Floor covering system comprising a lighting system

Abstract

The invention provides a floor covering system (10) with (a) a PVC-based floor covering (100) and (b) a lighting system (200) arranged to generate light (210). The PVC-based floor covering (100) has a user side (101) and an opposite back side (102). The lighting system (200) is arranged at the back side (102) of the PVC-based floor covering (100). The PVC-based floor covering (100) has a light transmission for light (210) generated by the lighting system (200) in the range of 0.5% to 30%, especially in the range of 1% to 20%.

Claims

1. A floor covering system comprising: a polyvinyl chloride (PVC) flooring having a user side and an opposite back side; and a lighting system for generating light, the lighting system provided at the back side of the PVC flooring, the lighting system comprising a plurality of light units, each light unit having one or more light sources disposed on a common substrate; an auxiliary layer comprising a first side and an opposite second side, the first side of the auxiliary layer positioned at the back side of the PVC flooring, the auxiliary layer further comprising a plurality of openings therethrough, wherein each of the plurality of light units is positioned entirely within a respective one of the openings in the auxiliary layer; wherein the PVC flooring has a light transmission for light generated by the lighting system in the range of 0.5% to 30% such that the lighting system is not visible through the user side of the PVC flooring, and further wherein the PVC flooring is configured to protect the lighting system from damage when a user walks on the floor covering system; and wherein the PVC flooring is disposed on at least two of the light units.

2. The floor covering system of claim 1, wherein the PVC flooring has a light transmission in the range of 1% to 20%.

3. The floor covering system of claim 1, further comprising: a sensor configured to detect an object on or near the floor covering; and a controller in communication with the sensor and configured to adjust a parameter of the lighting system in response to detection by the sensor of the object.

4. The floor covering system of claim 1, wherein the opposite back side of the PVC flooring defines a plurality of recesses, each of the plurality of recesses configured to host at least one light source of the lighting system.

5. The floor covering system of claim 1, wherein the system comprises a plurality of tiles.

6. The floor covering system of claim 1, further comprising an auxiliary layer arranged between at least part of the lighting system and at least part of the PVC flooring, wherein the auxiliary layer is selected from the group consisting of levelling layers and adhesive layers.

7. The floor covering system of claim 1, wherein the floor covering system is configured to provide way guiding to the user.

8. The floor covering system of claim 1, wherein the PVC flooring comprises a filler material selected from the group consisting of calcium carbonate, aluminum trihydrate, polycarbonate, glass, and mixtures thereof.

9. The floor covering system of claim 1, wherein the PVC flooring comprises a filler material having a refractive index in the range of 1.45 to 1.65.

10. A floor covering system comprising: a plurality of interconnected flooring tiles and a lighting system, the lighting system having a plurality of light sources disposed on a common substrate; wherein each of the flooring tiles comprises a polyvinyl chloride (PVC) flooring layer having a user side and an opposite back side; and wherein the lighting system is provided at the back side of the PVC flooring; an auxiliary layer comprising a first side and an opposite second side, the first side of the auxiliary layer positioned at the back side of the PVC flooring layer, the auxiliary layer further comprising a plurality of openings therethrough, wherein each of the plurality of light units is positioned entirely within a respective one of the openings in the auxiliary layer; wherein the PVC flooring layer has a light transmission for light generated by the lighting unit in the range of 0.5% to 30% such that the lighting system is not visible through the user side of the PVC flooring when no light is emitted by the lighting system, and further wherein the PVC flooring layer is configured to protect the lighting unit from damage when a user walks on the floor covering system; wherein at least two of the flooring tiles are disposed on the common substrate of the lighting system.

11. The floor covering system of claim 10, wherein the PVC flooring layer has a light transmission in the range of 1% to 20%.

12. The floor covering system of claim 10, further comprising: a sensor configured to detect an object on or near the floor covering; and a controller in communication with the sensor and configured to adjust a parameter of the lighting system in response to detection by the sensor of the object.

13. The floor covering system of claim 10, wherein each of the flooring tiles defines a plurality of recesses, each of the plurality of recesses configured to host at least one light source of the lighting system.

14. The floor covering system of claim 10, further comprising an auxiliary layer arranged between at least part of the lighting unit and at least part of the PVC flooring layer, wherein the auxiliary layer is selected from the group consisting of levelling layers and adhesive layers.

15. A flooring tile comprising: a polyvinyl chloride (PVC) flooring layer having a user side and an opposite back side, and at least one recess at the back side; and a lighting system for generating light, the lighting system provided at the back side of the PVC flooring, the lighting system comprising a plurality of light units, each light unit having a plurality of light sources disposed on a common substrate, the light sources of at least one of the light units protruding in the at least one recess of the PVC flooring layer; an auxiliary layer comprising a first side and an opposite second side, the first side of the auxiliary layer positioned at the back side of the PVC flooring layer, the auxiliary layer further comprising a plurality of openings therethrough, wherein each of the plurality of light units is positioned entirely within a respective one of the openings in the auxiliary layer; wherein the PVC flooring layer has a light transmission for light generated by the lighting unit in the range of 0.5% to 30% such that the lighting unit is not visible through the user side of the PVC flooring when no light is emitted by the lighting unit, and further wherein the PVC flooring layer is configured to protect the lighting unit from damage when a user walks on the floor covering system.

16. The flooring tile of claim 15, wherein the PVC flooring layer has a light transmission in the range of 1% to 20%.

17. The flooring tile of claim 15, wherein the flooring tile is configured to connect to a neighboring flooring tile.

18. The flooring tile of claim 15, wherein the flooring tile defines a plurality of recesses, each of the plurality of recesses configured to host at least one light source of the lighting unit.

19. The flooring tile of claim 15, wherein the flooring tile is configured to provide way guiding to the user.

20. The flooring tile of claim 15, further comprising a filler material selected from the group consisting of calcium carbonate, aluminum trihydrate, polycarbonate, glass, and mixtures thereof.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Embodiments of the invention will now be described, by way of example only, with reference to the accompanying schematic drawings in which corresponding reference symbols indicate corresponding parts, and in which:

(2) FIG. 1 schematically depicts an embodiment and the floor covering system according to the invention;

(3) FIGS. 2a to 2f schematically depict embodiments and variants thereof of the floor covering system according to the invention;

(4) FIGS. 3a to 3b schematically depict embodiments and variants thereof of the floor covering system according to the invention;

(5) FIG. 4 schematically depicts an embodiment and variants thereof of the floor covering system according to the invention;

(6) FIG. 5 schematically depicts an embodiment and variants thereof of the floor covering system according to the invention;

(7) FIG. 6a schematically depicts an embodiment of a laminate flooring tile for use in the flooring covering system of the invention; and

(8) FIG. 6b schematically depicts a lighting system to be placed below the laminate flooring tile when used in floor covering system according to the invention.

DETAILED DESCRIPTION OF THE EMBODIMENTS

(9) FIG. 1 schematically depicts an embodiment of a floor covering system 10 according to the present invention. The floor covering system 10 comprises (a) a floor covering 100 and (b) a lighting system 200 arranged to generate light 210.

(10) The floor covering 100 has a user side 101 and an opposite back side 102. The lighting system 200 has a top side 201 and a bottom side 202. The lighting system 200 is arranged at the back side 102 of the floor covering 100. As can be seen in FIG. 1, the top side 201 of the lighting system 200 and the back side 102 of the floor covering 100 are facing each other. The back side 102 may also be indicated as illumination side. The lighting system 200 in this embodiment comprises a plurality of light sources 205, such as LEDs. The lighting system 200 is arranged to generate light 210 (when switched on). In this embodiment, the lighting system 200 comprises one lighting unit 250 (i.e. the lighting unit is the lighting system); in general the lighting system 200 may comprise a plurality of lighting units 250 (see below). The lighting system 200 may be powered by an external power source (indicated with V).

(11) The floor covering 100 has a light transmission for light 210 generated by the lighting system 200 in the range of 0.5% to 30%, especially in the range of 1% to 20%. In this way, an observer/user perceiving the user side 101 of the floor covering 100 will essentially not see the lighting system 200 or other items behind the back side 102 of the floor covering 100. The observer will observe the floor covering 100 as normal floor covering 100. However, when the lighting system 200 provides light 210, this light 210 is observed by the observer. The source of light is hidden; the light itself is perceived.

(12) The floor covering 100 is chosen from the group consisting of PVC floorings and laminate floorings.

(13) The invention is also directed to the floor covering 100 per se, having user side 101 and opposite back side 102, and having a light transmission for light 210 in the range of 0.5% to 30%, especially in the range of 1% to 20%, wherein the floor covering 100 is chosen from the group consisting of PVC floorings and laminate floorings. The floor covering 100 may be a PVC flooring comprising a filler material. The filler material may for instance comprise one or more materials selected from the group consisting of calcium carbonate, aluminium trihydrate, polycarbonate, and glass. The invention is also directed to the lighting system 200 per se.

(14) The lighting system 200 in general comprises a substrate or support, indicated with reference 203, which substrate or support 203 comprises the light source(s) 205. For instance, support 203 may be a PCB (printed circuit board). To such PCB, LEDs may be provided.

(15) FIGS. 2a to 2c schematically depict non-limiting means/embodiments with an auxiliary layer, for instance to smooth or level the lighting system 200. These embodiments show an auxiliary layer 500, arranged between at least part of the lighting system 200 and the floor covering 100. The auxiliary layer may for instance comprise an adhesive. The auxiliary layer may also be arranged as levelling layer. In FIG. 2a, the auxiliary layer 500 is substantially only present between the light sources 205 and not over the light sources 205. FIG. 2a schematically depicts a cross-section. To illustrate the terms downstream and upstream in relation to FIG. 2a: user side 101 is downstream of back side 102; back side 102 is upstream of user side 101.

(16) FIG. 2b schematically depicts a top view of the embodiment of FIG. 2a, however without the floor covering 100. It can be clearly seen that the levelling layer 500 has openings, indicated with reference 503, for the light sources 205. Hence, the lighting system 200 may provide light 210, without substantial absorption of the levelling layer 500, since the levelling layer 500 has openings 503 to allow light 210 travel in the direction of the floor covering 100.

(17) FIG. 2c schematically depicts an embodiment wherein the auxiliary layer 500 is also arranged over the light sources 205. The auxiliary layer may be chosen to be transmissive for light 210 of the lighting system 200.

(18) The levelling layer 500 may be part of the lighting system 200, i.e. it may be a layer attached to the lighting system 200. For instance, it may be a laminate of support 203 (such as a PCB) and levelling layer 500. The levelling layer may in an embodiment be made of PCB material.

(19) FIG. 2d is used to illustrate some parameters of the lighting system 200. The total height of the lighting system is indicated with h2; the height of the support 203 is indicated with h1 and the height of the light source(s) 205, if protruding from the top side 201 of the lighting system 200 (or support 203), is indicated with h3; i.e. h2=h3+h1. The total height h2 may for instance be in the range of about 1 mm.

(20) FIG. 2e schematically depicts an embodiment wherein the floor covering 100 comprises recesses 104, also indicated as covering recess. Variants are schematically depicted, wherein the left part of the Figs. shows a plurality of recesses, arranged to host at least part of the lighting system 200, more precisely at least part of the lighting unit 250 drawn on the left. More precisely, in this variant the recesses 104 are arranged to host the light sources 205 of the (left) lighting unit 250. At the right, a variant of recess 104 is shown, also arranged to host at least part of the lighting system 200, more precisely in this variant at least part of the (right) lighting unit 250. More precisely, in this variant, the recess 104 is arranged to host the (right) lighting unit 250.

(21) FIG. 2f depicts a specific variant of the lighting system 200 schematically depicted in FIG. 2a. The lighting system 200 comprises a substrate 203, which is especially a PCB. Light sources 203 and/or other (electronic) components of the lighting system 200 are embedded in levelling layer (indicated as auxiliary layer 500), in recesses 204 (these recesses 204 may also be indicated as openings 503). In this way, a flat lighting system 200 may be provided. The levelling layer may also be PCB material, laminated to the PCB substrate. Hence, in this way a PCB (Printed Circuit Board) with one or more recesses 204 may be obtained, especially for hosting one or more light sources 205. The one or more recesses 204 may be arranged to host one or more light sources 205 and/or one or more other electrical components, such as electrical connections, power source(s), controller(s), etc. The lighting unit 250 schematically depicted in FIG. 2f may be considered a laminate.

(22) FIG. 3a schematically depicts an embodiment wherein the floor covering 100 comprises a plurality of floor covering tiles 150. FIG. 3b schematically depicts an embodiment wherein the lighting system 200 comprises a plurality of lighting units 250. FIG. 3b by way of example also shows (optional) electric connections 251 between (adjacent) lighting units 250. Note that the floor covering system 100 may also comprise a plurality of floor covering tiles 150 and a plurality of lighting units 250. In an embodiment, the number of floor covering tiles 150 may be larger than the number of lighting units 250. In such embodiment, when lighting units 250 may not be adjacent, (also) an auxiliary layer may be arranged between the lighting units 250. A unit may for instance have dimensions like 5 cm to 50 cm length and width, and 0.1 mm to 1 mm height.

(23) FIG. 4 schematically depicts some variants of the invention. Here, the floor covering tile 150 is a PVC floor covering tile that comprises connectors 103. These may be used to connect multiple tiles 150 and form a closed tile area, i.e. a PVC flooring. Further, by way of illustration, light 210, emanating from the user side 101, in the form of a symbol is depicted.

(24) FIG. 5 schematically depicts an embodiment of the floor covering system 10 further comprising a controller 300 arranged to control the lighting system 200, more precisely the light 210 that may be generated by the lighting system 200. The controller 300 may be arranged external from the lighting system, but may also be integrated in the lighting system 200. The controller 300 controls the one or more light sources 205. Optionally, the floor covering system 10 may further comprise a sensor 400. The controller 300 may then be arranged to control the light 210 of the lighting system 200 in response to a sensor signal of the sensor 400. The term sensor may also relate to a plurality of sensors. Such plurality of sensors may for instance be arranged to sense the same parameter (like touch of a user) at different locations, or to sense different parameters (like touch of a user and smoke, respectively).

(25) FIG. 6a schematically depicts an embodiment of a laminate flooring tile for use in the floor covering system of the invention. The laminate flooring tile 700 comprises recess 701, which penetrates through the inner core layer 702 and the sound inhibitor layer 703 (which is an example of an optional backing layer). The recess 701 does not penetrate through the photographic layer 704 and protective layer 705. This allows the lighting system 706, comprising the light source 708, to be placed below the laminate flooring tile 700 when used in a floor covering system according to the invention, as shown in FIG. 6b, so that light 707 can penetrate through the laminate flooring tile 700. When the lighting system 706 is placed below the laminate flooring tile 700, the part of the laminate flooring tile 700 that remains on top of the recess 701 is preferably separated from the top of the light source 708 by a distance of at least 1 mm, more preferably at least 3 mm, to prevent direct contact between the laminate flooring tile 700 and the light source 708, which could damage the light source 708, when pressure is exerted on the laminate flooring tile 700, for example by people standing or walking on the floor covering system.

(26) The recess 701 may be filled with a transparent or at least light transmissive material. The advantage of this approach is that the robustness of the laminate flooring tile 700 is improved. For example, a suitable material may be a polymer material, such as PVC, PMMA, PE, PP, or a silicone rubber. When the lighting system 706 is placed below the laminate flooring tile 700 wherein the recess 701 is filled with a transparent or at least light transmissive material, the transparent or at least light transmissive material is preferably separated from the top of the light source 708 by a distance of at least 0.5 mm, to prevent direct contact between the transparent or at least light transmissive material and the light source 708, which could damage the light source 708, when pressure is exerted on the laminate flooring tile 700, for example by people standing or walking on the floor covering system.

(27) The recess 701 may also not fully penetrate through the inner core layer 702 (in other words, a thin layer of inner core material remains) in order to improve the robustness of the laminate flooring tile 700. This remaining layer of inner corer material has to have a thickness that allows light 707 to be transmitted, preferably a thickness of less than 1 mm, more preferably less than 0.5 mm. A laminate flooring tile with such a recess may be manufactured by providing a laminate flooring tile, providing a recess at the back side of the laminate flooring tile, having a depth so that a thin layer of inner core material remains, the thin layer having being light transmissive, and optionally filling the recess with a light transmissive material.

(28) The recess 701 may be used as a mixing cavity to mix the colors of a plurality of LEDs with different colors. Preferably the colors are generated by an RGB LED. The advantage of this approach is that the recess 701 not only provides ease of installation, but also provides the optical function of mixing light.

(29) In case the recess 701 is used as a color mixing cavity, it may have a pre-determined shape so that this pre-determined shape is visible on the front side of the laminate flooring tile 700 when the lighting system 706 is turned on. The recess 701 may for example have a rectangular shape.

(30) The recess 701 may contain a plurality of LEDs. In one example, the recess 701 has the shape of an arrow, and contains 80 LEDs in various places within the recess 701. In this way, a uniformly illuminated arrow will be visible on the front side of the laminate flooring panel 700 when the LEDs are turned on.

(31) The laminate flooring tile 700 may be provided with a plurality of recesses 701 in order to allow flexibility in placement of a lighting system. This means that light sources are not installed at every recess, but instead only a few recesses are used. This embodiment may for example be used to provide a line of light sources near the walls of a room.

(32) Alternatively, instead of having the recess 701, the entire inner core layer 702 may be made from a light transmissive material.

(33) To improve alignment between the lighting system 706 and the laminate flooring tile 700, the lighting system 706 may be attached to the laminate flooring tile 700, for example by using an adhesive, but preferably by using a click connection. In this way the lighting system 706 may still be moved and placed freely, but the lighting system 706 is easier to align to the laminate flooring tile 700.

(34) Electric power may be distributed through the laminate flooring tile 700. To achieve this, the laminate flooring tile 700 may be provided with a conductor arrangement on or through the laminate flooring tile 700. Electric connections are made between this conductor arrangement and the lighting system 706 during installation, for example by clicking the lighting system 706 onto the laminate flooring tile 700. The advantage of this approach is that no additional electric wires are required and no soldering is required, because this is handled by clicking the lighting system 706 onto the conductor arrangement in the laminate flooring tile 700.

(35) Preferably, the laminate flooring tile 700 comprises connectors that allow multiple tiles to be connected together, in order to connect the power lines between a plurality of laminate flooring tiles. In order to supply power to the lighting system 706, an installer now only needs to make a power connection to one of the laminate flooring tiles, in order to power all laminate flooring tiles in a network. The conductor arrangement may also comprise an additional conductor line which may be used as a data connection to the lighting system 706. The lighting system 706 may comprise a controller for controlling the light output in response to a data signal on the data connection.

(36) The recess 701 may be filled with a light guide, such that the light 707 can be spread even further than a mixing chamber would be able to achieve. The light guide may be a lossy light guide to give a uniform light output, but the light guide may also have light out-coupling sites, in order to make for example a dotted light output pattern.

(37) The floor covering system 10 may be used to show decorative patterns, but may also be used to provide information, such as by providing a light pattern containing information like arrows, commercial information, etc. (see also above).

(38) A person standing or walking on the floor covering system 10, more precisely on the user side 101 of the floor covering 100, is preferably not able to see the lighting system 200 (when in an off state) from above. This may especially be achieved through the relatively low transmission of not more than about 15%, preferably not more than about 10%, such as 5% or lower.

(39) In a further embodiment the floor covering system 10 is used to make an emergency escape route lighting system that may be activated in case of an emergency. The embodiment comprises the floor covering system 10 located on the floor. The floor covering system 10 may comprise a plurality of light sources 205, which may optionally be connected with each other. The light transmissive floor covering (tiles) is (are) used to cover the lighting system 200. The lighting system 200 may for example be arranged to generate light 210 in the shape of light spots, but may also be in the shape of arrows, to point into the right direction for escape. This arrow may also be made variable, such that the direction of the arrow may be changed depending on the location of the emergency. For example, the arrow may point away from a fire hazard. Instead of an arrow, also blinking lights may be used to point into a direction. In this way, also information may be provided, like arrows indicating in a specific direction, commercial information. One or more of colour, pattern shape, on/off state, output intensity, and information content of the light 210 may be variable and may be controlled by the controller.

(40) Further, one or more of colour, pattern shape and information content of the light 210 may be dependent on a sensor signal of a sensor (such as a touch or approach sensor or fire sensor or smoke sensor or thermal sensor, etc.) (not depicted), wherein the sensor is arranged to sense an object on or in the vicinity of the floor covering system 10 or is arranged to sense a feature selected from the group consisting of smoke and heat, and wherein the controller 300 is arranged to control one or more of colour, on/off state, intensity, pattern shape and information content of the light 210 in dependence of the sensor signal.

(41) Optionally, the controller 300 may also control other apparatus, indicated with reference 600, such as other lighting sources. The light 210 may for instance be controlled in response to a sensor signal of one or more sensors 400. One or more of such sensors 400 may for instance be arranged to measure the light level (in a space or room), which light level may for instance at least partly receive a contribution of other light sources, including day light.

(42) The term substantially herein, such as in substantially flat or in substantially consists, etc., will be understood by the person skilled in the art. In embodiments the adjective substantially may be removed. Where applicable, the term substantially may also include embodiments with entirely, completely, all, etc. Where applicable, the term substantially may also relate to 90% or higher, such as 95% or higher, especially 99% or higher, even more especially 99.5% or higher, including 100%. The term comprise includes also embodiments wherein the term comprises means consists of. Likewise, the term about may, where applicable, indicate a deviation of 10% or less, or 5% or less, or 1% or less, or 0.5% or less, or even 0.1% or less, and also in an embodiment no (measurable) deviation. As will be clear to the person skilled in the art, small deviations from numerical values may, where applicable, in general be allowed. Hence, except for the values in the definition of about above, numerical values may, where applicable deviate a 10% or less, or 5% or less, or 1% or less, or 0.5% or less, or even 0.1% or less from the given value. To stress this, herein sometimes the word about is used before numerical values.

(43) Furthermore, the terms first, second, third and the like in the description and in the claims, are used for distinguishing between similar elements and not necessarily for describing a sequential or chronological order. It is to be understood that the terms so used are interchangeable under appropriate circumstances and that the embodiments of the invention described herein are capable of operation in other sequences than described or illustrated herein.

(44) The devices herein are amongst others described during operation. As will be clear to the person skilled in the art, the invention is not limited to methods of operation or devices in operation.

(45) It should be noted that the above-mentioned embodiments illustrate rather than limit the invention, and that those skilled in the art will be able to design many alternative embodiments without departing from the scope of the appended claims. In the claims, any reference signs placed between parentheses shall not be construed as limiting the claim. Use of the verb to comprise and its conjugations does not exclude the presence of elements or steps other than those stated in a claim. The article a or an preceding an element does not exclude the presence of a plurality of such elements. The invention may be implemented by means of hardware comprising several distinct elements, and by means of a suitably programmed computer. In the device claim enumerating several means, several of these means may be embodied by one and the same item of hardware. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage.