein in any way, but rather as merely
describing the implementations of various embodiments described
herein.
[0022] The term vinyl tile or vinyl-based tile is used herein to
refer to any resilient floor tile product that may be composed, at
least partially, of vinyl, such as PVC for example, or other
thermoplastic resins.
[0023] Reference is first made to FIG. 1, shown is a side
cross-sectional view of a groutable vinyl tile 100 according to one
embodiment. Vinyl tile 100 has a decorative upper surface 2 that is
wear resistant and decorative to imitate ceramic, stone, marble or
other material. Vinyl tile 100 also has a lower surface 4 for
supporting vinyl tile 100 on a sub-floor. Vinyl tile 100 is
designed as a floating floor such that lower surface 4 supports the
vinyl tile on the subfloor without the use of adhesive or nails.
Floating floors are typically faster, cheaper and easier to install
since they do not require extensive subfloor preparation or need to
be adhered to the subfloor.
[0024] Vinyl tile 100 has edge 6 between the lower surface 4 and
decorative upper surface that has a male coupling member 8 for
joining with female coupling member 10 on opposing edge 8 of an
adjacent vinyl tile 100. Male coupling member 8 has vertical insert
12 for mating with one of two grooves 14 and 16. Vertical insert 12
can be shaped to interlock with grooves 14 and 16 using methods
known in the art. For example, vertical insert 12 can form a
pressure fit within grooves 14 and 16 or vertical insert 12 can be
shaped to have a locking protrusion that mates with a projection
within grooves 14 and 16. The corners 7 and 9 between edges 5 and 6
can be rounded off, as shown in FIG. 1, or in alternative
embodiments, corners 7 and 9 can be chamfered.
[0025] The upper surface of female coupling member 10 has a
grout-accepting surface 18, that along with edges 6 and 8 form
grouting channel 20 when joining with an adjacent flooring tile. In
other embodiments grout-accepting surface 18 can be on the male
coupling member, such as, for example, the vinyl floor tile
embodiment shown in FIG. 6. Grout-accepting surface 18 and edges 6
and 8 can be manufactured to improve bonding with grouting material
to strengthen the chemical bond between vinyl floor tile 100 and
grouting material. For example, these surfaces may be textured to
improve bonding with grouting material.
[0026] Removable protective layer 3 can also cover decorative upper
surface 2. Removable protective layer 3 can be a waterproof plastic
sheet that is applied to vinyl tile 100 during manufacturing. When
applying grout to vinyl tile 100, removable protective layer 3
prevents grout from drying directly on decorative upper surface 2
to prevent damage to decorative upper surface 2, such as, for
example, creating a haze on decorative upper surface 2. Edges 3a
and 3b of removable protective layer 3 can also provide a top edge
for grouting channel 20 that will provide a uniform straight line,
aligned with edges of vinyl tile 100 to simplify application of
grouting material to grouting channel 20. After installation and
grouting of vinyl tile 100, removable protective layer 3 can be
removed.
[0027] Vinyl tile 100 can include glass filament layer 22 that can
be used to provide increased strength and rigidity to either male
coupling member 8 or female coupling member 10. As shown in FIG. 1,
male coupling member 8 is thinner than other portions of vinyl tile
100 but includes glass filament layer 22 to provide strength to
what would otherwise be a thinner and weaker portion of vinyl tile
100 that would be susceptible to breaking. Glass filament layer 22
also helps reduce the amount of expansion and contraction of vinyl
tile 100 that is a common cause of bonding and separation issues
with many existing vinyl products.
[0028] Reference is next made to FIG. 2, shown is a side
cross-sectional view of a narrow grouting channel 20 between
adjoining groutable vinyl tiles according to the embodiment shown
in FIG. 1. Grouting channel 20 shown in FIG. 1 has a 3 millimeter
grout width that is determined by vertical insert 12 mating with
groove 14 of female coupling member 10. Mating of vertical insert
12 with groove 14 mechanically bonds an adjacent floor tile without
the use of an adhesive, improving the ease and speed at which vinyl
tile 100 can be installed compared to other vinyl floor products.
Since groove 14 determines the width of grouting channel 20, there
is no need to use spacers to fix the size of the grouting
channel.
[0029] After vinyl tile 100 has been mechanically connected in the
installation process, grouting material 22 is then applied into
grouting channel 20 to provide an appearance similar to grouted
ceramic tiles. Grouting material 22 can also be used to form a
chemical bond between adjacent vinyl tiles 100 that strengthens the
mechanical bond formed between vertical insert 12 and one of
grooves 14 and 16. Grouting material 22 can vary depending on the
application and can be an epoxy, acrylic, urethane, Portland cement
or latex based grouting material specifically for use with
groutable vinyl tile. Use of both mechanical bonding and chemical
bonding provides a stronger bond between adjacent vinyl tiles than
existing vinyl products that mainly rely on adhesive. Using
mechanical bonding to lay the floor is faster and more cost
efficient since no adhesive is required. Combining the mechanical
bonding with chemical bonding using grouting material 22 increases
the strength between adjacent floor tiles reducing failures, such
as separation between vinyl tiles and cracking of grouting
material.
[0030] Reference is next made to FIG. 3, shown is a side
cross-sectional view of adjoining groutable vinyl tiles according
to the embodiment shown in FIG. 1. Grouting channel 20 shown in
FIG. 3 has a 5 millimeter grout width that is determined by
vertical insert 12 mating with groove 16 of female coupling member
10. FIGS. 2 and 3 illustrate that variable grout widths of grouting
channel 20 can be achieved based on which groove 14, 16 mates with
vertical insert 12. Other embodiments could design female coupling
member to include more than two grooves to provide multiple grout
widths. Grout widths of 3 mm and 5 mm are provided as examples and
any width or combination of widths can be designed by varying the
position and width of grooves on female coupling member 10.
[0031] Reference is next made to FIG. 4, shown is side
cross-sectional view illustrating the composition of layers of an
embodiment of a groutable vinyl tile 400. As described above,
decorative upper surface 2 can be covered by removable protective
layer 3 that can be removed after installation to protect
decorative upper surface 2 during installation. The top layer of
vinyl tile 400 that is exposed to foot traffic is top coat layer 24
that can be made from, but is not limited to, polyurethane,
aluminum oxide or ceramic to form a protective clear film layer for
durability and protection against rips, tears and gouges. Below top
coat layer 24 is wear layer 26 that provides a clear layer that
makes vinyl tile 400 easy to clean and resist scratches and scuffs.
Wear layer 26 can be made from urethane or enhanced urethane
products as is known in the art. A thicker wear layer 26 provides
greater resistance to scratches and scarring.
[0032] Print film layer 28 is below wear layer 26 and provides the
design of vinyl tile 400. Print film layer 28 provides the pattern,
color and style to replicate tile, stone or marble. A rotogravure
printing process, among others, can be used to produce print film
layer 28. Next, silencing layer 30 is disposed below print film
layer 28 and is typically composed of a cushioned vinyl foam that
dampens sounds, provides cushioning and indentation recovery.
[0033] The next layer below silencing layer 30 is glass filament
layer 22 that provides strength to vinyl tile 400 to minimize
contraction and expansion while still maintaining some flexibility
to ease the installation process. Minimizing contraction and
expansion also helps to prevent cracking or separation of grout
between vinyl tiles and separation of the tiles themselves. Glass
filament layer 22 also provides increased rigidity to coupling
members 8, 10 that would otherwise be weak and prone to damage.
Glass filament layer 22 typically includes a matrix of fine glass
fibers.
[0034] Below glass filament layer 22 is core sheet 32 that helps
provide vinyl tile 400 with structure and strength. The bottom-most
layer is balance layer 34 that supports vinyl tile 400 on a
subfloor to allow vinyl tile 400 to float on the subfloor (i.e. not
adhered with adhesive or nails). Both core sheet 32 and balance
layer 34 are typically composed of PVC.
[0035] Dimensions of an exemplary embodiment of vinyl tile 400 can
include a wear layer with a thickness between 0.01 mm and 1 mm, a
silencing layer with a thickness of approximately 1 mm, and a core
sheet 32 and balance layer 34 with a combined thickness of
approximately 2.75 mm. These dimensions are provided as examples
and can be varied as is known in the art. Use of glass filament
layer allows for thinner and lighter construction of vinyl tile 400
resulting in a thickness typically between 3 mm to 6 mm.
Alternative tile constructions can also mount the vinyl tile to a
MDF or HDF backer board similar to a laminate construction. The
thickness of the backer board can be 6 to 15 mm with an attached
vinyl tile of between 2 mm and 6 mm.
[0036] Reference is next made to FIG. 5, shown is a top plan view
of a groutable vinyl tile 500 according to the embodiment shown in
FIG. 1. Groutable vinyl tile 500 is shown having two edges 5a and
5b having female coupling members and two edges 6a and 6b having
male coupling members. Alternative embodiments may have only a
single male and female coupling member on opposing edges of the
tile. Other embodiments may only include the coupling members on
portion of the edge of the tile rather than over the entire edge as
is shown in FIG. 5.
[0037] Reference is next made to FIG. 6, shown is a side
cross-sectional view of an adjoining groutable vinyl tile 600
according to an alternative embodiment. Groutable vinyl tile 600 is
a variant where the upper surface of male coupling member 8 has
grout-accepting surface 18 and an upwardly oriented vertical insert
12. Female coupling member 10 has downward opening grooves 14, 16
for accepting vertical insert 12 to form grouting channel 20.
[0038] Reference is next made to FIG. 7, shown is a side
cross-sectional view of adjoining groutable vinyl tile 700
according to another alternative embodiment having a fixed grout
width. Male coupling member 8 is supported on the subfloor and has
an upward facing vertical insert 12 for coupling with groove 14 of
female coupling member 10. Male coupling member 8 can be comprised
of the core sheet 32 and balance layer 34. Female coupling member
10 has an upper insert 40 extending from edge 5 that mates with an
insert-accepting groove 42 in edge 6. The upper surface of upper
insert 40 has a grout-accepting surface 18 that forms the lower
surface of grouting channel 20. Upper insert 40 preferably is
formed from a layer of vinyl tile 600 containing glass filament
layer 22 to provide strength and rigidity to upper insert 40.
[0039] Upper insert 40 can have a chamfered edge 44 between the
lower edge 46 and extending edge 48 of upper insert 40.
Insert-accepting groove 42 can also have a mating chamfered edge 50
so that upper insert 40 can be inserted at a downward angle during
the installation process. Similarly, vertical insert 12 can have
chamfered edge 52 to allow angled insertion with chamfered edge 54
of groove 14. In other embodiments the chamfered edges can instead
be rounded to ease with installation or manufacture of vinyl tile
700.
[0040] Reference is next made to FIG. 8, shown is a side
cross-sectional view of adjoining groutable vinyl tile 800
according to another alternative embodiment having a variable grout
width. Groutable vinyl tile 800 is similar to the fixed grout width
tile shown in FIG. 7 but female coupling member 10 has grooves 14
and 16 that can accept vertical insert 12 from male coupling member
8 to determine the width of grouting channel 20. FIG. 8 illustrates
the narrow grouting channel 20 width by mating vertical insert 12
with groove 16 whereas FIG. 9 illustrates the wide grouting channel
20 width by mating vertical insert 12 with groove 14.
[0041] Reference is next made to FIG. 10, shown is a side
cross-sectional view of groutable vinyl tile 1000 having beveled
edges 1007, 1009 defining grouting channel 20 according to another
embodiment. Vinyl tile 1000 has a decorative upper surface 1002
that can be covered by removable protective layer 1003 to protect
decorative upper surface 1002 from damage during installation and
grouting, and when installation and grouting are complete removable
protective layer 3 can be removed. Lower surface 1004 supports
vinyl tile 1000 on a sub-floor and can have a non-slip backing
1005. Using non-slip backing 1005 allows vinyl tile 1000 to float
on the subfloor but still prevents vinyl tile 1000 from shifting
during installation and grouting or from heavy foot traffic after
vinyl tile 1000 is installed. Non-slip backing 1005 can be composed
of a high friction material, such as, for example, rubber or
plastic, and can be patterned to increase friction with the
subfloor.
[0042] Reference is next made to FIG. 11, shown is a side
cross-sectional view of groutable vinyl tile 1000 shown in FIG. 10
abutting with an adjacent groutable vinyl tile 1000. Opposing edges
1006 and 1008 between decorative upper surface 1002 and lower
surface 1004 have top beveled edge portions 1007 and 1009,
respectively. Beveled edge portions 1007, 1009 form a grouting
channel 1020 when abutted to an adjacent vinyl tile 1000. Since
abutting tiles form grouting channel 1020, there is no need for
using spacers to determine the grout size, thus simplifying the
installation of vinyl tile 1000. Application of grouting material
1022 can also provide a chemical bond between adjacent vinyl tiles
1000.
[0043] The width of grouting channel 1020 can be determined during
manufacture of vinyl tile 1000 by varying the degree of beveling of
top edges 1007 and 1009. Similarly, the depth of grouting channel
1020 can also be varied to provide more or less surface area for
bonding with grouting material 1022 to achieve the required
strength. The surface of top edges 1007 and 1009 can also be
treated or patterned during the manufacturing process to increase
bonding with grouting material 1022.
[0044] Removable protective layer 1003 has edges 1003a and 1003b
that also help define a top edge for grouting channel 1020 that can
provide a uniform straight line, aligned with edges of vinyl tile
1000 to simplify application of grouting material to grouting
channel 20. After installation and grouting of vinyl tile 1000,
removable protective layer 3 can be removed.
[0045] While the exemplary embodiments have been described herein,
it is to be understood that the invention is not limited to the
disclosed embodiments. The invention is intended to cover various
modifications and equivalent arrangements included within the scope
of the appended claims, and scope of the claims is to be accorded
an interpretation that encompasses all such modifications and
equivalent structures and functions.
* * * * *