Abstract
Carpet tile which includes a base layer having a top side and a bottom side, wherein preferably pile yarns are provided on the top side of the base layer, and a backing layer fixedly connected to the bottom side of the base layer. The backing layer constitutes a bottom surface of the carpet tile, wherein on the bottom surface of the carpet tile an adhesive is applied, and wherein the adhesive imparts adhesive properties to the bottom surface which are sufficient to allow the bottom surface to be attached to a suitable support surface, as well as to be detached from the same support surface onto which it has been attached previously.
Claims
1-46. (canceled)
47. A tile, in particular a carpet tile, comprising: a base layer having a top side and a bottom side, wherein pile yarns are provided on at least a part of the top side of the base layer, and at least one adhesive layer, affixed, either directly or indirectly, to the bottom side of the base layer, wherein the adhesive layer defines at least a part of a bottom surface of the tile, wherein the adhesive layer imparts adhesive properties sufficient to allow the tile to be releasably attached to a suitable support surface, wherein the adhesive layer covers the substantially entire bottom side of the base layer, wherein a bottom side of the adhesive layer forms an even surface.
48. The tile according to claim 47, wherein the adhesive of the adhesive layer is present on edges and/or corners of the bottom surface of the tile, and preferably on at least 50% of the total bottom surface of the tile.
49. The tile according to claim 47, wherein the adhesive of the adhesive layer is a pressure sensitive adhesive (PSA), preferably of a detachable type.
50. The tile according to claim 47, wherein the tile has two, preferably opposite, side edges which are respectively provided with interconnecting profiles such as a tongue and a groove profile, wherein preferably the profiles are an integral part of the backing layer material, and/or of an intermediate core layer when such is included in the carpet tile.
51. The tile according to claim 47, wherein a removable protective film is attached onto the adhesive layer on the bottom surface of the carpet tile and/or on the bottom side of the adhesive layer.
52. The tile according to claim 47, wherein the base layer comprises a decorative layer and optionally at least one transparent wear layer covering said decorative layer.
53. The tile according to claim 47, wherein the adhesive strength of a bottom side of the adhesive layer is at least 170 g/cm.
54. The tile according to claim 47, wherein the adhesive layer is configured to impart polar force driven adhesive properties when a load or pressure is exerted to said adhesive layer.
55. The tile according to claim 47, wherein the adhesive layer is formed by a pressure sensitive adhesive layer.
56. The tile according to claim 47, wherein the adhesive layer is a hydrophobic layer.
57. The tile according to claim 47, wherein a plurality of superficial suction holes is formed in at least a lower surface of the adhesive layer, wherein the superficial suction holes are open in a direction facing away from the base layer and substantially closed in a direction facing the base layer.
58. The tile according to claim 57, wherein the superficial suction holes together define a void footprint, wherein material at the lower surface of the adhesive 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.
59. The tile according to claim 57, wherein the adhesive layer is configured to impart polar vacuum driven adhesive properties when a load or pressure is exerted to said adhesive layer.
60. tile according to claim 47, wherein the adhesive layer is at least partially cured.
61. The tile according to claim 47, wherein the adhesive layer and/or the base layer comprises an antimicrobial substance; and/or wherein the adhesive layer and/or the base layer is coated with an antimicrobial agent.
62. The tile according to claim 1, wherein the adhesive layer covers at least one side wall of the base layer, wherein said side wall connects to the bottom side of the base layer, and wherein, preferably, a removable protective film is attached onto the adhesive layer covering the substantially entire side of the adhesive layer facing away from the base layer.
63. The tile covering consisting of a plurality of neighbouring tiles according to claim 47.
64. A method of producing a tile, in particular a carpet tile, according to claim 1, comprising the steps of: a) providing a base layer having a top side and a bottom side, wherein, preferably pile yarns are provided on at least a part of the top side of the base layer, b) affixing, either directly or indirectly, an adhesive layer to the bottom side of the base layer, wherein the adhesive layer is configured to impart adhesive properties sufficient to allow the tile to be releasably attached to a suitable support surface, wherein the adhesive layer preferably covers the substantially entire bottom side of the base layer, and c) realizing a connection between a removable protective film and a bottom surface of the adhesive layer.
65. The method according to claim 64, wherein during step c) the adhesive layer is applied in initially liquid state onto the protective film, after which the adhesive layer is at least partially cured.
66. The method according to claim 64, wherein during step b) the adhesive layer is applied in an at least partially cured state.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0124] The invention will be further explained with reference to the appended figures, wherein:
[0125] FIG. 1 shows a cross-sectional view of a first possible embodiment of a tile according to the invention;
[0126] FIG. 2 shows a cross-sectional view of a second possible embodiment of a tile according to the invention;
[0127] FIG. 3 shows a third possible embodiment of a tile according to the invention;
[0128] FIG. 4 is a cross-sectional view indicated by section A-A in FIG. 3; and
[0129] FIG. 5 is a cross-sectional view indicated by section B-B in FIG. 3.
DESCRIPTION OF THE INVENTION
[0130] FIG. 1 shows a tile (101), in particular a carpet tile (101), comprising a base layer (102) and a backing layer (103) attached to a lower side of said base (102). The base layer (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 layer (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 layer (103). The backing layer (103) comprises an elastic layer (107). The elastic layer (107) defines a bottom surface of the tile (101). The elastic layer (107) comprises a plurality of cells (108), which are merely schematically shown in the figures. The cells (108) can have air or a gas trapped inside.
[0131] The diameter size of the cells (108) is for example situated between 5 μm to approximately 1 mm. The elastic layer (107) has for example a thickness situated between 0.1 and 6 mm. In the shown embodiment is the elastic layer (107) made of a foam material and/or comprise a foaming agent. The bottom surface of the elastic layer (107) has an air-tight sealing effect. Furthermore, the bottom surface of the elastic layer (107) is provided with an adhesive layer (109) which allows the bottom surface of the tile to be attached to a suitable support surface, as well as to be detached from the same support surface onto which it has been attached. Optionally, the elastic layer (107) and the adhesive layer (109) may be integrated and form a single elastic, adhesive layer.
[0132] The backing structure (103) furthermore comprises another internal adhesive layer (110). This adhesive layer (110) is for example a solventless, hot melt adhesive layer (110) disposed on the pre-coat layer (106). A releasable liner (110) may be used to initially protect the adhesive layer (109) prior to use.
[0133] FIG. 2 shows a tile (201), in particular a carpet tile (201), comprising a base layer (202) projecting upwardly therefrom. The carpet tile (201) furthermore comprises a backing layer (203) attached to a lower side of the base layer (202). The backing layer (203) comprises an elastic layer (207) defining a bottom surface of the tile (201), onto which a pressure sensitive adhesive layer (209) is provided which allows the bottom surface of the tile to be attached to a suitable support surface, as well as to be detached from the same support surface onto which it has been attached. Optionally, the elastic layer (207) and the adhesive (209) layer may be integrated and form a single elastic, adhesive layer.
[0134] The elastic layer (207) is of a comparable type as in FIG. 1, having a foam structure including cells (208). 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 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) may act as backing layer, and 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. A releasable liner (210) may be used to initially protect the adhesive layer (209) prior to use.
[0135] 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), that is provided with an adhesive layer (not visible) as shown in FIGS. 1 and 2, to allow for both an easy attachment onto and detachment from a support surface.
[0136] Furthermore, the tile (301), and in particular the backing structure (303), comprises an intermediate core layer (312), situated in between the base (302) and the elastic layer (303). The intermediate layer (312) 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 core layer (312) 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 core layer (312) comprises an upper side (313) and a lower side (314). The core layer (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 layer (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 (312) 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.
[0137] 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 layer (312). By means of the vertical dashed line the border between the sideward tongue (329) and the core layer (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) 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 same—commonly horizontal—plane, 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.
[0138] 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).
[0139] The above-described inventive concepts are illustrated by several illustrative embodiments of carpet tiles and non-carpet tiles. 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.
[0140] 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.
[0141] 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.
