TILES BACKED WITH PATTERNS OF PRESSURE SENSITIVE ADHESIVE

Abstract

A surface covering tile has a plurality of edges extending between the face and the back surface. A pressure sensitive adhesive is disposed on the back surface and covers less than 40% of the back along each one of the plurality of edges where the back surface intersects the plurality of edges. For highly porous back surfaces, the pressure sensitive adhesive is selected and applied in a manner limiting penetration into the back surface. The amount of pressure sensitive adhesive required to affix the tile is reduced, and the tile can be optionally constructed in a manner that facilitates lateral movement of the tile during installation.

Claims

1. A surface covering tile comprising: a face; a back opposite the face; a plurality of edges extending between the face and the back, each edge intersecting the back along a back cut edge; and a pressure sensitive adhesive disposed on the back, the pressure sensitive adhesive covering less than 40% of the back along each back cut edge.

2. The surface covering tile of claim 1, wherein: the tile comprises a thickness between the face and the back, each edge spanning the thickness; the pressure sensitive adhesive extends along the back to the plurality of edges at a plurality of discrete points along each back cut edge; and a distance between any two points in the plurality of discrete points along a given back cut edge is less than twice the thickness of the tile.

3. The surface covering tile of claim 2, wherein the distance between any two points in the plurality of discrete points is less than about 1.5 times the thickness of the tile.

4. The surface covering tile of claim 1, wherein the back comprises a porous surface.

5. The surface covering tile of claim 1 wherein: the pressure sensitive adhesive forms a pattern across the back; and the pattern comprises a plurality of curvilinear lines or a plurality of rectilinear intersecting lines.

6. The surface covering tile of claim 1 wherein: the pressure sensitive adhesive forms a pattern across the back; the pattern comprises a plurality of discrete areas of pressure sensitive adhesive, the plurality of discrete areas separate from each other; and the back contains pressure sensitive adhesive only in the discrete areas.

7. The surface covering tile of claim 1 wherein: the back comprises: first areas containing the pressure sensitive adhesive; and second areas separate from the first areas, the second areas free of pressure sensitive adhesive; the surface covering tile comprises: a first thickness between the face and the back in the first areas; and a second thickness between the face and the back in the second areas, the second thickness greater than the first thickness; and the surface covering tile is compressible in the second areas under pressure applied to the back and the face to decrease the second thickness.

8. The surface covering tile of claim 1, wherein the surface covering tile further comprises an open scrim attached to at least a portion of the back, the pressure sensitive adhesive disposed on the scrim.

9. The surface covering tile of claim 1, wherein the pressure sensitive adhesive comprises: a first coverage density at locations adjacent the plurality of back cut edges; and a second coverage density of pressure sensitive adhesive at locations remote from the plurality of back cut edges, the first coverage density greater than the second coverage density.

10. The surface covering tile of claim 1, wherein the pressure sensitive adhesive comprises amorphous polyalphaolefin acrylic.

11. The surface covering tile of claim 1, wherein the pressure sensitive adhesive is suitable for application to the back a temperature from about 270 F. to about 370 F. and has a viscosity range of from about 8,000 centipoise to about 13,000 centipoise at 350 F.

12. The surface covering tile of claim 1, wherein the pressure sensitive adhesive comprises a thickness of from about 0.001 inches to about 0.100 inches.

13. The surface covering tile of claim 1, wherein the pressure sensitive adhesive comprises a pattern containing a plurality of lines disposed across the back, each line comprising a width of from about 0.030 inches to about 0.200 inches.

14. The surface covering tile of claim 1, wherein at least one of a thickness of the pressure sensitive adhesive and a weight of the pressure sensitive varies across the back surface.

15. The surface covering tile of claim 1, wherein the surface covering tile comprises a release sheet attached to and covering the pressure sensitive adhesive.

16. The surface covering tile of claim 1, wherein: the back comprises a back surface area; and the pressure sensitive adhesive covers less than about 25% of the back surface area.

17. The surface covering tile of claim 1, wherein: the surface covering tile comprises a felt; the felt comprises a needle-exit surface; and the back corresponds to the needle-exit surface.

18. The surface covering tile of claim 1, wherein: the surface covering tile comprises a felt; the felt comprises: the back; and a plurality of fiber tufts extending from the back and created by needling the felt with widely spaced high-gauge needles; the pressure sensitive adhesive covers the fiber tufts; and the fiber tufts extend into the pressure sensitive adhesive.

19. The surface covering tile of claim 1, wherein the back comprises a flattened, pre-calendered surface.

20. A method for creating a surface covering tile comprising a porous and recoverably compressible back, the method comprising: applying a pressure sensitive adhesive to only a portion of a surface area of the back; applying a release sheet to the back; compressing the surface covering tile to a uniform thickness across the surface area of the back; and removing the release sheet and allowing the surface covering tile to expand to create a first thickness in the surface covering tile in the portion of the back containing the pressure sensitive adhesive and a second thickness in the surface covering tile outside the portion of the back containing the pressure sensitive adhesive, the second thickness greater than the first thickness.

21. The method of claim 20, wherein: applying the pressure sensitive adhesive comprises applying the pressure sensitive adhesive to a partially open scrim; and the method further comprises applying the partially open scrim to the back while applying the release sheet and compressing the surface covering tile.

22. The method of claim 21, wherein the open scrim comprises a woven fabric, a knit fabric or nonwoven fabric.

23. The method of claim 22, wherein the open scrim comprises aramid fibers, carbon fibers or yarns.

24. The method of claim 20, wherein applying the pressure sensitive adhesive further comprises: pressing a plurality of nozzles into the back; and injecting the pressure sensitive adhesive onto the surface covering tile through the plurality of nozzles.

25. The method of claim 20, wherein the method further comprises attaching a face layer to a backing layer to create the surface covering tile, the face layer comprising a fibrous layer, a non-fibrous layer, a solid layer or a porous layer and the back of the surface covering tile comprising a surface of the backing layer opposite the face layer.

26. The method of claim 20, wherein the method further comprises cooling the pressure sensitive adhesive rapidly immediately following application to raise a viscosity of the pressure sensitive adhesive and to inhibit migration of the pressure sensitive adhesive into the surface of the back.

27. A method for applying an open pattern of pressure sensitive adhesive to a back of a surface covering tile, the method comprising: depositing the open pattern of pressure sensitive adhesive on a release sheet; placing the release sheet on the back of the surface covering tile such that the pattern of pressure sensitive adhesive engages the back; pressing the release sheet onto the back; and removing the release sheet from the surface covering tile while leaving the pattern of pressure sensitive adhesive on the surface covering tile.

28. The method of claim 27, wherein pressure sensitive adhesive covers less than about 40% of a surface area of the back.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0026] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate a plurality of embodiments and, together with the following descriptions, explain these embodiments.

[0027] FIG. 1 is a schematic illustration of a perspective view of an embodiment of the composite floorcovering with a patterned pressure sensitive adhesive layer;

[0028] FIG. 2 is a schematic illustration of a perspective view of another embodiment of the composite floorcovering with a patterned pressure sensitive adhesive layer;

[0029] FIG. 3 is a schematic illustration of a side view of an embodiment of the composite floorcovering having elements projecting from the back and engaging the pressure sensitive adhesive;

[0030] FIG. 4 is a schematic illustration of the back of an embodiment of the composite floorcovering containing a curvilinear pattern of pressure sensitive adhesive with the curved lines intersecting;

[0031] FIG. 5 is a schematic illustration of the back of another embodiment of the composite floorcovering containing a rectilinear pattern of pressure sensitive adhesive with the rectilinear lines crossed over in a plaid pattern;

[0032] FIG. 6 is a schematic illustration of the back of yet another embodiment of the composite floorcovering containing a pattern of pressure where the pressure sensitive pattern is not interconnected;

[0033] FIG. 7 is a schematic illustration of a side view of an embodiment of the composite floorcovering having areas between the pressure sensitive adhesive that are raised beyond the pressure sensitive adhesive pattern and compressible to facilitate planar adjustment during tile installation;

[0034] FIG. 8A is a schematic illustration of a side view of an embodiment of the composite floorcovering with a pressure sensitive adhesive pattern containing reinforcing elements;

[0035] FIG. 8B is a schematic illustration from the front face of an embodiment of the composite tile containing a pressure sensitive adhesive coated on a scrim applied to the back of the composite tile;

[0036] FIG. 9A is a schematic illustration of the back of an embodiment of the composite tile containing a plaid pattern of pressure sensitive adhesive having a heavier concentration of adhesive adjacent the cut edges;

[0037] FIG. 9B is a schematic illustration of the back of an embodiment of the composite tile containing pressure sensitive adhesive pattern of discrete shapes having a heavier concentration of adhesive adjacent the cut edges;

[0038] FIG. 10A is a schematic illustration of a cross section an embodiment of a felt backing needled from the side adjacent the face of the composite floorcovering to produce tufts on the back side to which a pattern of pressure sensitive adhesive is applied; and

[0039] FIG. 10B is a schematic illustration of a cross section of an embodiment of a composite floorcovering having a backing prepared as illustrated in FIG. 10A and receiving a face layer and a pressure sensitive adhesive pattern

DETAILED DESCRIPTION

[0040] The following description of the embodiments refers to the accompanying figures. The same reference numbers in different figures identify the same or similar elements. Reference throughout the whole specification to one embodiment or an embodiment means that a particular feature, structure or characteristic described in connection with an embodiment is included in at least one embodiment of the subject matter disclosed. Thus, the appearance of the phrases in one embodiment or in an embodiment in various places throughout the specification is not necessarily referring to the same embodiment. Further, particular features, structures or characteristics may be combined in any suitable manner in one or more embodiments.

[0041] Exemplary embodiments are directed to surface coverings and surface covering tiles having a face, a back opposite the face and a plurality of edges or sides extending between the face and the back. Suitable surface covering tiles include floorcovering tiles. Each edge intersects the face along a face cut edge and the back along a back cut edge. The surface covering tile has a thickness between the face and the back, and each edge spans the thickness. In one embodiment, the back is a porous surface. In one embodiment, the back is a porous fibrous felt. The back can be the needle entrance side of the felt or can be the side of the felt containing fiber tufts that are driven through the felt using a plurality of needles such as coarse needles. In one embodiment, the face is a fibrous material. The surface covering tile can be a single layer of material or can be multiple layers of material. For example, the surface covering tile can be a face layer placed over a backing layer. The face layer can be a fibrous layer, and the backing layer can be a felt.

[0042] Pressure sensitive adhesive (PSA) is disposed on at least a portion of the back. In one embodiment, the pressure sensitive adhesive is a material applied at high temperature and cooled rapidly. Suitable pressure sensitive adhesives include, but are not limited to, amorphous polyalphaolefin acrylic, tackified rubbers and block polymers. In one embodiment, the PSA is based on elastomers compounded with a suitable tackifier, e.g., a rosin ester. These elastomers can be based on acrylics, which can have sufficient tack on their own and do not require a tackifier. In one embodiment, the PSA is a biologically-based acrylate macromonomer grafted onto the backbone of an acrylate. The resulting PSA contains 60% bio-based materials. In one embodiment, the PSA is a hot-melt PSA containing butyl rubber, ethylene-vinyl acetate (EVA) with high vinyl acetate content. In one embodiment nitriles and silicone rubbers utilize special tackifiers based on MO silicate resins, which are composed of a monofunctional trimethyl silane (M) reacted with quadra-functional silicon tetrachloride (Q).

[0043] In one embodiment, the pressure sensitive adhesive is material suitable for application to the back a temperature from about 270 F. to about 370 F. In addition, the pressure sensitive adhesive has viscosity range of from about 8,000 centipoise to about 13,000 centipoise at 350 F. In one embodiment, the pressure sensitive adhesive has a thickness of from about 0.001 inches to about 0.100 inches.

[0044] In one embodiment, the pressure sensitive adhesive covers less than 40% of the back along each back cut edge. In one embodiment, the PSA covers only a portion of the back surface area of the back of the surface covering tile. The pressure sensitive adhesive covers less than about 25% of the back surface area. In one embodiment, the pressure sensitive adhesive is disposed on from about 20% to about 80% of the back surface area of the back of the surface covering tile. In one embodiment, the pressure sensitive adhesive covers about 40% of the back surface area. Therefore, about 20% to about 80% of the surface area of the back of the surface covering tile is open and does not contain any adhesive, and the PSA is arranged in an open pattern.

[0045] In one embodiment, instead of using an open pattern, the basis weight of the PSA is controlled to limit the amount of PSA applied to the surface covering tile. In one embodiment, at least one of the thickness, area weight, and weight profile of the pressure sensitive adhesive varies across the back surface. In one embodiment, the pressure sensitive adhesive has a first coverage density on the back on areas adjacent the edges and a second coverage density of on areas remote from edges. The first coverage density is greater than the second coverage density. This embodiment helps to hold the edges on the floor, countering a tendency of the edges to curl up at the seams between two adjacent tiles.

[0046] In one embodiment, the PSA adhesive is applied in a pattern containing a plurality of lines disposed across the back. In one embodiment each line has a width of from about 0.030 inches to about 0.200 inches wide. The pattern can contain a plurality of curvilinear lines or a plurality of rectilinear intersecting lines. In one embodiment, the pattern contains a plurality of discrete areas of pressure sensitive adhesive. The areas in the plurality of discrete areas are separate from each other, and the back contains pressure sensitive adhesive only in the discrete areas.

[0047] In one embodiment, the back has first areas containing the pressure sensitive adhesive and second areas separate from the first areas. The second areas are free of pressure sensitive adhesive. The surface covering tile has a first thickness between the face and the back in the first areas and a second thickness between the face and the back in the second areas. The second thickness is greater than the first thickness. The surface covering tile back is compressible in the second bare areas under pressure applied to the back and the face to decrease the second thickness, for example, to at least the first thickness.

[0048] In one embodiment, the pressure sensitive adhesive extends along the back to a plurality of discrete points along each back cut edge. A distance between any two points in the plurality of discrete points along a given back cut edge is less than twice the thickness of the tile, preferably less than about 1.5 times the thickness of the tile. In one embodiment, the surface covering tile also includes an open scrim attached to at least a portion of the back of the tile. The pressure sensitive adhesive is disposed on the scrim. In one embodiment, the surface covering tile includes a release sheet attached to and covering the pressure sensitive adhesive.

[0049] When the surface covering tile back is a felt, the PSA can be disposed on a needle-entrance or needle-exit surface corresponding to the back. Alternatively, the that back is a surface of the felt, and a plurality of fiber tufts extend from the back. The fiber tufts are created by needling the felt with widely spaced high-gauge needles. The pressure sensitive adhesive covers the fiber tufts, and the fiber tufts extend into the pressure sensitive adhesive.

[0050] Referring initially to FIG. 1, an embodiment of a single-layer surface covering tile 100 is illustrated having a face 101 and a back 108 opposite the face. As an alternative to the single-layer surface covering tile, the surface covering tile can include two layers by attaching a separate backing layer to the face layer. For two layers, the back of the surface covering tile is the back surface of the separate backing layer. When the surface covering tile is applied to a surface to be covered, the back is placed adjacent the surface to be covered, and the face is exposed. A plurality of edges 102 or sides extend between the face and the back. The edges or sides define a tile thickness 104 between the face and the back. These edges can be rectilinear as shown or curvilinear. The plurality of edges can be parallel to each other or can intersect each other at various angles, resulting in any rectilinear or curvilinear variety of intermeshing shapes of tiles. The edges intersect the face along face cut edges 112 and intersect the back at back cut edges 110.

[0051] In one embodiment, the pressure sensitive adhesive extends along the back to each one of the back cut edges 110. In one embodiment, the pressure sensitive adhesive does not extend completely along each back cut edge. For example, the pressure sensitive adhesive extends along or covers less than 40% of the length 114 of a given back cut edge, i.e., the total length of the back cut edge covered by the pressure sensitive adhesive is less than about 40% of the overall length of the back cut edge.

[0052] In one embodiment, the pressure sensitive adhesive extends along the back to the plurality of edges or is located along the cut back edge at a plurality of discrete points 103. In addition, the distance 106 between any two points in the plurality of discrete points, including a first distance X between the points where the pattern of PSA ends at the edge in a first direction and a second distance Y where the pattern of PSA ends in a second direction perpendicular to the first direction, is less than twice the thickness 104 of the tile. Therefore, the PSA extends to the cut edges without being interrupted by a gap exceeding the thickness of the tile by a factor larger than 2, preferably not exceeding the thickness of the tile by a factor larger than 1.5. These patterns of PSA with the limitation on the spacing between discrete points of PSA along the cut edges ensure that relatively or sufficiently heavy PSA is present at the cut edges, and the use or application of an excessive overall level or amount of PSA on the back of the surface covering tile is eliminated. Reducing the overall amount, level or percentage of coverage of PSA avoids adverse effects on the breathability of surface covering tiles having porous materials such as carpet tiles.

[0053] Referring now to FIG. 2, another embodiment of a surface covering tile 200 is illustrated having a face 201 and a particularly porous back 208 opposite the face. The PSA is applied in a pattern to the back. In one embodiment, the patent of PSA is applied using methods suitable to prevent excessive flow of the adhesive and to limit penetration of the adhesive into the porous surface of the back. These methods for applying the pattern of PSA include, but are not limited to, the use of a polymer applied at a high temperature and rapidly cooled. Therefore, the PSA forms projections extending above the porous surface of the back.

[0054] As illustrated, the porous back 208 is relatively flat, and the pattern of PSA extends along the back of the tile and is located along the back cut edge 210 of the edges 202 of the tile at a plurality of discrete points 203. In one embodiment, the PSA penetrates through the back and into the backing layer to a limited degree. Consequently, in addition to limiting the overall weight of PSA, the limited depth of penetration of the PSA facilitates retention of most or all of the PSA to remain on the surface to be covered when the tile is removed.

[0055] Referring now to FIG. 3, another embodiment of a surface covering tile 300 having a face 301, a back 308 opposite the face and an edge 305 extending from the face to the back is illustrated. The surface covering tile includes a plurality of projecting elements 304 extending out from the surface covering tile along the back 308. These projecting elements include fibers and fiber tufts. The projecting elements extend into the PSA that is applied to the back of the surface covering tile and that extends to the back cut edge at a plurality of discrete points 303. In one embodiment, the projecting elements extend partially through the PSA. In another embodiment, the projecting elements extend completely through the PSA. By extending the projecting elements through the PSA, the PSA is anchored securely to the back and backing layer. Upon removal of the surface covering tile from the surface to be tiled, most or all of the anchored PSA is pulled from the surface and remains attached to the back of the surface covering tile. The result is an adhesive-free surface that is easily or readily prepared for the attachment of replacement tiles or for the application of alternative types of surface coverings.

[0056] Referring to FIG. 4, an embodiment of a back 408 of a surface covering tile is illustrated with a pattern of PSA formed by a plurality of curvilinear lines 403 of PSA applied to the back of the surface covering tile. The curvilinear lines are separated by a plurality of bare areas 415 that do not contain any adhesive. The plurality of discrete points are defined where the curvilinear lines intersect the back cut edge. The tile in the bare areas may have the same thickness as the areas containing the curvilinear lines, a lesser thickness or a greater thickness. The curvilinear lines can be systematically curvilinear, e.g., all having the same general shape, or randomly curvilinear. Therefore, the pattern of PSA can be a regular pattern or a random pattern. In one embodiment, the curvilinear lines are separated or spaced from each other. Alternatively, the curvilinear lines of PSA overlap or cross, as shown.

[0057] Referring to FIG. 5, an embodiment of a back 508 of a surface covering tile is illustrated containing a pattern of PSA formed by a plurality of rectilinear lines 503 of PSA applied to the back of the surface covering tile. The rectilinear lines are separated by a plurality of bare areas 515 that do not contain any adhesive. The plurality of discrete points are defined where the rectilinear lines intersect the back cut edge. The tile in the bare areas may be the same thickness as the areas containing the rectilinear lines, a lesser thickness or a greater thickness. The rectilinear lines can be parallel or can intersect in random patterns or in a regular pattern. In one embodiment, the rectilinear lines are parallel and spaced from each other. Alternatively, the rectilinear lines of PSA overlap or cross in a plaid or grid pattern, as shown.

[0058] Referring now to FIG. 6, an embodiment of a back 608 of a surface covering tile is illustrated with a pattern or PSA that is not interconnected, e.g., is not a pattern formed from interconnected curvilinear or rectilinear lines. The pattern of PSA can be formed from dots or random lines 603 of PSA or from shapes or other discrete areas of PSA applied to the back 608 of the tile. The pattern includes pressure sensitive adhesive only in the discrete areas, and the bare areas 615 between the discrete areas of adhesive do not contain any adhesive.

[0059] Referring now to FIG. 7, another embodiment of a surface covering tile 700 having a face 701 and a back 708 opposite the face is illustrated. This embodiment provides for the positioning of the surface covering tile over the surface to be covered while making adjustments to the exact positioning of the location of the tile before the PSA is engaged on the surface to be covered. Positioning of the surface covering tile without PSA surface engagement is provided by areas of the back containing the PSA having a lower profile than the surrounding areas that are free of PSA. These surrounding areas, however, are elastically compressible, enabling the handling and planar adjustment of the tile during installation and eventual affixing of the tile to the desired surface upon application of a compressing force to the face of the tile.

[0060] As illustrated, the back of the surface covering tile includes a plurality of adhesive areas 703 disposed across the surface area of the back and containing the pressure sensitive adhesive and a plurality of bare areas 704 separate from the adhesive areas. The surface covering tile has a first thickness 717 in the adhesive areas and a second thickness 719 in the bare areas. The second thickness is greater than the first thickness such that the bare areas engage the surface to be covered first before the adhesive areas. The back, in the bare areas, is compressible under a pressure applied to the face of the tile in a direction as indicated by arrow A. This decreases the second thickness and brings the PSA areas into contact with the surface to be covered, securing the tile to the surface to be covered.

[0061] Referring now to FIG. 8A, another embodiment of a surface covering tile 800 is illustrated having a face 801 and a back 808 opposite the face. The PSA 803 is applied to the back in accordance with any pattern or method described herein. Disposed within each area or line of PSA are one or more auxiliary or reinforcing elements 820. The reinforcing elements include, for example, fibers, fibrils or fabrics that help maintain one or more of the location, shape and thickness of the PSA. In one embodiment, fibers are coated with PSA, and the coated fibers are attached to the back of the surface covering tile in accordance with the desired pattern.

[0062] Referring now to FIG. 8B, another embodiment of a surface covering tile 810 is illustrated having a face 811 and a back 818 opposite the face. In accordance with this embodiment, the PSA is not applied directly to the back of the surface covering tile. The pattern of PSA 813 is applied to a separate open scrim 821. Preferably, the scrim is prepared with materials resisting expansion or contraction with variations of temperature or moisture or the application of force. In one embodiment, the scrim is coated with PSA. Alternatively, the scrim is embedded in PSA. The scrim containing the desired pattern of PSA is attached to the back of a tile. In one embodiment, the PSA-coated scrim does not cover the entire back of the surface covering tile. In one embodiment, the portions of the back of the surface covering tile containing the scrim have a lower profile than the surrounding areas, facilitating adjustments of the surface covering tile during the installation process. Suitable scrims include a woven fabric, an over-bonded fabric and a perforated nonwoven fabric. These fabrics can be prepared with reinforcing fibers or yarns, for example, carbon fibers or aramid fibers resisting expansion or contraction. Therefore, as an additional benefit, the scrim stabilizes the surface covering tile. In another embodiment, not shown, the pattern of PSA is deposited on a release sheet, and the release sheet is subsequently brought in contact with the back of the tile. In this embodiment, a scrim is not used.

[0063] In one embodiment, the pattern of PSA varies in at least one of thickness, concentration and density across the back of the surface covering tile. Referring to FIG. 9A, a pattern of PSA is applied to the back 908 of the surface covering tile. The pattern of PSA pattern contains a plurality of intersecting rectilinear lines 903 forming a plaid pattern or grid and having areas of heavier concentrations of PSA 922 adjacent the back cut edges 910. The heavier concentrations of PSA can be achieved by increasing the number of rectilinear lines in a given area or by increasing the size or thickness of each rectilinear line in the desired areas.

[0064] Referring to FIG. 9B, the PSA is applied to the back 918 of the tile as a pattern containing a plurality of discrete shapes 913 across the entire back of the surface covering tile. The pattern of PSA is applied to the back of the surface covering tile with areas of heavier concentrations of PSA 924 adjacent and along the back cut edges 930. In both embodiment, the concentration of PSA is lower in the middle or central area of the back of the tile. This arrangement helps secure the cut edges of the tiles and prevent the cut edges from raising away from the surface to be covered. In one embodiment the central area of the tile is free of PSA, and the pattern of PSA is interrupted along the back cut edges of the tile.

[0065] Referring now to FIG. 10A, in one embodiment, the surface covering tile is a felt 1011 having a back surface 1008 and a side opposite the back surface 1009. The felt is additionally needled on the side 1009 opposite the back using a plurality of coarse widely-spaced needles 1005. These needles produce a plurality of tufts 1006 extending out from the back 1008. The pattern of PSA is applied to the tufts, and the PSA can be anchored in the tufts, for example, as illustrated in FIG. 3. Alternately the PSA applied to the back surface has a lower profile than the surrounding tufts, for example, as illustrated in FIG. 7, to facilitate planar adjustment during installation of the tile, before being affixed to the surface to be covered.

[0066] Referring to FIG. 10B, in one embodiment, a separate face layer 1002 having a surface 1001 is attached to a felt layer 1011 prepared as described above with respect to FIG. 10A. The separate face layer is applied on the side opposite the back surface 1009. The pattern of PSA 1003 is applied to the back surface and some of the fibers within the tufts 1006 are contained within the PSA. This forms the surface covering tile containing PSA 1003. The separate face layer can be fibrous or non-fibrous, porous or solid.

[0067] In addition to surface covering tiles backed with PSA, exemplary embodiments are also directed to methods for making the surface covering tiles and attaching the surface covering tiles to a desired surface. Suitable methods for applying the PSA to the back of each tile include, but are not limited to, spraying, spraying and curing, printing including transfer printing directly to the back of the tile, and transfer printing onto a transfer sheet or release sheet that can then be pressed with heat or otherwise activated in contact with the tile or tile material.

[0068] The penetration of the PSA into the backing and the propensity to proceed into the backing are adjusted by controlling the conditions and patterns used to attach the PSA to the back. These conditions and patterns include, the viscosity of the applied PSA, the temperature of the PSA as applied, the geometry of the PSA pattern, the porosity of the back, the receptivity of the back to the PSA, the level of pressure used to apply the PSA, the absence of pressure in applying the PSA, the cooling rate used to set the PSA and combinations thereof. In one embodiment, the receptivity of the back is adjusted by needle-punching a felt backing layer. The needle-punched surface on the needle-entrance side is flat, with surface fibers that are rather tightly anchored and flat and suitable for applying the pattern of PSA onto the surface with high viscosity, followed by rapid cooling to achieve easier release from the tile and better recycleability of the tile. In another embodiment, high adhesion to the backing is secured and PSA residuals on the tiled surface upon eventual removal are avoided by using the fiber tufts emerging from the surface to anchor the PSA securely onto the backing. Suitable methods for forming distinct tufts that are particularly effective in anchoring PSA to the back are described in U.S. Patent Application Publication No. 2018/0014678 A1, which is incorporated by reference herein in its entirety. In these embodiments, widely-spaced coarse needles are used to drive distinct tufts of fibers through a felt.

[0069] In one embodiment, a method for creating a surface covering tile having a porous and recoverably compressible back applies a pressure sensitive adhesive to only a portion of a surface area of the back. In on embodiment, a plurality of nozzles are pressed into the back, and the pressure sensitive adhesive is injected onto the surface covering tile through the plurality of nozzles. A release sheet is applied to the back, and the surface covering tile is compressed to a uniform thickness across the surface area of the back. The release sheet is removed, allowing the surface covering tile to expand to create a first thickness in the surface covering tile in the portion of the surface are of the back containing the pressure sensitive adhesive and a second thickness in the surface covering tile outside the portion of the back containing the pressure sensitive adhesive. The second thickness is greater than the first thickness.

[0070] In one embodiment, the pressure sensitive adhesive is not applied directly to the back, but it is applied to a partially open scrim, for example, in the desired pattern of pressure sensitive adhesive. The partially open scrim containing the pattern of pressure sensitive adhesive is then applied to the back, for example, while applying the release sheet and compressing the surface covering tile. Suitable open scrims include, but are not limited to, a woven fabric, a knit fabric and a nonwoven fabric. In one embodiment, the open scrim contains aramid fibers, carbon fibers, yarns or combinations thereof.

[0071] In one embodiment, the surface covering tile is a single layer. Alternatively, a face layer is attached to a backing layer to create the surface covering tile. Suitable face layers include, but are not limited to, a fibrous layer, a non-fibrous layer, a solid layer and a porous layer. The back of the surface covering tile is a surface of the backing layer opposite the face layer.

[0072] An exemplary embodiment is directed to a method for applying an open pattern of pressure sensitive adhesive to a back of a surface covering tile. The open pattern of pressure sensitive adhesive is applied on a release sheet, and the release sheet is placed on the back of the surface covering tile such that the pattern of pressure sensitive adhesive engages the back. The release sheet is pressed onto the back and subsequently removed from the surface covering tile while leaving the pattern of pressure sensitive adhesive on the surface covering tile. In one embodiment, the pattern of pressure sensitive adhesive covers less than about 40% of a surface area of the back.

[0073] The foregoing written description uses examples of the subject matter disclosed to enable any person skilled in the art to practice the same, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the subject matter is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims.