Abstract
The invention relates to a tile, in particular a carpet tile. The invention also relates to the use a tile according to the invention as floor tile, wall tile, or ceiling tile. The invention further relates to a tile covering consisting of a plurality of tiles according to the invention. The invention additionally relates to a carpet covering consisting of at least one carpet tile according to the invention.
Claims
1. A tile, in particular a carpet tile, comprising: a base, preferably a primary carpet base having pile yarns projecting upwardly therefrom, a backing structure attached to a lower side of said base, preferably said primary carpet base, said backing structure comprising an elastic layer, made from an anisotropic material, defining a lower surface of the tile, wherein a plurality of superficial suction holes is formed in at least a lower surface of said elastic layer, wherein the superficial suction holes are open in a direction facing away from the base and substantially closed in a direction facing the base, wherein the superficial suction holes together define a void footprint, wherein material at the lower surface of the elastic layer in between said superficial suction holes define a material footprint, wherein the ratio between the void footprint and the material footprint is at least 4, preferably at least 5, more preferably at least 6, thereby allowing the tile to be quickly attached to a support surface and removed therefrom.
2. The tile according to claim 1, wherein the substantially entire lower surface of the elastic layer is provided with suction holes.
3. The tile according to claim 1, wherein the size of the suction holes varies throughout the entire lower surface of the elastic layer.
4. The tile according to claim 1, wherein the elastic layer is made from a foam material.
5. The tile according to claim 1, wherein the elastic layer comprises a foaming agent.
6. The tile according to claim 1, wherein the elastic layer is at least partially composed of at least one material selected from the group consisting of: ethylene vinyl acetate (EVA), polyurethane (PU), polyethylene (PE), polypropylene (PP), polystyrene (PS), poly vinyl chloride (PVC), rubber, or mixtures thereof.
7. The tile according to claim 1, wherein the elastic layer comprises at least one cross-linking agent.
8. The tile according to claim 1, wherein the elastic layer comprises a filler, in particular, talc, chalk, wood, and/or calcium carbonate.
9. The tile according to claim 1, wherein a number or substantially all of the suction holes have a diameter situated in between 5 m to approximately 1 mm, preferably in between 10 m and 500 m.
10. The tile according to claim 1, wherein the density of the elastic layer varies along the thickness of the elastic layer.
11. The tile according to claim 1, wherein the elastic layer has a thickness situated in between 0.1 and 6 mm.
12. The tile according to claim 1, wherein each of the suction holes, and preferably the entire lower surface of the elastic layer, is free of glue.
13. The tile according to claim 1, wherein the lower surface of the elastic layer has a sealing effect, preferably an air-tight sealing effect.
14. The tile according to claim 1, wherein a lower surface of the elastic layer is provided with a sealing coating, preferably an air-tight sealing coating.
15. The tile according to claim 1, wherein initially, before use, a removable protective film is attached to the lower surface of the elastic layer.
16. The tile according to claim 1, wherein the backing structure comprises a pre-coat layer disposed on the primary carpet base, and at least one, preferably solventless, hot melt adhesive layer disposed on the pre-coat.
17. (canceled)
18. The tile according to claim 1, wherein the tile comprises a thermoplastic material securing said primary carpet base to said backing structure, wherein said thermoplastic material is preferably provided with at least one stabilizing material embedded therein.
19. The tile according to claim 1, wherein the primary carpet base comprises a fibrous face wear surface secured to a primary backing sheet, wherein the primary backing sheet preferably has a fibrous back surface.
20-25. (canceled)
26. The tile according to claim 1, wherein the backing structure comprises at least one intermediate layer, preferably a substrate layer, situated in between the base and the elastic layer, wherein the intermediate layer either rigid or flexible, and wherein said intermediate layer comprises at least one material of the group of materials consisting of: wood, in particular MDF or HDF; a polymer, in particular PVC, PE, PP, or PU; mineral, or mixtures thereof.
27-28. (canceled)
29. The tile according to claim 1, wherein the tile comprises at least one pair of opposite tile edges, wherein said pair of opposite tile edges is provided with a pair of complementary coupling parts allowing a plurality of such tiles to be connected.
30. The tile according to claim 29, wherein the complementary coupling parts are configured to couple at least two tiles, such that a locking of the tiles in a first direction, perpendicular to a plane of the tile, and also a locking of the tiles in a second direction, parallel to the plane of the panel, is realized.
31-34. (canceled)
35. The tile according to claim 1, wherein the base comprises a decorative layer and a transparent wear layer covering said decorative layer.
36-37. (canceled)
38. The tile according to claim 1, wherein the superficial suction holes are substantially hemispherically shaped.
39. The tile according to claim 1, wherein elastic layer material defining said superficial suction holes is provided with an impermeable coating.
40. The tile according to claim 1, wherein elastic layer material comprises a plurality of interconnected, open cells.
41. (canceled)
42. A tile covering consisting of a plurality of tiles according to claim 1.
43. The tile covering according to claim 42, wherein the tiles are mutually coupled.
44. (canceled)
Description
[0087] The invention will be elucidated on the basis of non-limitative exemplary embodiments shown in the following figures. Herein:
[0088] FIG. 1 shows a cross-sectional view of a first possible embodiment of a tile according to the invention;
[0089] FIG. 2 shows a cross-sectional view of a second possible embodiment of a tile according to the invention;
[0090] FIG. 3 shows a third possible embodiment of a tile according to the invention;
[0091] FIG. 4 is a cross-sectional view indicated by section A-A in FIG. 3; and
[0092] FIG. 5 is a cross-sectional view indicated by section B-B in FIG. 3.
[0093] FIG. 1 shows a tile (101), in particular a carpet tile (101), comprising a base (102) and a backing structure (103) attached to a lower side of said base (102). The base (102) of the shown embodiment is a primary carpet base (102) having pile yarns (104) projecting upwardly therefrom. The pile yarns (104) shown consist of loop piles (104). It is however also possible that the pile yarns (104) consist of cut piles, twisted piles or any other suitable pile yarns in for example a level- or multilevel configuration. The loop piles (104) are possibly synthetic yarns, such as nylon, polyester, polypropylene, acrylic or blends thereof. In the shown embodiment, the loop piles (104) are tufted in the primary carpet base (102). The primary carpet base (102) comprises a primary backing sheet (105), which can for example be a non-woven sheet, a woven sheet, a non-woven polyester sheet, a polypropylene sheet, a glass fibre scrim or tissue sheet or combinations thereof. To bond the tufts in position on the base (102), and in particular on the primary backing sheet (105), a pre-coat layer (106) is applied. This pre-coat layer (106) can for example be a latex layer (106). This pre-coat layer (106) can possibly form part of the backing structure (103). The backing structure (103) comprises an elastic layer (107). The elastic layer (107) defines a lower surface of the tile (101). The elastic layer (107) comprises a plurality of suction holes (108), which are merely schematically shown in the figures. The suction holes (108) can have air or a gas trapped inside. The suction holes (108) provided at the lower surface of the elastic layer (107) are referred to as superficial suction holes (108), which enable the elastic layer (107) to be quickly attached to a support surface (not shown) and removed therefrom. In the shown embodiment is the entire elastic layer (107) provided with suction holes (108) in a random configuration. It is also possible that the elastic layer (107) comprises suction holes (108) forming a uniform pattern. It is however also possible that only a lower surface of the elastic layer (107) is provided with suction holes (108). The size of the suction holes (108) varies in the shown embodiment throughout the entire elastic layer (107). The diameter size of a number of suction holes (108) is for example situated between 5 m to approximately 1 mm. The diameter of a number of suction holes (108) is for example in between 10 m and 500 m. The elastic layer (107) has for example a thickness situated between 0.1 and 6 mm. The elastic layer (107) may have a uniform density, however it is also possible that the density of the elastic layer varies along the thickness of the elastic layer (107). In the shown embodiment is the elastic layer (107) made of a foam material and/or comprise a foaming agent. The lower surface of the elastic layer (107) has an air-tight sealing effect. The tile (101) comprises, in the shown embodiment, a removable protective film (109) which is attached to the lower surface of the elastic layer (107). The protective film (109) is for example a peel-off layer (109) and is removed before or during use of the tile (101) such that the suction holes (108) are exposed. The backing structure (103) furthermore comprises an adhesive layer (110). This adhesive layer (110) is for example a solventless, hot melt adhesive layer (110) disposed on the pre-coat layer (106). Such hot melt adhesive (110) preferably comprises at least one material selected from the group consisting of: bitumen, petroleum resin composition. Preferably, the surface area ratio between the void footprint defined by the (empty surface area of the) superficial suction holes, and the material footprint defined by the (non-empty) material fraction at the lower surface of the elastic layer (107) is at least 4, preferably at least 5, more preferably at least 6, thereby allowing the tile to be quickly and relatively firmly attached to a support surface, while easy removal of the tile from said support surface is maintained.
[0094] FIG. 2 shows a tile (201), in particular a carpet tile (201), comprising a base (202) or primary carpet base (202) having pile yarns (204) projecting upwardly therefrom. The carpet tile (201) furthermore comprises a backing structure (203) attached to a lower side of said primary carpet base (202). The backing structure (203) comprises an elastic layer (207) defining a lower surface of the tile (201), wherein a plurality of suction holes (208) is formed allowing the tile to be quickly attached to a support surface (not shown) and removed therefrom. The suction holes (208) are randomly positioned and the size of the suction holes (208) varies throughout the entire lower surface of the elastic layer (207). The elastic layer (207) is made from a foam material, and can possibly comprise a foaming agent. Non-limited examples of the materials whereof the elastic layer (207) can be composed are ethylene vinyl acetate (EVA), polyurethane (PU), polyethylene (PE), polypropylene (PP), polystyrene (PS), poly vinyl chloride (PVC), rubber, or mixtures thereof. The elastic layer (207) may furthermore comprises a cross-linking agent and/or a filler, such as talc, chalk, wood, and/or calcium carbonate. Each of the suction holes (208) can however be free of glue. The pile yarns (204) shown in this embodiment consist of cut pile yarns (204). The cut pile yarns (204) can for example comprise nylon or other suitable material implemented in a PVC or hot-melt adhesive (206) which is laminated to a primary backing sheet (205), which can also be referred to as reinforcement layer (205). The primary backing sheet (205) comprises for example a woven or non-woven material. The hot melt adhesive (206) can for example comprise a bitumen and/or petroleum resin composition. The primary carpet base (202) can possibly furthermore comprise a fibrous face wear surface secured to the primary backing sheet (205), wherein the primary backing sheet (205) preferably has a fibrous back surface. The backing structure (203) comprises furthermore an intermediate layer (211), situated in between the base (202) and the elastic layer (203). The intermediate layer (211) is either rigid or flexible, and comprises at least one material of the group of materials consisting of: wood, in particular MDF or HDF; a polymer, in particular PVC, PE, PP, or PU; mineral, or mixtures thereof. The tile (201) can also possibly comprise a protective layer (not shown), for example as shown in FIG. 1.
[0095] FIG. 3 shows a tile (301), in particular a panel (301), more in particular a floor panel (301) or wall panel (301) according to the invention. The tile (301) is interconnectable with similar tiles (301) for forming a floor covering. The tile (301) comprises a base (302) and a backing structure (303) attached to a lower side of said base (302). The backing structure (303) comprises an elastic layer (307) defining a lower surface of the tile (301), wherein a plurality of suction holes (308) is formed in said elastic layer (307) allowing the tile (301) to be quickly attached to a support surface (not shown) and removed therefrom. Furthermore, the tile (301), and in particular the backing structure (303), comprises an intermediate layer (311), preferably a substrate layer (311), situated in between the base (302) and the elastic layer (303). The intermediate layer (311) is either rigid or flexible, and comprises at least one material of the group of materials consisting of: wood, in particular MDF or HDF; a polymer, in particular PVC, PE, PP, or PU; mineral, or mixtures thereof. The thickness of the intermediate layer (311) is for example at least 3 millimetre. The base (302) may comprise a top structure comprising a decorative layer, which may be printed onto the base layer, on top of which a protective layer may be applied. The base (302) can for example be a primary carpet base having pile yarns projecting upwardly therefrom, for example as shown in FIGS. 1 and 2. The intermediate layer (311) comprises a centrally located core (312) provided with an upper side (313) and a lower side (314). The core (312) is integrally connected with a first pair of opposite edges, in particular a first edge (315) and a complementary second edge (316), located at the long lateral sides of the tile (301). The core (312) is also integrally connected with a second pair of opposite edges, in particular a third edge (317) and a complementary fourth edge (318), located at the short sides of the tile (301) in this exemplary embodiment. A benefit of the presence of the intermediate layer (311) as shown in FIG. 3 is that mutual locking of adjacent tiles (301) is enabled. Locking of adjacent tiles (301) in a first direction, perpendicular to a plane of the tile (301), and also a locking of the tiles (301) in a second direction, parallel to the plane of the tile (301), can herewith be realized. Furthermore, the change of curling or disfiguring of tiles (301) is reduced. The shown tile (301) has a rectangular shape. It is, however also possible that the tile (301) comprises a square, pentagonal, hexagonal or octagonal shape. The tile (301) may possibly comprise a protective film such as a peel-off layer (not shown), which can be removed before or during use of the tile (301) such that the suction holes (308) are exposed. An example of such protective film is shown in FIG. 1.
[0096] FIG. 4 is a cross-sectional view indicated by section A-A in FIG. 3. In this cross-section, the shape of the complementary first edge (315) and second (316) edge are shown in detail. The first edge (315) comprises a sideward tongue (329) which is integrally connected to the core (312). By means of the vertical dashed line the border between the sideward tongue (329) and the core (312) is visualised. A front region (329A) of the sideward tongue (329) is provided with a rounded bottom surface (320). An outer end of the rounded bottom surface (320) adjoins an inclined locking surface (321). An opposite end of the rounded bottom surface (320) adjoins a bearing surface (322) making part of a back region (329B) of the sideward tongue (329). The second edge (316) of the intermediate layer (311) comprises an upper lip (323) and a lower lip (324) defining a recess (325). Both lips (323, 324) are integrally connected to the core (312). By means of the vertical dashed line the border between the lips (323, 324) and the core (312) is visualised. As shown in FIG. 3, the width of the upper lip (323) is substantially smaller than the width of the lower lip (324). The recess (325) has a shape which is complementary to the shape of the sideward tongue (329). More in particular, a top surface (326) of a back region (324a) of the lower lip (324) has a (complementary) rounded shape, configured to co-act with the rounded front region (329a) of the sideward tongue (329), while a front region (324b) of the lower lip (324) is provided with a upwardly protruding shoulder (327), configured to co-act with the bearing surface (322) of the sideward tongue (329). A lower surface (328) of the upper lip (323) is inclined and corresponds to the locking surface (321) of the sideward tongue (329). Locking at the first edge (315) and the second edge (316) of adjacent tiles (301) by insertion of the sideward tongue (329) of a tile (301) to be coupled into the recess (325), wherein said tile (301) is initially held in an inclined position. After insertion of the sideward tongue (329) into the recess, the tile (301) to be coupled will be pivoted (angled) in downward direction about an axis parallel to the first edge (315) until both tiles (301) are positioned in the samecommonly horizontalplane, wherein the locking surface (321) of the sideward tongue (329) will engage the locking surface of the upper lip (328), and wherein at least a bottom front part is accommodated substantially form-fittingly in the recess (325), and wherein the bearing surface (322) is supported by the shoulder (327). Locking at the first edge (315) and the second edge (316) leads to locking of the connected tiles (301) in both horizontal direction and vertical direction. The angling down locking principle of the first and second edges (315, 316) is a relatively easy locking principle which facilitates mutual coupling of tiles at these edges (315, 316) tremendously.
[0097] FIG. 5 is a cross-sectional view indicated by section B-B in FIG. 3. In this cross-section, the shape of the complementary third edge (317) and second (318) edge are shown in detail. The third edge (317) comprises an upward tongue (339), an upward flank (330) and an upward groove (331) formed between upward tongue (339) and upward flank (330). The upward tongue (339) is connected to the core (312) by means of a bridge (332), which is preferably resilient to some extent. A side (339a) of upward tongue (339) facing toward upward flank (330) extends in the direction of the normal N1 of the upper side (313) of the core (312). The tangent R1 and the normal N1 of the upper side (313) of the core (312) are thus directed toward each other (converging orientation), wherein the angle enclosed by R1 and N1 is preferably between 0 and 10 degrees in this exemplary embodiment. Due to the converging orientation of the upward flank (330) and the side (339a) of the upward tongue (339) facing toward to the upward flank (330), the upward groove is a closed groove, which is only accessible to a complementary counterpart by deformation of the upward tongue (339) and/or bridge (332). Another side (339b) of upward tongue (339) facing toward upward flank (330) forms an aligning edge enabling facilitated realization of a coupling to an adjacent tile (301). As shown, this side (339b) functioning as aligning edge is directed away from the normal N1 of upper side (313) of the core (312). An upper side (339dd of upward tongue (339) does however extend in the direction of the normal N1 of the upper side (313) of the core (312), and runs inclining downward in the direction of the side (339e) of upward tongue (339) facing away from upward flank (330). This chamfering provides the option of giving the complementary fourth edge (318) a more robust and therefore stronger form. A part of the side (339e) of upward tongue (339) facing away from upward flank (330) is oriented substantially vertically and is moreover provided with an outward bulge (333). A lower part (330a) of upward flank (330) is oriented diagonally, while an upper part (330b) of upward flank (330) is shown to be substantially vertical and forms a stop surface for fourth edge (318). In between the inclined part (330a) and the substantially vertical part (330b) of the upward flank an additional coupling element, in particular an additional bulge (334), is provided. A lower wall part (331a) of upward groove (331) is oriented substantially horizontally in this exemplary embodiment. The fourth edge (318) is substantially complementary to third edge (317). The fourth edge (318) comprises a downward tongue (345), a downward flank (346) and a downward groove (347) formed in between downward tongue (345) and downward flank (346). The downward tongue (345) is connected to the core (312) by means of a bridge (348), which is preferably resilient to some extent. A side (345a) of downward tongue (345) facing toward downward flank (346) lies in the direction of the normal N2 of the lower side (413) of the core (312). This means that a tangent R2 of side (345a) of downward tongue (345) and the normal of the lower side (314) of the core (312) are mutually converging, wherein the angle enclosed by R2 and N2 is preferably between 0 and 10 degrees in this exemplary embodiment. More preferably, the inclination of R1 is identical to the inclination of R2; hence, R1 and R2 are preferably parallel. Due to the converging orientation of the downward flank (346) and the side (345a) of the downward tongue (345) facing toward to the downward flank (346), the downward groove (347) is a closed groove, which is only accessible for the upward tongue (339) of an adjacent tile (301) by deformation of the downward tongue (345) and/or bridge (348), as a result of which the entrance of the downward groove can be widened (temporary). A side (345b) of the downward tongue (345) facing away from downward flank (346) is diagonally oriented, but has a flatter orientation than the complementary side (330a) of upward flank (330), whereby a gap (air space) will be formed in the coupled position, which will generally facilitate coupling between two tiles (301). The inclining side (345b) of downward tongue (345) also functions as aligning edge for the purpose of further facilitating coupling between two tiles (301). Another side (345c) facing away from downward flank (346) takes a substantially vertical form, though is provided with a small cavity (349) configured to co-act with the additional bulge (334) of another tile (301). A top part of the side (345c) facing away from downward flank (346) forms a complementary stop surface for stop surface (330b) of upward flank (330) (of an adjacent tile). Downward flank (346) is oriented substantially vertically and is provided with a recess (340) adapted to receive the outward bulge (333) of the upward tongue (339) (of an adjacent tile).
[0098] The above-described inventive concepts are illustrated by several illustrative embodiments. It is conceivable that individual inventive concepts may be applied without, in so doing, also applying other details of the described example. It is not necessary to elaborate on examples of all conceivable combinations of the above-described inventive concepts, as a person skilled in the art will understand numerous inventive concepts can be (re)combined in order to arrive at a specific application.
[0099] It will be apparent that the invention is not limited to the working examples shown and described herein, but that numerous variants are possible within the scope of the attached claims that will be obvious to a person skilled in the art.
[0100] The verb comprise and conjugations thereof used in this patent publication are understood to mean not only comprise, but are also understood to mean the phrases contain, substantially consist of, formed by and conjugations thereof.
