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.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

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

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

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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° F. but has tack at about 20 psi at 75° 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.

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.

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.

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

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”.

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.”

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.

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.

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.

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

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:

FIG. 1 is a perspective view of a floor covering without moisture-release channels according to the present invention;

FIG. 2 is a cross-sectional view of a floor covering without moisture-release channels according to the present invention;

FIG. 3 is a perspective view of a floor covering with moisture-release channels according to the present invention;

FIG. 4 is a cross-sectional view of a floor covering with moisture-release channels according to the present invention;

FIG. 5 is a flowchart of one typical production process according to the invention;

FIG. 6 is a perspective view of an alternative embodiment of floor covering formed in accordance with the present invention.

FIG. 7 is a bottom perspective view of the floor covering shown in FIG. 6;

FIG. 8 is a broken-away and enlarged view of a corner portion of the floor covering shown in FIG. 7;

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;

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;

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;

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;

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;

FIG. 15 is a broken-away illustration of a floor covering formed in accordance with the present invention being applied to a sub-floor;

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;

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;

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;

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;

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;

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

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

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.

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.

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”.

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.

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.

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° C., a density of 1.0-1.1 g/cm³, and a curing speed greater than 10 M/min/Lamp (80 Wcm⁻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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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).

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.

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.

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).

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.

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.

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.