A Covering Element for Floor Covering, A Floor Covering and a Method for Installing a Floor Covering

Abstract

A method for installing a floor covering comprising the steps of:providing a thinset composition (21) on top of a subfloor (20)providing a covering element (1) on top of said thinset composition (1) when the thinset composition (21) is in an uncured or partially cured state, wherein said covering element (1) has an upper side and a lower side (1b) and is removably attached to an intermediate layer (14) at its lower side (1b), so that said intermediate layer (14) enters into contact with the thinset composition (21).

Claims

1. A method for installing a floor covering comprising the steps of: providing a thinset composition on top of a subfloor; providing a covering element on top of said thinset composition when the thinset composition is in an uncured or partially cured state, characterized in that said covering element has an upper side and a lower side and is removably attached to an intermediate layer at its lower side, so that said intermediate layer enters into contact with the thinset composition.

2. The method according to claim 1, wherein after curing of the thinset composition the intermediate layer is bonded to the thinset composition.

3. The method according to claim 1, wherein the covering element has one of a magnetic and a magnetic receptive element on its lower side and said intermediate layer comprises the other of the magnetic and the magnetic receptive layer.

4. (canceled)

5. The method according to claim 3, wherein that the magnetic receptive element on the lower side of the covering element comprises a metal sheet.

6. The method according to claim 1, wherein the thinset composition comprises one of a magnetic and a magnetic receptive element.

7. The method according to claim 6, wherein the thinset composition comprises one of a cement-based composition, a polymer-based composition, and a combination thereof.

8. The method according to claim 1, wherein the covering element comprises a ceramic tile.

9. The method according to claim 8, wherein the covering element comprises a reinforcing element configured for improving the impact resistance of the tile.

10. The method according to claim 9, wherein the reinforcing element compresses the tile.

11. The method according to claim 1, wherein the intermediate layer has substantially one of the same planar shape, the same planar dimension, and a combination thereof of the covering element.

12. The method according to claim 1, wherein the intermediate layer comprises one of an adhesive and a low tack adhesive coating on one of its surfaces.

13. The method according to claim 1, wherein the covering element comprises an edge and a lining at least partially covering said edge.

14. A floor covering comprising: a thinset composition on a subfloor; a covering element comprising a ceramic tile wherein said covering element has an upper side and a lower side and is removably attached to an intermediate layer at its lower side.

15. The floor covering according to claim 14, wherein the intermediate layer is bonded to the thinset composition.

16. The floor covering according to claim 15, wherein the covering element has one of a magnetic and a magnetic receptive element on its lower side and said intermediate layer comprises one of a magnetic and a magnetic receptive layer, wherein the intermediate layer is configured to generate a magnetic field on both its surfaces.

17. The floor covering according to claim 16, wherein the magnetic receptive element on the lower side of the covering element comprises a metal sheet.

18. The floor covering according to claim 14, wherein the thinset composition comprises one of a magnetic and a magnetic receptive element

19. A covering element for a floor covering, comprising a ceramic tile having an upper side and a lower side and that is removably attached to an intermediate layer at its lower side.

20. The covering element according to claim 19, wherein the floor comprises one of a magnetic and a magnetic receptive element on its lower side and wherein said intermediate layer comprises the other of the magnetic and the magnetic receptive layer.

21. (canceled)

22. The covering element according to claim 20, wherein the magnetic receptive element on the lower side of the covering element comprises a metal sheet.

Description

[0050] Further characteristics and advantages of the invention will be apparent from a perusal of the following description, provided by way of example and in a non-limiting way, with the aid of the figures shown on the attached sheets.

[0051] FIG. 1 schematically shows an axonometric view of a covering element according to an aspect of the invention;

[0052] FIG. 2 schematically shows an enlargement of the cross section taken along the plane II-II of FIG. 1;

[0053] FIG. 3 schematically shows a first step of a method according to an aspect of the invention;

[0054] FIG. 4 schematically shows a second step of the method according to an aspect of the invention, and further schematically shows a surface covering according to another aspect of the invention;

[0055] FIG. 5 schematically shows an enlargement of the cross section taken along the plane V-V of FIG. 4;

[0056] FIG. 6 shows the same view of FIG. 5 in an alternative embodiment of the invention;

[0057] FIG. 7 schematically shows the floor of FIG. 4 in a special configuration;

[0058] FIG. 8 schematically shows an enlargement of the cross section taken along the plane VIII-VIII of FIG. 6;

[0059] FIG. 1 shows an axonometric view of a covering element 1 for floors. The covering element has an upper side 1a, for example having a d?cor, and a lower side 1b adapted to face a subfloor. The covering element 1 comprises a tile 2 of ceramic material, for example porcelaneous stoneware, red body (single fired), monoporosa ceramic or clinker. The tile 2 may be replaced in an equivalent manner by a tile made of hard and/or fragile material such as glass, glass-ceramic, cement, and/or natural stone.

[0060] The tile 2 has a substantially rectangular shape, square for example, and has edges 3 and a decorative upper surface 4. The upper surface 4 comprises a pattern 5 which, for example, simulates wood, natural stone or cement. Preferably, the pattern 5 is printed by digital printing.

[0061] FIG. 2 shows an enlargement of the cross section taken along the plane II-II of FIG. 1. As shown in FIG. 2, the tile 2 of the example comprises a body 6 of ceramic material and a covering layer 7 that covers the upper surface of the body 6. For example, the covering layer 7 comprises at least a glaze, an engobe, a smaltobbio and/or a grog. The covering layer 7 substantially defines the upper surface 4 of the tile 2. The pattern is advantageously produced in, on top of, or under the covering layer. In the preferred embodiment, the body 6 has a color which is similar, or preferably identical, to that of the pattern 5, for example with the same color as the glaze. The tile 2 has a thickness S1 of between 4 and 30 mm, preferably between 5 and 12 mm.

[0062] In the example shown in FIG. 2, the edges 3 of the tile 2 comprise a lower bevel 8 and an upper bevel 9. In particular, the lower bevel 8 occupies a lower portion of the edge 3, for example two thirds of the thickness S1, while the upper bevel 9 occupies an upper portion del edge 3, for example one third of the thickness S1 of the tile 2. The lower bevel 8, in use, forms an angle ? with the horizontal plane which is less than 90?, for example less than 85?. The upper bevel 9, in use, forms an angle ? with a vertical plane which is less than 90?, for example less than 90?, or preferably less than 45?.

[0063] The covering element 1 further comprises a lining 10 of the edges 3 of the tile 2. In the preferred example shown in the figure, the lining 10 is configured to cover only the lower bevel 8. Preferably, the lining 10 is made of a polymeric material, preferably thermoplastic, for example PVC, PE or ABS. For example, the lining 10 is provided in the form of a strip of polymeric material glued to the edge 3. Advantageously, the lining 10 has a color capable of imitating, or preferably identical to, the color of the upper surface 4 and/or of the body 6 of the tile 2.

[0064] As shown in FIG. 2, the covering element 1 comprises a reinforcing element 11 configured to improve the mechanical strength of the tile 2; in particular, it is configured to increase the toughness of the tile 2. Even more particularly, the reinforcing element 11 compresses the body 6 of the tile 2 thereby improving the impact resistance of the tile 2 itself. The reinforcing element 11 is fixed to a lower surface 12 of the tile 2.

[0065] FIG. 2 shows a preferred embodiment in which the reinforcing element 11 comprises a metal sheet, made for example of steel, preferably galvanized or stainless steel. Preferably, the metal sheet of the reinforcing element 11 is configured to generate a compressive state in the tile 2, particularly starting from the lower surface 12 thereof. Thus, as the tile 2 is in a compressive state, a significant improvement in the impact resistance is obtained, since the compressive state impedes crack propagation. To achieve this objective, the reinforcing element 11 is initially put under tension (stretched or elongated) by means of mechanical or thermal stretching, and is then fixed under the tile 2 while still in the elongated state. The stretching is then released, by interrupting the mechanical stressing or cooling the reinforcing element, so as to put the tile 2 under compression.

[0066] According to the preferred embodiment, the metal sheet of the reinforcing element 11 has a coefficient of thermal expansion that is greater than the coefficient of thermal expansion of the tile 2. As a result of this solution, the metal sheet can be stretched by heating so as to expand in a substantially uniform manner in all directions. After the sheet of the reinforcing element is fixed under the tile 2, it may be cooled so as to contract and put the tile 2 under compression. Preferably, the metal sheet of the reinforcing element 11 has a Young's modulus that is greater than the Young's modulus of the tile 2, being for example two or three times the Young's modulus of the tile 2. Thus, when the elongated state of the reinforcing element 11 is released, the sheet can effectively put the tile 2 under compression. For example, said reinforcing element is applied according to the method described in the international application WO 2010/072704, which is incorporated herein by reference.

[0067] In a preferred embodiment, the reinforcing element 11 has a thickness S2 of between 0.05 mm and 1 mm, preferably between 0.05 mm and 0.5 mm, or even more preferably between 0.1 and 0.2 mm, for example 0.12 mm.

[0068] The reinforcing element 11 is fixed to a lower surface 12 of the tile 2, in particular of the body 6 thereof, by means of an adhesive, preferably a thermosetting resin, for example an epoxy, polyurethane, acrylic and/or hotmelt glue.

[0069] In the embodiment shown in FIG. 2, the reinforcing element 11 has substantially the same shape as the tile 2. In particular, the reinforcing element 11 has a slightly smaller horizontal size (in plan view) than that of the lower surface 12 of the tile 2. For example, the reinforcing element 11 has edges 13 that do not project beyond the edges 3 of the tile 2. That is to say, the edges 13 of the reinforcing element 11 are contained within the perimeter defined by the edges 3 of the tile 2.

[0070] It should be noted that, as shown by FIG. 2, the lower surface 12 of the tile 2 is usually smooth, that is to say free of relief structures, also known as a mark. Thus, the adhesion between the reinforcing element 11 and the lower surface 12 of the tile 2 is improved 22 so as to improve the reinforcing effect of the reinforcing element 11.

[0071] In the most preferred embodiment of the invention, illustrated herein, the reinforcing element 11 made of a metal sheet is magnetic receptive, for example may advantageously have ferromagnetic and/or paramagnetic characteristics, preferably ferromagnetic, so that it can be attracted by a magnetic element.

[0072] In FIG. 2, it is shown that an intermediate layer 14 is removably attached to the covering element 1 at its lower side 1b. The intermediate layer 14 comprises a polymeric sheet 15, for example made of chlorinated polyethylene elastomer, with magnetic particles, for example of strontium ferrite, embedded therein. In the most preferred embodiment, the intermediate layer 14 generates a magnetic field both its upper and lower surface 16 and 17.

[0073] As illustrated in FIG. 2, the intermediate layer 14 comprises on its upper surface 16 an adhesive coating 18 preferably a low-tack adhesive coating. In this way it is possible to combine the magnetic attraction with a low-tack adhesion to improve the adhesion between the covering element 1 and the intermediate layer 14. Moreover, the combination of the magnetic attraction with the low-tack adhesion allows the reduction of the intensity of the magnetic field thereby limiting the cost of the intermediate layer 14. Said adhesive coating 18 can comprise, for example, a polyurethane resin, polyaspartic resin, acrylic resin, epoxy resin.

[0074] The intermediate layer 14 shows a thickness S3 of at least 0.2 mm, preferably at least 1 mm and of maximum 2 mm, preferably maximum 1.5 mm.

[0075] Preferably, the intermediate layer 14 shows shape and/or dimension substantially corresponding to the shape and/or dimension of the covering element 1. For example, the intermediate layer 14 has a dimension that is suitable to cover at least the 80% of the lower surface of the covering element 1.

[0076] FIG. 3 shows a first step of a method for installing the covering element 1 on a subfloor, in this case a screed 20. In this first step a thinset composition 21 is spread on the screed 20, for example by means of a trowel or a roller 22. During this first step the thinset composition 21 is uncured and is in a liquid or pasty state.

[0077] In the preferred example the thinset composition 21 is a combination of an organicbased composition and resin-based composition. The cement-based composition can comprise one or more of cementitious component like, Portland cement, calciumbased cement, for example calcium-sulphate based cement, aluminum-based cement, and/or fillers, preferably inorganic fillers, like clays or silica. The resin-based composition can comprise acrylic or epoxy composition.

[0078] In the preferred embodiment, the thinset composition 21 comprises magnetic receptive particles, for example ferro silicon particle and/or magnetite that can be attracted by the intermediate layer 14.

[0079] In the preferred embodiment, the thinset composition 21 comprises at least the 20% wt (by weight), preferably at least the 30% wt of cement-based composition, at least 20% wt (by weight), preferably at least the 30% wt of resin-based composition, and at least 20% wt (by weight), preferably at least the 30% wt of magnetic receptive element.

[0080] The thinset composition 21 has a setting time between 5 h and 30 minutes.

[0081] FIGS. 4 and 5 show a second step of the method of the invention wherein the covering elements 1 are installed on the thinset composition 1 for forming a floor covering 23. It is important to note that the covering elements 1 are installed on the thinset composition 21 when the latter is uncured or partially cured. Moreover, in this second step of the method, the intermediate layer 14 is removably attached to the covering element 1 so to enter in direct contact with the thin set composition 21 and prevents the contact between the covering element 1 and the thinset composition 21 itself.

[0082] The intermediate layer 14 magnetically attracts the magnetic receptive particles of the thinset composition 21 so that they will concentrate in an upper portion 24 thereof thereby maximizing the bonding between the intermediate layer 14 and the thinset composition 21.

[0083] The magnetic attraction exerted by the intermediate layer 14 and the low tach adhesive attraction exerted by the adhesive coating 18 keep the covering elements 1 in position in the floor covering 23 even in case of an heavy traffic.

[0084] Thanks to the fact that when the covering elements 1 are installed on the thinset composition when this is still in an uncured state, it is possible to adjust their position and/or the quantity of the thinset composition 21 below them to correct unevenness of the screed 20 to make sure that a well levelled floor covering 23 is obtained. For example, the upper surfaces 4 of the tiles 2 can lay all on a same plane. This can also be obtained with the help of levelling tools as wedges for example.

[0085] As shown in FIG. 5, the edges 3 of the covering elements 1 contact each other, in particular in correspondence of the linings 10. In this case, the covering element are not fixed each other and, since they are only removably attached to the intermediate layer 14, they can be removed from the floor covering 23 and reused.

[0086] FIG. 6 shows an alternative embodiment of the invention wherein the tiles 2 have edges 3 that are free from said linings 10 and wherein a joint 25 between said edges 3 is partially filled by a grout 26, preferably polymer based. Preferably the grout 26 is provided in the joint 25 only once the setting time of the thinset composition 21 is expired.

[0087] The grout 26 is provided in the joint 25 in such a way that an interspace 27 is formed between the thinset composition 21 and the grout 26. In this way, the grout 26 can be cut and the covering elements 1 removed without that the thinset composition 21 and/or the intermediate layer 14 are contaminated by the grout 26.

[0088] As shown in FIGS. 7 and 8, once once the setting time of the thinset composition 21 is expired the intermediate layer 14 remains solidly bonded to the thinset composition. Therefore, the covering elements 21 can be removed from the floor covering 23 but the intermediate layers 14 remains bonded to the thinset composition 21 so that the latter two form a subfloor system 28 that is ready to receive new covering elements 1, for example with a different d?cor 5. As shown in FIG. 8 the upper surface of said subfloor system 28 is substantially formed by the upper surfaces 16 of the intermediate layers 14 which lay substantially all on the same plane as a consequence of the fact that they have been placed on the thinset composition when the latter was in uncured state and when they were attached to the covering elements 1.

[0089] The present invention is in no way limited to the hereinabove described embodiments, but may be realized according to different variants without leaving the scope of the present invention.

[0090] Further, as is clear from the content of the description, the present invention relates to one or more of the items as listed below, numbered from 1 to 53:

[0091] 1.A method for installing a floor covering comprising the steps of: [0092] providing a thinset composition (21) on top of a subfloor (20) [0093] providing a covering element (1) on top of said thinset composition (1) when the thinset composition (21) is in an uncured or partially cured state,
wherein said covering element (1) has an upper side and a lower side (1b) and is removably attached to an intermediate layer (14) at its lower side (1b), so that said intermediate layer (14) enters into contact with the thinset composition (21).

[0094] 2.The method according to item 1, wherein after curing of the thinset composition (1) the intermediate layer (14) is bonded to the thinset composition (21).

[0095] 3.The method according to any of the preceding items, wherein the covering element (1) has a magnetic or magnetic receptive element (11) on its lower side (1b) and said intermediate layer (14) comprises a magnetic or magnetic receptive layer.

[0096] 4.The method according to item 3, wherein the intermediate layer (14) is configured to generate a magnetic field on both its surfaces (16, 17).

[0097] 5.The method according to item 3 or 4, wherein the intermediate layer (14) comprises a polymer sheet (15) with magnetic or magnetic receptive particles.

[0098] 6.The method according to any of the items from 3 to 5, wherein the intermediate layer (14) is formed by one layer.

[0099] 7.The method according to any of the items from 3 to 6, wherein the magnetic receptive element on the lower side (1b) of the covering element (1) comprises a metal sheet (11).

[0100] 8.The method according to any of the preceding items, wherein the thinset composition (21) comprises a magnetic or magnetic receptive element 9.The method according to item 8, wherein said thinset composition (21) comprises at least 20% wt (by weight), preferably at least the 30% wt of magnetic receptive or magnetic element.

[0101] 10.The method according to item 8 or 9, wherein the thinset composition (21) comprises a cement-based and/or a resin-based composition.

[0102] 11.The method according to item 10, wherein the thinset composition (21) comprises at least the 20% wt (by weight), preferably at least the 30% wt of cement-based composition; and/or at least 20% wt (by weight), preferably at least the 30% wt of resinbased composition.

[0103] 12.The method according to any of the preceding items, wherein the covering element (1) comprises a tile (2) made of a brittle material like: ceramic, natural stone, mineral-based tile, cement-based tile or glass.

[0104] 13.The method according to item 12, wherein the covering element (1) comprises a reinforcing element (11) configured for improving the impact resistance of the tile (2).

[0105] 14.The method according to item 13, wherein the reinforcing element (11) compresses the tile (2).

[0106] 15.The method according to any of the preceding items, wherein the intermediate layer (14) has substantially the same planar shape and/or planar dimension of the covering element (1).

[0107] 16.The method according to any of the preceding items, wherein the intermediate layer (14) comprises an adhesive or low tack adhesive coating (18) on one of its surfaces.

[0108] 17.The method according to any of the preceding items, wherein the covering element (1) comprises an edge (3) and a lining (10) at least partially covering said edge (3).

[0109] 18.The method according to item 17, wherein said lining (10) covers at least a lower bevel (8) of said edge (3).

[0110] 19.The method according to any of the items from 1 to 16, wherein the method comprises the step of grouting (26) a joint (25) between edges (3) of adjacent covering elements (1).

[0111] 20.The method according to item 19, wherein an intermediate space (27) is formed between said grout (26) and said thinset composition (21) and/or said intermediate layer (14).

[0112] 21.A floor covering (23) comprising: [0113] a thinset composition (21) on a subfloor (20) [0114] a covering element (1)
wherein said covering element (1) has an upper side and a lower side (1b) and is removably attached to an intermediate layer (14) at its lower side (1b).

[0115] 22.The floor covering (23) according to item 21, wherein the intermediate layer (14) is bonded to the thinset composition (21).

[0116] 23.The floor covering (23) according to item 21 or 22, wherein the covering element (1) has a magnetic or magnetic receptive element (11) on its lower side (1b) and said intermediate layer (14) comprises a magnetic or magnetic receptive layer.

[0117] 24.The floor covering (23) according to item 23, wherein the intermediate layer (14) is configured to generate a magnetic field on both its surfaces (16,17).

[0118] 25.The floor covering (23) according to item 23 or 24, wherein the intermediate layer (14) comprises a polymer sheet (15) with magnetic or magnetic receptive particles.

[0119] 26.The floor covering (23) according to any of the items from 23 to 25, wherein the intermediate layer (14) is formed by one layer.

[0120] 27.The floor covering (23) according to any of the items from 23 to 26, wherein the magnetic receptive element on the lower side (1b) of the covering element (1) comprises a metal sheet (11).

[0121] 28.The floor covering (23) according to any of the items from 21 to 27, wherein the thinset composition (21) comprises a magnetic or magnetic receptive element

[0122] 29.The floor covering (23) according to item 28, wherein said thinset composition (21) comprises at least 20% wt (by weight), preferably at least the 30% wt of magnetic receptive or magnetic element.

[0123] 30.The floor covering (23) according to item 28 or 29, wherein the thinset composition (21) comprises a cement-based and/or a resin-based composition.

[0124] 31.The floor covering (23) according to item 30, wherein the thinset composition (21) comprises at least the 20% wt (by weight), preferably at least the 30% wt of cement-based composition; and/or at least 20% wt (by weight), preferably at least the 30% wt of resin-based composition.

[0125] 32.The floor covering (23) according to any of the items from 21 to 31, wherein the covering element (1) comprises a tile (2) made of a brittle material like: ceramic, natural stone, mineral-based tile, cement-based tile or glass.

[0126] 33.The floor covering (23) according to item 32, wherein the covering element (1) comprises a reinforcing element (11) configured for improving the impact resistance of the tile (2).

[0127] 34.The floor covering (23) according to item 33, wherein the reinforcing element (11) compresses the tile (2).

[0128] 35.The floor covering (23) according to any of the items from 21 to 34, wherein the intermediate layer (14) has substantially the same planar shape and/or planar dimension of the covering element (1).

[0129] 36.The floor covering (23) according to any of the items from 21 to 35, wherein the intermediate layer (14) comprises an adhesive or low tack adhesive coating (18) on one of its surfaces (16, 17).

[0130] 37.The floor covering (23) according to any of the items from 21 to 36, wherein the covering element (1) comprises an edge (3) and a lining (10) at least partially covering said edge (3).

[0131] 38.The floor covering (23) according to item 37, wherein said lining (10) covers at least a lower bevel (8) of said edge (3).

[0132] 39.The floor covering (23) according to any of the items from 1 to 16, wherein it comprises a grout (26) at least partially filling a joint (25) between edges (3) of adjacent covering elements (1).

[0133] 40.The floor covering (23) according to item 21, wherein an intermediate space (27) is present between said grout (26) and said thinset composition (21) and/or said intermediate layer (14).

[0134] 41.A covering element (1) for floors covering (23) having an upper side and a lower side (1b) and that is removably attached to an intermediate layer (14) at its lower side (1b).

[0135] 42.The covering element (1) according to item 41, wherein it comprises a magnetic or magnetic receptive element (11) on its lower side (1b) and wherein said intermediate layer (14) comprises a magnetic or magnetic receptive layer.

[0136] 43.The covering element (1) according to item 42, wherein the intermediate layer (14) is configured to generate a magnetic field on both its surfaces (16,17).

[0137] 44.The covering element (1) according to item 42 or 43, wherein the intermediate layer (14) comprises a polymer sheet (15) with magnetic or magnetic receptive particles.

[0138] 45.The covering element (1) according to any of the items from 42 to 44, wherein the intermediate layer (14) is formed by one layer.

[0139] 46.The covering element (1) according to any of the items from 42 to 46, wherein the magnetic receptive element on the lower side (1b) of the covering element (1) comprises a metal sheet (11).

[0140] 47.The covering element (1) according to any of the items from 41 to 46, wherein it comprises a tile (2) made of a brittle material like: ceramic, natural stone, mineralbased tile, cement-based tile or glass.

[0141] 48.The covering element (1) according to item 47, wherein the covering element (1) comprises a reinforcing element (11) configured for improving the impact resistance of the tile (2).

[0142] 49.The covering element (1) according to item 48, wherein the reinforcing element (11) compresses the tile (2).

[0143] 50.The covering element (1) according to any of the items from 41 to 49, wherein the intermediate layer (14) has substantially the same planar shape and/or planar dimension of the covering element (1).

[0144] 51.The covering element (1) according to any of the items from 41 to 50, wherein the intermediate layer (14) comprises an adhesive or low tack adhesive coating (18) on one of its surfaces (16, 17).

[0145] 52.The covering element (1) according to any of the items from 41 to 51, wherein it comprises an edge (3) and a lining (10) at least partially covering said edge (3).

[0146] 53.The covering element (1) according to item 52, wherein said lining (10) covers at least a lower bevel (8) of said edge (3).