Patent Application
20210131120
Ceramic tiles are among the most widely installed flooring around the world. Installing ceramic tiles, however, takes much effort and the cost of installation per square foot is very high compared to vinyl or wood planks which can be installed with click technology.
Various thermoplastic planks comprising a core, print layer and optionally an overlay are disclosed in, for example U.S. Pat. Nos. 6,617,009, 6,986,934, 7,211,310, 7,419,717, 7,763,345, and 8,021,741. In these planks, the core is comprised of at least one thermoplastic material and the print layer is preferably an aminoplast resin impregnated printer paper. Optionally, the edges of these thermoplastic planks may have a tongue and groove design for attachment to each other in a floating floor system.
Various alternative configurations for attachment of planks of a plank flooring system are disclosed, for example, in U.S. Pat. Nos. 7,770,350, 7,866,115, 8,099,919, and 8,875,465 and Published U.S. Patent Application Nos. 2003/0024199, 2004/0016196 and 2005/0097860.
Further, floor planks with a core modified to include a sound absorbing layer or a cork layer providing sound and heat insulation are disclosed in U.S. Pat. Nos. 8,234,829 and 8,171,691, respectively.
A floor plank of a laminate of two layers of flexible plastic sheet material laminated together in offset relationship to define an offset marginal portion for each of the layers is disclosed in U.S. Pat. No. 7,155,871.
Layered wood composites for flooring are disclosed in U.S. Pat. Nos. 7,544,423 and 7,261,947.
In addition, floor coverings with protective aluminum oxide in the outermost surface are disclosed in Published U.S. Patent Application No. 2002/0025446, while building panels with a decorative surface having a wear layer including fibers, binders and wear resistant particles are disclosed in U.S. Pat. No. 8,431,054.
Engineered waterproof plastic composite flooring and wall covering planks with a veneer layer, an extruded plastic composite core, a click-lock edge fastening system and an optional underlayer are disclosed in U.S. Pat. No. 9,234,357. Various veneer layers inclusive of stone or tile veneers are disclosed. However, such a veneer is less than 3 mm thick as per industry standards. See veneer definition in en. with the extension wikipedia.org/wiki/Wood veneer of the world wide web. A stone or tile veneer less than 3 mm thickness can easily break and does not provide for robust flooring. Further, the adhesive layer that bonds veneer to the core is described as a water resistant hot melt adhesive and is applied during the manufacture of the engineered flooring at temperatures over 200° F. Hence, the tile will be very difficult to dismantle from the substrate when needed. Further, even if the tile is dismantled, damage to the tile or the substrate is likely, thereby preventing reuse.
Further, commercially available polymer cores can dent easily and provide inadequate support for a rigid ceramic tile on top. In addition, the polymer core has thermal expansion coefficient which is significantly more than that of ceramic tile, which could lead to damage to the joints, cracking of core, and buckling of floor itself.
A modular tile assembly having a substantially rigid substrate, at least one sealant layer and at least one stone, ceramic or porcelain tile is disclosed in U.S. Pat. No. 7,993,731. The sealant layer that bonds stone, ceramic or porcelain tile to the substrate below is described as hot glue or polyurethane resin adhesive. Conventional adhesives such as one component thermo-setting urethane adhesives are described. Use of these adhesives makes removal of tile from substrate very difficult. Further, even if the tile is dismantled, damage to the tile or the substrate is likely, thereby preventing reuse.
A floating floor system that uses real porcelain tile is SnapStone. This system uses real porcelain tile which is permanently adhered to a tray engineered with click together tabs which are then snapped together to create grout lines. The system is described as being installable over most existing hard surfaces without the need for thin set, hacker board and mortar. However, the plastic frame is specific to the size of tile and the number of stock keeping units for this system is large. Further, the tile has to be rectified as tolerances should be very tight. This limits offerings and increases the cost of the product.
Accordingly, there is a need for cost-effective, easy to install, hard tile products wherein each component in the assembly can be easily removed, replaced or reused when needed. This will enable home owners to replace damaged tiles or refresh their flooring with tiles of new designs.
The present disclosure relates to an easy to install hard tile product that significantly reduces effort and time for installation as well easy dismantling and replacement when needed thus creating value for the consumer.
An aspect of the present disclosure is directed to an engineered plank. The plank comprises hard tile comprising mineral or metal with a Mohs hardness scale rating of 4 or greater, a composite core with a Mohs hardness scale rating of less than 4, an attachment system which attaches the hard tile to the composite core, and a connection system to connect to adjacent engineered planks. In some nonlimiting embodiments, the attachment system is a removable attachment system so that the hard tile is not permanently attached to the composite core. Nonlimiting examples of hard tile which can be used in these engineered planks include ceramic, porcelain, natural stone, glass, metal or metal alloy such as steel. The present disclosure enables such hard tile to be assembled easily via the composite core, attachment system and connection system. Further, embodiments comprising a removable attachment system enable easy dismantling without damage to the hard tile or composite core.
In one nonlimiting embodiment of the engineered plank of the present disclosure, the thickness of the hard tile is greater than 3 mm
In one nonlimiting embodiment of the engineered plank of the present disclosure, the attachment system attaching the hard tile to the composite core comprises an adhesive. Nonlimiting examples of adhesives include removable hot melt adhesives, pressure sensitive adhesives, moisture resistant adhesives, and combinations thereof.
In another nonlimiting embodiment of the engineered plank of the present disclosure, the attachment system attaching the hard tile to the composite core is magnetic.
In one nonlimiting embodiment, the composite core of the engineered plank has a coefficient of expansion of core in the range 5×10−6 to 30×10−6 inch/inch/deg F.
In one nonlimiting embodiment, the composite core of the engineered plank has a dent resistance such that long term denting per ASTM F970 is less than 0.005 inches and/or short term denting per ASTM F1914 is less than 0.005 inches.
In one nonlimiting embodiment, the composite core of the engineered plank comprises a polymer selected from high density polyethylene, polypropylene, polyethylene, low density polyethylene, polyamide, polyester, polyvinyl chloride, polylactic acid or a copolymer, recycled polymer or blend thereof. In one nonlimiting embodiment, the composite core may further comprise a filler and/or an additive.
In some nonlimiting embodiments, the engineered plank may further comprise a second attachment system on the composite core to which an underlayment layer may be adhered. In some nonlimiting embodiment, the engineered plank may further comprise an underlayment layer adhered to the composite core.
Another aspect of the present disclosure relates to a system for covering floors, walls and other hard surfaces with these engineered planks. The system comprises two or more of the engineered planks connected adjacently via the connection system.
In one nonlimiting embodiment, the hard tile is inset from the edge of the composite core to provide a gap when connected to an adjacent engineered plank. In this embodiment, when the gaps are filled in with grout, caulk or sealant, any water on the hard tile may be prevented from reaching click joints, potentially penetrating joints and reaching subfloors, thus preventing mold/mildew and odor issues.
In one nonlimiting embodiment, gaps between hard tile of connected planks are grouted using, for example, an acrylic, urethane, epoxy or cementitious grout. In one nonlimiting embodiment, any gaps between hard tile of connected planks are filled with a removable caulk or sealant, for example an acrylic latex, silicone, or butyl rubber. This embodiment, in addition to preventing water penetration, permits removal of the caulk or sealant from the grout lines, enabling moving and replacement of the planks as needed.
Disclosed herein is an engineered plank and system of connected engineered planks for use as coverings for floors, walls and other hard surfaces.
The engineered planks of the present disclosure comprise a hard tile with Mohs hardness of 4.0 or greater. Such hard materials cannot be easily joined with, for example, tongue and groove type joints as they are not flexible enough to create water tight seals when the joints are assembled during installation. Traditionally, such hard tile such as ceramic, porcelain and natural stone tile are installed with grout, which involves significant effort and cost to install.
In the engineered planks of the present disclosure, hard tile with Mohs hardness of 4.0 or higher are assembled on a composite core with a Mohs hardness of less than 4 and with a connection system which allows for easily joining during installation.
Hard tile used in the engineered planks of the present disclosure comprise mineral or metal with a Mohs hardness scale rating of 4 or greater. Nonlimiting examples include hard tile comprising ceramic, porcelain, natural stone, glass, metal and/or metal alloy such as steel with Mohs hardness ranging from 4.5 for normal steel to 5.5 for glass, 7.0 for ceramic and 7.5-8.0 for hardened steel. Preferred is that the hard tile be 3 mm or greater in thickness. In one nonlimiting embodiment, the hard tile may range from 3 mm to 30 mm in thickness. In another embodiment, the hard tile may range from 3 mm to 25 mm in thickness. In yet another embodiment, the hard tile may range from 3 mm to 15 mm in thickness, or from 3 mm to 12 mm, or from 3 mm to 10 mm, or from 3 mm to 8 mm, or from 3 mm to 6 mm in thickness. Nonlimiting examples of such hard tile are commercially available and include Crossville and Laminam tile, both manufactured by Crossville Inc. (Crossville, Tenn.), tile manufactured by Dal-tile (Dallas, Tex.), Crossville Inc. (Crossville, Tenn.) and Marazzi (Sunnyvale, Tex.), and such.
In one nonlimiting embodiment, the edges of the hard tile are beveled to create a grouted appearance.
In one nonlimiting embodiment, the hard tile may be coated for easier cleaning. In one nonlimiting embodiment, the hard tile may include an additive to enhance, for example, antimicrobial efficacy.
In one nonlimiting embodiment, the hard tile are inset from the edge of the composite core to provide a gap when connected to an adjacent engineered plank. In this embodiment, when the gaps are filled in with grout, caulk or sealant, it prevents water on the hard tile from reaching click joints, potentially penetrating joints and reaching subfloors, thus preventing mold/mildew and odor issues.
The engineered planks further comprise a composite core. Composite core thickness varies from about 2 mm to about 20 mm.
In one nonlimiting embodiment, the composite core has a Mohs hardness rating less than 4.0.
In one nonlimiting embodiment, the composite core is a water resistant high density or medium density fiber board.
In one nonlimiting embodiment, the composite core comprises a polymer. Nonlimiting examples of polymers useful in the composite core of the present disclosure include high density polyethylene, polypropylene, polyethylene, low density polyethylene, polyamide, polyester, poly vinyl chloride (PVC), polylactic acid or any copolymers or recycled polymers or blends thereof.
In one nonlimiting embodiment, the composite core further comprises a filler. Nonlimiting examples of fillers useful in the composite core include limestone, talc, calcium carbonate, wood dust, bamboo dust, cork, perlite, glass fiber, polyamide fiber, cellulosic fiber, wood fiber, a polymeric fiber, glass, sand, synthetic fiber, fly ash, flax fiber, hemp fiber, Kaolin clay, Mica, Wollastonite (CaSiO3), carbon black or any combination thereof.
The composite core can have a density of 1.0 to 2.4 gm/cc, preferably in the range 1.3-2.1 gm/cc.
In one nonlimiting embodiment, the filler to polymer ratio of the composite core ranges from about 5:95 to about 95:5 by weight.
In addition, the composite core may further comprise an additive. Nonlimiting examples of additives which can be used include colorants, anti-UV agents, UV absorbers, fire retardants, anti-fungal agents, antimicrobial agents, coupling agents, reinforcing agents, interfacial adhesion promoting agents, stabilizers, antioxidants, lubricants, plasticizers, and recycled additives and any combinations thereof.
In the present disclosure, the composite core may have a dent resistance such that long term denting per ASTM F970 is less than 0.005 inches. In addition, or alternatively, the composite core may have a dent resistance such that short term denting per ASTM F1914 is less than 0.005 inches.
Nonlimiting examples of core composites that have acceptable dent resistance (less than 0.005 inches of dent per ASTM F970) include STAINMASTER® 5.74″×47.74″ Washed Oak, STAINMASTER® 12″×24″ Light Brown Stone, and such commercial products.
In one nonlimiting embodiment, the composite core has a coefficient of expansion of core closer to the range of expansion of the hard tile. For example, porcelain tile has a coefficient of expansion of 2×10−6 inch/inch/deg F., clay tile has a coefficient of expansion of 3.5×10−6 inch/inch/deg F. and marble has a coefficient of expansion ranging from 3.1×10−6 to 7.9×10−6 to 30×10−6 inch/inch/deg F. See americanelements with the extension.com/thermal-expansion-coe.html of the world wide web. Typical Luxury Vinyl core has PVC (expansion coefficient of about 28×10−6 inch/inch/deg F.) and limestone (expansion coefficient of 4.4×10−6 inch/inch/deg F.) as per americanelements with the extension.com/thermal-expansion-coe.html of the world wide web. Increasing filler content tends to decrease thermal coefficient of expansion (ref: Wood Plastic Composites, Anatole A Klyosov, Page 362). In one nonlimiting embodiment, the composite core used in the present disclosure has a coefficient of expansion of core in the range 5×10−6 to 30×10−6 inch/inch/deg F. At this decreased coefficient of expansion, damage to the joints, cracking of the core, and/or buckling of any covering comprising the planks is reduced.
The engineered planks further comprise an attachment system which attaches the hard tile to the composite core. In one nonlimiting embodiment, the attachment system is a removable attachment system allowing for removal, dismantling and/or replacement of tile attached to the composite core without damage to the tile or composite core.
In one nonlimiting embodiment, the attachment system of the engineered planks comprises an adhesive which adheres the hard tile to the composite core. Various adhesives capable of adhering hard tile such as stone, ceramic or porcelain tile to the composite core can be used. Nonlimiting examples include: hot melt adhesives such as ethylene vinyl acetate copolymer, ethylene acrylate copolymer, ethylene n-butyl acrylate, ethylene acrylic acid, ethylene ethyl acetate, polyurethanes, and amorphous polyolefins; pressure sensitive adhesives such as styrene-ethylene/propylene, styrene-isoprene-styrene (SIS), acrylate polymer, biobased acrylates, thermo plastic elastomer, natural rubber, silicone rubber; and moisture resistant adhesives such as a commercially available EnviroSTIX™ adhesive, which is a polyacrylic product made by Base King in Dalton, Ga., polyvinyl acetate, epoxy resin, resorcinol-formaldehyde, and polyurethane. Removable adhesives made of acrylic copolymer emulsions such as Covinax 211-15, Covinax 211-01, Covinax 225-00, and removable pressure sensitive adhesive such as Covinax SMA-01 made by Franklin International, Columbus, Ohio are suitable when removal of tiles may be desired. Removable hot melt adhesive such as 3M 3798 LM made by 3M, St Paul, Minn. are also suitable.
In an alternative nonlimiting embodiment, the engineered plank further comprises an attachment system which magnetically attaches the stone, ceramic or porcelain tile to the composite core. See Example 5 and
In addition, the engineered plank of this disclosure comprises a connection system to connect to adjacent engineered planks. Various ways for connection to an adjacent engineered plank via the core are known and can be used in the present disclosure. In one nonlimiting embodiment, the composite core is edge profiled using currently available click-lock technologies to have tongue and groove type joints. Various designs for this click-lock technology have been described and are available from Unilin (Wielbeke, Belgium), Valinge (Viken, Sweden), or Classen (Kaisersesch, Del.). Such technologies are widely used in the hard surfaces flooring industry. Alternatively, a lock-grip strip technology may be used. Similar ways for connection which can be routinely adapted for use in the present disclosure are set forth in U.S. Pat. Nos. 7,770,350, 7,866,115, 8,099,919, and 8,875,465 and Published U.S. Patent Application Nos. 2003/0024199, 2004/0016196 and 2005/0097860, teachings of which are incorporated herein by reference. with a connection system to connect to an adjacent engineered plank. In this nonlimiting embodiment, the composite core is flexible and soft enough for the joints to seal when assembled.
The engineered planks of the present disclosure may further comprise a second attachment system on the core composite on the side opposite to the hard tile with an underlayment layer optionally adhered to it. Nonlimiting second attachment systems may be magnetic or may comprise adhesives such as described herein. Nonlimiting examples of underlayment layers include cork, rubber, foam and paper layers. Such underlayment layers may be added to provide gripping effect of the plank to the surface to which it is being applied as well as sound dampening effect.
Planks of the present disclosure are engineered by adhering hard tile to the core composite via the attachment system. Optionally, a second attachment system may be applied to the core composite on the side opposite to the tile for adherence to an underlayment layer. Planks of the present disclosure can be engineered into various shapes and sizes. In one nonlimiting embodiment, the plank is rectangular in shape with a thickness of up to about 1.25 inches, a width from about 2 to about 12 inches and a length from about 4 to 96 inches. Alternatively, the planks may be square, polygonal such as pentagonal, hexagonal or joined together in, for example, but not limited to, a herringbone pattern or French pattern.
Two or more of the planks can then be easily connected via the connection system thus providing an easy to install system for covering floors, walls and other hard surfaces.
Accordingly, the present disclosure also provides systems for covering floors, walls and other hard surfaces comprising two or more of the engineered planks connected adjacently via the connection system. The engineered planks can be cut to size and shape by well known methods used to cut ceramic, porcelain or natural stone or metals. Equipment for cutting ceramic, porcelain or natural stone tiles include wet/dry saws such as SKIL 7″ wet table top saw or Ryobi 4″ hand held wet tile saw, or BOSCH Multi-X tool. Metal tiles can be cut with bench shears, power saws or hack saw.
In one nonlimiting embodiment, systems of the present disclosure may comprise beveled hard tile.
In one nonlimiting embodiment, the hard tile is inset from the edge of the composite core to provide a gap when connected to an adjacent engineered plank.
In one nonlimiting embodiment, the connected planks are then grouted using, for example, an acrylic, urethane, epoxy or cementitious grout. In one nonlimiting embodiment, the grooves between connected tiles are filled with a removable caulk or sealant, such as, for example an acrylic latex, silicone, butyl rubber, oil based asphalt caulk, polyurethane, caulking cord or cementitious grout. In this embodiment, when the gaps are filed in with grout, caulk or sealant, it prevents water from above reaching click joints, potentially penetrating joints and reaching subfloors, thus preventing mold/mildew and odor issues. If replacement or movement of a plank or planks is required, the caulk/sealant can be removed by prying out from the grout line, the click joints can be dismantled, and any plank or planks needing replacement or movement can be removed and/or replaced or reassembled.
In the case of magnetic assembly between the hard tile and the composite core, replacement or movement of the hard tile of the engineered plank or planks can be easily facilitated by pulling the hard tile off from the magnetic assembly and replacing with a new hard tile. Alternatively, the entire engineered plank or planks may be removed by prying out from the grout line and dismantling the connection system that connects to the adjacent planks.
The engineered planks and systems of the present disclosure are just as easy to install as Luxury Vinyl with click or grip lock stick technologies and do not require skilled labor which is ordinarily needed for installing grouted ceramic and stone floor. Assemblies such as shown in
The following Test Methods and Examples demonstrate the present disclosure and its capability for use. The disclosure is capable of other and different embodiments, and its several details are capable of modifications and/or substitution in various apparent respects, without departing from the spirit and scope of the present disclosure. Accordingly, the Examples are to be regarded as illustrative in nature and non-limiting.
The following are standard tests well known to professionals in hard surfaces industry.
Long term dent test ASTM F970—Simulates denting potentially caused by furniture or static loads.
Short term dent test ASTM F1914—Simulates denting caused by high loading applied in a small area (e.g. high heels, pointed objects).
Chair castor joint integrity test EN425—Simulates stress due to moving loads and its impact on click joints of assembled panels.
Water absorption test ASTM EN13329 Annex G—Measures thickness swelling due to water exposure. Any significant swelling could create distortion and warping of panel assemblies.
Edge Curl test ASTM F2199: This test method is used to measure the ability of floor tile to retain its original dimensions following exposure to heat simulating a long service life at reasonable and expected temperatures.
Dimensional stability test EN 434—Dimensional stability after exposure to heat.
Additional tests as given below are specifically designed to evaluate certain flooring properties:
Temperature cycling test: Assembled small panels are installed in an Environmental chamber and cycled through a temperature range of 40 deg F. to 120 deg F., as an example, to confirm ability of such assembled flooring to withstand variations in temperature indoors without warping and distortion.
Mohs Hardness test: The Mohs scale of mineral hardness is a qualitative ordinal scale characterizing scratch resistance of various minerals through the ability of harder material to scratch softer material. Scale is in the range 1 to 10.
Installation test: This test is used to determine relative ease of installation. Time to install flooring by a professional installer is measured for both test and control samples. Relative ease of cutting control as well as test samples is also recorded.
A short-term dent test was performed on a commercially available composite core product, having a polymer core, PVC print layer and wear layer on top.
An engineered plank of the present disclosure was prepared. Hard tile of ceramic 6.9″×19.7″×9 mm thickness in size (Addison Oak wood plank ceramic tile commercially available from Floor & Decor) was assembled on to a core composite of Traffic Master Allure Ultra 7.5″×47.6″×5 mm thick vinyl plank (commercially available from Home Depot) using double sided adhesive tape (See
The core composite had a connection system of click joints. The gap between ceramic tile was maintained evenly across all sides to create space for caulking. Two planks were assembled together to create a two-plank assembly first (See
After 24 hours, the four-plank assembly of
The four-plank assembly of
A large surface coverage can be obtained by similarly connecting multiples of such plank assemblies of
Various commercially available flooring samples were tested for dent resistance. ASTM F970 for long-term dent resistance and ASTM F1914 for short-term dent resistance tests were conducted and results along with connection types are shown in Table 1. Substrates as cores with the dent resistance of less than 0.005 inches would be preferred for the purposes outlined in the present disclosure.
Hard tile of ceramic sized 6.9″×19.7″×9 mm thickness (Addison Oak wood plank ceramic tile commercially available from Floor & Décor) was assembled with a peel and stick magnetic receptive layer (MBR030S004PS—MagneBuild PS Receptive) supplied by Magnetic Building Solutions LLC, Dalton Ga. (see
The ceramic tile with magnetic receptive layer of
In this embodiment, the individual vinyl planks have click joints and more than one such plank assembly (as in
This application claims the benefit of International Application No. PCT/US2018/027848, filed on Apr. 17, 2018, which further claims priority to U.S. Provisional Patent Application Ser. No. 62/486674, filed on Apr. 18, 2017, the disclosures of which are incorporated herein in their entirety by reference.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US2018/027848 | 4/17/2018 | WO | 00 |
| Number | Date | Country | |
|---|---|---|---|
| 62486674 | Apr 2017 | US |
