Patent Grant
8394217
This invention relates to improved methods and apparatus concerning floor tiles and planks, such as for example, vinyl floor tiles and planks, rubber floor tiles and planks and other resilient floor tiles and planks.
There are various devices known in the prior art concerning floor planks. One or more prior art techniques concerning floor planks are shown in U.S. Pat. Nos. 7,155,871 and 7,322,159, which are incorporated by reference herein.
There are various devices known in the prior art concerning floor tiles and planks. One or more prior art techniques concerning floor planks are shown in U.S. Pat. No. 4,195,107 to Timm, U.S. Pat. No. 4,180,615 to Bettoli, U.S. Pat. No. 4,348,477 to Miller, U.S. Pat. No. 4,990,188 to Micek, U.S. Pat. No. 4,439,480 to Sachs, and U.S. Published patent application Ser. no. US 2006/0156663 to Chen-chi Mao, which are incorporated by reference herein.
Known polyvinyl chloride (PVC) floor planks and tiles (so-called vinyl floor in U.S., or PVC floor in Europe, Australia and some other Asian and African countries) employ specialized adhesives (such as “pressure sensitive” adhesives) for affixing the floor planks or tiles to a subfloor, subfloor surface, or underlayment. Two major methods are used for applying adhesives for so called PVC or vinyl floors. In the first method, adhesive is manually applied onto the surface of subflooring or underlayment, and then the vinyl floor is manually applied to the adhesive-coated surface of subflooring or underlayment. In the second method an adhesive-backed vinyl floor plank or tile is provided, in which the adhesive is already applied over the back of vinyl floor or floor plank or tile, without the need of preparing an adhesive-coated surface on top of the subflooring or underlayment. However, typically for the second method, a flooring primer may need to be applied on top of the surface of the subflooring or underlayment, depending on the condition of the subfloor or underlayment. The second known method helps to provide a substantial saving in labor and time by simply allowing removal of a backing, such as a piece of paper or plastic film coated with releasing substance such as polyurethane, silicone, or acrylic, to expose a protected adhesive material on the back of a floor plank or tile.
However, the two aforementioned known methods of floor plank or tile installation do not provide satisfactory performance due to some significant problems. Firstly, for either method, the job of planning installation of a new floor, including many floor planks or tiles, can be confusing. It may be difficult to properly position and balance the overall vinyl floor (comprised of many floor planks or tiles) in a room. Before laying the floor planks or tiles down, measuring and centering the underlayment may be formidable. Any mistake made at a beginning stage may require removal, replacement, repair, or even entire re-installation of all of the floor planks or tiles.
Secondly, for a renewal or replacement installation, i.e. for a replacement of an existing vinyl floor with a new vinyl floor, a complete cycle for the renewal or replacement installation can be relatively long because among other reasons, removal and replacement are somewhat challenging. Sometimes, the removability of a fully adhered vinyl floor (including a plurality of floor planks or tiles) comes up with great difficulty. Furthermore, repair can be arduous, too. Repair usually involves removing existing or damaged vinyl floor planks or tiles or even an entire floor comprised of many floor planks or tiles. Repair may also involve scraping and patching the subflooring, and remedying, such as leveling and repairing, the underlayment, and re-spreading adhesive on top of the repaired or remedied subflooring.
Thirdly, diverse varieties of subflooring and underlayment with distinct qualities and conditions need to be cautiously evaluated during the preparation of installation of a vinyl flooring, including contents of moisture, smoothness of surface, leveling of ground, cleanness of surface, rating of alkali and other factors. Most of pre-installation tests can exclusively be accomplished by professional contract installers, manufacturers or laboratories.
Fourthly, the particular subflooring or underlayment onto which the vinyl floor planks or tiles must be laid may be comprised of any one of a wide variety of materials such as concrete, gypsum, plywood, and existing floorings such as vinyl, ceramic, hardwood, and laminate. Each one of these different subflooring or underlayment materials typically has different features and properties, and the adhesive applied to the subflooring must take into account these different features and properties. For example, a different adhesive may need to be applied to a concrete subflooring versus a plywood subflooring, or the adhesive may need to be applied in a different manner depending on the subflooring material
Fifthly, the brands, qualities and types of adhesive, particularly the contents, ingredients and physical properties, may influence or even impact the performance of installation of PVC or vinyl floor planks or tiles. Therefore, installers, whoever are professional contractors or amateur consumers need to spend additional time to research and study different types of adhesives, or may also need technical support from manufacturers, manufacturer's representatives or manufacturer's distributors.
Sixthly, some types of adhesive may fail to maintain adequate cohesion strength because of the problem of plasticizer migration into adhesive. Plasticizer typically exists in the base layer of vinyl floors, or may exist in some resilient type of underlayment or subflooring. Storage conditions and storage period of adhesives may also impact how the adhesives adhere to a surface.
Seventhly, excessive use of adhesives may cause “ooze”, which means adhesive coming out from seams or joints between floor tiles or planks. This “ooze” causes an undesirable visual appearance on the flooring and/or in the waste of labor and time to get rid of and clean up.
Eighthly, deficit or unevenness of spreading adhesive may cause installation failure due to loose pieces from subflooring or underlayment.
In addition to the difficulties of implementing installation satisfactorily, as mentioned above, another disadvantage is that the application of adhesive produces essentially permanent structures that are difficult to alter, repair or remove once a vinyl floor, including a plurality of vinyl planks or tiles, has been installed. There are various hardware tools and chemicals for removing adhesive-installed vinyl floors, however, it is very difficult, if not impossible to completely eliminate adhesive residue from a subflooring or underlayment, or to completely restore a subflooring to an original intact condition.
Traditionally, adhesive is absolutely required to achieve the installation of vinyl floor. However, before, during and after the use of adhesive all may have inconveniences, concerns and problems to both household amateur consumers and professional contract installers.
It is known to magnetically adhere floor planks or tiles to an iron or other metal subfloor. For example, a process is known of laying magnetic-backed vinyl tiles on an iron sheet. The iron sheet typically contains a synthetic plastic composition material filled with iron powder, and the iron sheet is typically provided on a roll or in sheets.
At least one embodiment of the present invention provides a method comprising the steps of putting together a first piece, wherein the first piece is comprised of a wear layer, a pattern layer, and a base layer, with the wear layer, the pattern layer, and the base layer arranged in a sandwich manner, such that the wear layer is on top of the pattern layer, the pattern layer is on top of the base layer, and the pattern layer is in between the wear layer and the base layer. The method may also include removing portions of the first piece to form a first floor plank.
The step of removing portions of the first piece to form a first floor plank may include removing a first substantially L-shaped portion of the wear layer, removing a second substantially L-shaped portion of the pattern layer, and removing a third substantially L-shaped portion of the base layer. The first substantially L-shaped portion of the wear layer and the second substantially L-shaped portion of the pattern layer are substantially the same size and shape, and are substantially aligned with one another prior to being removed from the first piece. The third substantially L-shaped portion of the wear layer is not aligned with the second substantially L-shaped portion of the pattern layer or the first substantially L-shaped portion of the wear layer prior to being removed from the first piece.
The step of removing portions of the first piece to form a first floor plank may be performed by a machine, such as a bevel machine.
The method may also include applying adhesive to locations on the first floor plank corresponding to where portions of the first piece have been removed. A removable covering may be applied to the adhesive so that the first floor plank can be stored for later installation as part of a floor covering.
The step of removing the first substantially L-shaped portion of the wear layer and the second substantially L-shaped portion of the pattern layer may include forming a first substantially L-shaped slot and a first substantially L-shaped rail. The step of removing the third substantially L-shaped portion of the base layer may include forming a second substantially L-shaped slot and a second substantially L-shaped rail. Adhesive may be applied to at least one of the first and the second substantially L-shaped slots and to at least one of the first and second substantially L-shaped rails, for adhering one floor plank with one or more substantially identical floor planks.
The method may further include applying a removable covering to the adhesive so that the first floor plank can be stored for later installation as part of a floor covering. The method may further include removing the removable covering from the first floor plank, and adhering the first floor plank to a second floor plank, which is substantially identical to the first floor plank, by adhering locations on the first floor plank corresponding to where portions of the first piece have been removed to locations on the second floor plank corresponding to where portions of a second piece have been removed, wherein the second piece is substantially identical to the first piece.
In at least one embodiment of the present invention an apparatus is provided which includes a piece for flooring. The piece for flooring may be a floor plank or floor tile. The piece for flooring may be comprised of a wear layer, a pattern layer, a base layer, and a backing layer. The base layer may be made of a mixture comprised of ilmenite powder. About one third of the mixture may be ilmenite powder. The mixture may also be comprised of calcium carbonate. The mixture may be comprised of calcium carbonate, wherein about one quarter of the mixture is calcium carbonate. The mixture may be further comprised of polyvinylchloride, wherein about one quarter of the mixture is polyvinylchloride. The backing layer may include a plurality of devices which are hexagonally shaped, and wherein the plurality of devices form a honeycomb structure which contacts a top floor surface when the piece is placed on the top floor surface. The backing layer may have a bottom surface including anti-slip backing film. The anti-slip backing film may be comprised of polyurethane.
At least one embodiment of the present application may include a method which may be comprised of placing a plurality of pieces for flooring on a subfloor to form a floor, wherein each of the plurality of pieces is comprised of a wear layer, a pattern layer, a base layer, and a backing layer; and wherein the base layer is made of a mixture comprised of ilmenite powder. Each of the plurality of pieces may be placed on the subfloor without applying an adhesive to adhere the plurality of pieces to the subfloor. Each of the plurality of pieces may have a structure or a composition as previously described.
At least one embodiment of the present invention provides a method and apparatus for installing floor planks or tiles. In at least one embodiment of the present invention, floor planks or tiles are installed without applying an adhesive to adhere the floor planks to a subflooring.
A principle object of one or more embodiments of the present invention is an improved technique in installing flooring, such as installing vinyl flooring, including floor tiles and planks. A floor plank or tile in accordance with an embodiment of the present invention may include an additional layer or supplemental coating, such as an anti-slip layer, on the back of the floor plank or tile.
It is another object of one or more embodiments of the present invention to provide a unique technique for attaching floor planks or tiles, such as vinyl floor planks or other resilient floor planks or tiles to subfloors, underlayments, or equivalent substrates.
It is another object of one or more embodiments of the present invention to provide floor planks or tiles which are configured to be attached to structural sub surfaces with a minimum of skill, effort and cost.
It is a further object of one or more embodiments of the present invention to provide a method and/or apparatus for floor planks or tiles, which allow floor planks or tiles to be fixed to structural sub surfaces without shifting over time, with use, due to outdoor weather, due to indoor temperature changes, due to foot traffic pivoting, or furniture movement.
It is a further object of one or more embodiments of the present invention to provide a non-movable, anti-slip layer or film laminated underneath a vinyl floor or equivalent resilient floor covering which is durable, non-deteriorating and not subject to blistering or bubbling from the effect of moisture or chemicals.
One or more embodiments of the present invention provide a non-skid substance coated over the surface of floor plank's or tile's backing layer. The non-skid substance may be durable, non-deteriorating and not subject to blistering or bubbling from the effect of moisture and chemicals.
One or more embodiments of the present invention may provide an abradant particle or particles such as carborundum, emery, corundum, asphalt, pitch, or bitumen embedded over the backing layer of a floor plank. The abradant particle, particles, or material may be durable, non-deteriorating and not subject to blistering or bubbling from the effect of moisture and chemicals.
One or more embodiments of the present invention may provide anti-slip emboss or texture on the backing layer of a floor plank, such as a resilient floor plank, which is durable, non-deteriorating and subject to strengthen the immovability of floor tiles or planks, when they are installed on a subfloor surface.
One or more embodiments of the present invention may provide a certain amount of a heavy weight substance added into a base layer as a filler for a resilient floor plank or tile. The heavy weight substance may enhance the immovability of tiles or planks.
Other objects or further scopes of applicability of one or more embodiments of the present invention will become apparent from the detailed description given hereinafter. It should be understood, however, that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled the art from this detailed description.
At least one embodiment of the present invention provides a method comprising the steps of putting together a first piece, wherein the first piece is comprised of a protective wear layer, a pattern layer, a resilient synthetic base layer, and a non-movable, anti-slip backing layer; with the wear layer, the pattern layer, base layer and backing layer, arranged in a sandwich manner, such that the wear layer is on top of the pattern layer, the pattern layer is on top of the base layer, the base layer is on the backing layer, and the pattern layer and base layer are between the wear layer and the backing layer.
In at least one embodiment, the method includes applying numerous embossed or textured cupules or devices (by press through heat or by engraving) on the backing layer. The devices or cupules on the backing layer may be arranged like regular hexagon honeycomb or beehive, but other patterns for the devices may be provided such as honeycomb, diamond, square, triangle and other patterns such as from a treadplate. The height of regular hexagon honeycomb may be about 0.1 millimeters to 0.3 millimeters. The distance between each two horizontal sides of adjacent devices or cupules may be three millimeters (mm) to five millimeters (mm). For a better performance, above mentioned height and horizontal distance of hexagon honeycomb can be adjusted.
In at least one embodiment, a method may further include applying a PVC non-movable anti-slip film or polyurethane non-movable, anti-slip film, or other substances with similar function, such as anti-slip textile, coating of aluminum oxide infused polyurethane (PU), Epoxy resin, acrylic, or Teflon(polytetrafluroethylene).
In at least one embodiment, a method may further include applying powdered ilmenite, or titanium powder, or copper powder, or tin powder to a synthetic mixture of polyvinyl chloride powder, Calcium Carbonate and other additives for producing the base layer of floor plank or tile, such as a resilient floor plank or tile, such as a vinyl floor plank or tile.
In at least one embodiment of the present application a floor plank is provided comprising a wear layer, a pattern film, and a magnetic base layer. The floor plank may have a length, a width, and a thickness, wherein the length and the width are substantially larger than the thickness. The magnetic base layer may have a magnetic field which is in a direction substantially parallel to a plane defined by the length and the width of the floor plank, and wherein the direction of the magnetic field is substantially perpendicular to the thickness of the floor plank.
The floor plank may further include an anti-slip layer, such as an anti-slip polyvinyl chloride layer or an anti-slip polyurethane layer. The pattern film is arranged so that it is between the wear layer and the magnetic base layer. The magnetic layer may have a magnetic north pole running along the length of the floor plank at a first end of the floor plank, and the magnetic layer may have a magnetic south pole running along the length of the floor plank at a second end of the floor plank, which is opposite the first end.
The floor plank may include a plurality of channels and rails, wherein each channel of the floor plank is configured to tightly receive a rail of an identical floor plank and each rail of the floor plank is configured to tightly fit into a channel of an identical floor plank. The floor plank may include a layer of a plurality of protruding devices. Each of the plurality of protruding devices may have a hexagonal surface.
In at least one embodiment, a method is provided, which includes placing a first floor plank on a subfloor, and placing a second floor plank, next to the first floor plank on the subfloor. Each of the first floor plank and the second floor plank may be as previously described. The first floor plank and the second floor plank may be placed on the subfloor so that the first floor plank and the second floor plank are adjacent one another and so that a magnetic pole of the magnetic base layer of the first floor plank is attracted to an opposite magnetic pole of the magnetic base layer of the second floor plank to thereby connect the first floor plank and the second floor plank.
The floor plank 100a shown in
The layer 102c and the portion 103 shown in
The floor plank 100a may further include slots or channels 104, 106, 108, and 110 shown in
The floor plank 100a may include a base layer which may be comprised of layer 102c and portion 103. The base layer may include a balance layer and a leveling layer. Typically, in at least one embodiment, only a base layer comes out of a calendering machine or extruder machine. The base layer is then immediately laminated, first with a pattern film and then with a wear layer, or with the pattern film and the wear layer at the same time, to form the piece 100 shown in
The wear layer is transparent, is part of the layer 102b, and is on the surface 102a of the floor plank 100a shown in
Typically a cutting die would be used to form the edges of the piece 100 which may be in the form of a conventional known plank or tile. A bevel machine or some other type of machine can be used to cut, bevel, etch, sculpt, carve, chisel out or otherwise form the slots or channels such as, slots or channels 104, 106, 108, 110, shown in
The base layer 101c of the unmodified piece 100 may be made in advance by calendering (sophisticated, base layer will be thin) or by sets of rollers (simple, base layer will be thicker). The wear layer, pattern film (layer 101b includes wear layer and pattern layer) and base layer (layer 101c may then be properly aligned, so that each layer has substantially the same length and width, is aligned with the other layers, and does not extend substantially beyond the other layers. After cutting, the aligned layers (101b and 101c) may then be sent to a hot press machine for lamination to form the piece 100.
A cutting die can be installed with a calendering machine or extrusion machine, so the entire production process may be made to be automatic and continuous. But due to technique bottleneck or budget limit, factory can also cut lamination sheet into slab, then send to independent, or stand off, cutting die to shape into piece 100.
The wear layer or the layer 101b is transparent, and typically has a thickness of from 0.03 millimeters to 1.2 millimeters. The base layer, or layer 101c of the piece 100, can itself be comprised of more than one layer, such as one, two, or three layers, typically depending on the thickness T1 of the piece 100. Although the base layer 101c may be comprised of more than one layer, it will still appear to be one layer, because any multiple layers of the base layer 101c will be laminated together, unless the layers are different colors.
The wear layer of the layer 101b of the piece 100, may be pure PVC, with greater pulling power (upward) when temperature goes down (for example, a relatively higher processing temperature versus relatively lower room temperature), and for such a PVC wear layer, typically a balance layer as part of the base layer 101c of the piece 100 is used to offset the pulling power of the wear layer. A leveling layer of the base layer 101c of the piece 100, would be the bottommost layer and is aimed at the subfloor or underlayment. If the subfloor or underlayment is uneven or not level, a relatively flexible leveling layer can help to keep a floor comprise of a plurality of planks identical to plank 100a, flat.
A fiber glass layer may optionally be placed between the pattern film layer at the bottom of layer 101b and the base layer 101c (or may be placed between leveling layer and balance leveler), however alternatively, fiber glass materials can be mixed in with the base layer 101c of the piece 100. Fiber glass materials mixed in with the base layer 101c can provide better dimensional stability.
For the lowest (price wise) end product for residential uses, a pattern may be printed on the back of a wear layer, then a pure white film may be paved underneath the pattern (on the non-pattern side) which is called a “feature layer/film”. The combination wear layer (with pattern on back) and “feature layer/film” may then be laminated onto a base layer, and thereafter a large slab or sheet including the combination wear layer and the base layer may be die cut to form a plurality of pieces each identical or similar to piece 100. For better anti-scratch, anti-cuff and better durability of the surface 102a,a coating may be spread on top of the surface 102a, such as a polyurethane coating. A coating of silicone, Teflon, or epoxy and other types of coatings may also be used on the surface 102a.
On the back of the floor plank or tile such as on surface 103a, shown in
The piece 100 shown in
The base layer 101c of the piece 100 of
The base layer, following cutting away portions of the piece 100 to form the plank 100a (wherein the base layer may be most of layer 102c and most of portion 103 in
Instead of die cutting to initially form the piece 100, another method such as waterjet, and CNC, Computer numerical control, which utilizes the commands of numerical control program (compiled by computer) to drive a motor of machine can be used.
After die cutting or some other method is used to initially form the piece 100, the piece 100 is modified into plank 100a. A bevel machine can be used which has a simple operation system to modify the piece 100 into the plank 100a and to thereby form the slots or channels 104, 106, 108, and 110 shown in
In order to produce the floor plank 100a from the piece 100, at least a lengthwise portion along length L1 of piece 100 and at least a width wise portion along width W1 of piece 100 are removed, typically to form an L-shaped portion, by cutting, beveling, etching, sculpting, carving, or chiseling out or otherwise removing various portions of the piece 100 of
After the piece 100 of
The slots or channels 104, 106, 108, and 110 shown in
Adhesive may be spread out onto or in at least one of slot 104 in
The slots or channels 104, 106, 108, and 110 shown in
In accordance with an embodiment of the present invention end-users don't have to spread any adhesive on tile/plank 100a or on the subfloor/underlayment. Also excessive adhesive will flow to a slot or channel instead of going up to the surface of a floor plank 100a or floor planks when they are abutted against one another. For example, excessive adhesive from rail 105 will flow into slot 104 in
Non-dry adhesive will flow due to pressure or heat (or migration, which is kind of interaction between adhesive and DOP/DINP). Migration, to some customers which means excessive adhesive; but to those skilled in the art, it may also means that adhesive became watery, kind of deteriorated.
The piece 100 may have a length L1, which may for example be thirty-six or forty-eight inches or any other length, and a width W1, which may be three, four, six, eight, nine, or twelve inches or any other width. The piece 100 may be replaced by or may be a tile, such as a floor tile which may be twelve inches by twelve, sixteen by sixteen, eighteen by eighteen, twelve by twenty-four, twelve by eighteen inches or any other size. The length L2 of the portion 102 of the plank 100a, shown in
In at least one embodiment, the plank 100a has the same overall length L1 as the piece 100, however, the layer 102b (including a pattern layer or design layer) has a shorter length L2, due to the fact that some of the layer 101b of the piece 100 is removed in the process of forming the layer 102b and the plank 100a from the piece 100.
For forming the sides by altering the piece 100, such as sides 102d-g and 103c-e shown in
Other ways can be used to create the sides of 102d-g and 103c-f (such as laser, waterjet, CNC, and sandy wheel.
The floor plank 100a may have different patterns on the surface 102a of the portion 102, such as wood, stone, carpet, etc, different colors such as white, green, red, multiple colors, etc., different finishes, such as different coatings and different surface textures, such as with embossing.
The thickness of wear layer, such as on surface 102a in
In accordance with a method and/or apparatus of an embodiment of the present invention a piece, such as piece 100 in
The process for producing the piece 100 of
In addition to forming at least two sides to form the top portion 102 in forming the plank 100a, at least one embodiment of the present invention includes forming at least two sides of the bottom portion 103, including at least one length wise, L2 side, such as either of sides 103c and 103d, and at least one widthwise side such as either of sides 103e and 103f shown in
The step of cutting, beveling, etching, sculpting, carving, or chiseling out or otherwise removing various portions of the piece 100 of
Referring to
The floor plank 501 may be considered to be a piece or may be formed from a piece in accordance with an embodiment of the present invention.
The wear layer 502 includes a right side 502a, a front 502b, a rear 502c, and a left side 502d as shown by
The wear layer 502 may include any known wear layer. The wear layer 502 may be substantially made of PVC (Polyvinylchloride).
The pattern layer 504 may include any known pattern layer. The pattern layer 504 may be printed on a white-based PVC (Polyvinylchloride) film, or on the back of a transparent PVC film.
The wear layer 502 may be a thin transparent layer. The pattern (or design) layer may be a thin design layer, such as a synthetic wood grain design layer or a polyvinyl chloride (PVC) synthetic wood grain design layer or a polypropylene synthetic wood grain design layer.
In accordance with an embodiment of the present invention, the base layer 506, may include a filler made of ilmenite powder, and in another embodiment may include a filler made of ilmenite powder and calcium carbonate. The base layer 506 may be made of a mixture of filler (such as a filler comprised of ilmenite powder and calcium carbonate), PVC (polyvinyl chloride), a plasticizer, and other additives, such as a stabilizer, such as carbon black, DOA, or rosin. These may be the only components or ingredients of base layer 506.
In at least one embodiment, for a batch of material for base layer 506, a batch may be made of a mixture of fifty kilograms (kgs) of virgin PVC, seventy-five kilograms (kgs) of ilmenite powder, sixty kilograms (kgs) of calcium carbonate, 0.45 killograms (kgs) of carbon black, 0.3 kilograms (kgs) of rosin (or resin oil), 0.75 kilograms (kgs) of stabilizer, five kilograms (kgs) of DOA, and thirty-five kilograms (kgs) of DINP.
If virgin PVC is used (i.e. not recycled PVC) then the ratio of PVC to filler by weight may range from 1.0 to 1.0 at one end of a first range to 1.0 to 1.3 at the other end of the first range. I.e. at one end of the first range, for every one gram of filler there may be one gram of PVC and at the other end of the first range, for every one gram of PVC there may be 1.3 grams of filler.
If recycled PVC is used then the ratio of recycled PVC to filler by weight may range from 1.0 to 1.0 (1:1) at one end of a second range to 1.0 to 2.0 (1:2) at the other end of the second range. I.e. at one end of the second range, for every one gram of recycled PVC there may be one gram of filler and at the other end of the second range for every one gram of recycled PVC there may be two grams of filler. The filler may be substantially or entirely made of ilmenite powder. The filler may be made of ilmenite powder and calcium carbonate, or may contain little or no calcium carbonate and substantially or only ilmenite powder.
However, it should be noted that recycled PVC typically includes within it an amount of filler, wherein the filler in the recycled PVC may include calcium carbonate, however the particular type of filler in the recycled PVC depends on which industry the recycled PVC is from. However, in one or more embodiments, the content of PVC in recycled PVC is less than virgin PVC because recycled PVC may be a mix of calcium carbonate and PVC. If recycled PVC is used, the ratio of recycled PVC to calcium carbonate may be 1:0 (i.e. no calcium carbonate) at one end of a range to 1:1 at another end of a range.
For at least one embodiment of the present invention, the plank/tile 501 has to smoothly contact the underlayment or subfloor or surface 600a of
The filler of the base layer 506, in accordance with one embodiment of the present invention, is made of a mixture of ilmenite powder and calcium carbonate and may be made of only ilmenite powder. The ratio of ilmenite powder to calcium carbonate may be about 1.25 to 1.0 (1.25:1). I.e. for every one and a quarter grams of ilmenite powder there may be one gram of calcium carbonate. A mixture of calcium carbonate and ilmenite powder is used, for at least the reason, that calcium carbonate is less expensive than ilmenite powder. The actual formula may change subject to the quality of raw materials used for the base layer 506, the temperature of the season, and the request of customer. For example, for request of customer, the customer may want greater hardness, a different type of flexibility, or a different type of overall tile/plank thickness, and these may affect the percentages of raw materials or materials used for the base layer 506.
For the base layer 506, in at least one embodiment, all raw materials which may include filler (such as a filler comprised of ilmenite powder and calcium carbonate), PVC (polyvinyl chloride), a plasticizer, and other additives may be mixed together and heated in a mixer, such as a Banbury mixer for pre-plasticization, to form an overall mixture. A Banbury mixer as known in the art is an internal mixer produced by Farrel Corporation, used for mixing or compounding plastics and interspersing reinforcing fillers in a resin system.
After the overall mixture is formed by the mixer, such as a Banbury mixture, the overall mixture may be sent to sets of rollers or to a calendering machine to produce the base layer 506. The wear layer 502, pattern layer 504, and base layer 506 may then be laminated together with a hot press machine. The base layer 506 material may need to be cut before lamination to fit the size of the hot press machine. Some factories can also laminate by using extruder or calendering machine, they don't have to cut the base layer 506 immediately but can automatically and continuously go on producing.
It is known to make a floor plank or tile with a filler including iron powder and calcium carbonate. However, ilmenite powder is not known for use in a base layer for a floor plank or tile. Using ilmenite powder in accordance with an embodiment of the present invention for a floor plank or tile, such as floor plank or tile 501, is better than using iron powder for several reasons. Firstly, ilmenite powder is as not sensitive to temperature, as iron powder is, which means that ilmenite powder is less likely to expand and contract than iron powder, and therefore a floor plank or tile, such as floor plank or tile 501 made of a base layer including ilmenite powder is less likely to expand and contract than a floor plank or tile make of iron powder.
Secondly, ilmenite powder is better than iron powder for keeping dimensional stability of a floor plank, meaning that the floor plank or tile 501 is less likely to expand or contract with ilmenite powder used for the base layer 506 than with iron powder. Expansion or contraction of the floor plank or tile 501, after installation on a floor surface such as 600a, may change size (or even shape) of floor plank or tile 1, and would be a problem for end-user, reseller or installer. Generally, contraction or expansion of a floor plank or tile, even before or during installation may cause problem because not every piece will expand or shrink to a same size.
Thirdly, Ilmenite powder has anti-oxidization properties that are better than iron powder, which means that ilmenite powder is less likely to rust than iron powder (also, a rusted iron may have bad smell). Fourthly, Ilmenite powder typically costs less than iron powder. Fifthly, for a floor plank or tile, such as 501, of an embodiment of the present invention, which can be used, and is used in at least one embodiment, without applying adhesives to the bottom surface 508e of the backing 508 or to the outer surfaces 511a and 511b and other outer surfaces of the plurality of devices 510, it is desirable to make the floor plank or tile 501 heavier. Increasing the weight of the floor plank or tile 501, makes it more difficult for the floor plank or tile 501 to move when placed on a floor surface, such as surface 600a of floor 600 in
In at least one embodiment of the present invention using ilmenite instead of iron, allows a plank or tile 1 to be made which uses 10% to 20% more calcium carbonate in the base layer 506 than in iron powder—calcium carbonate base layers of the prior art. With the same weight of ilmenite or iron, it is possible to put more calcium carbonate in the base layer 506, which means less PVC can be put in the base layer 6 compared with PVC in base layers of the prior art, so we can save cost and increase weight. Due to the use of ilmenite, we can use more calcium carbonate. The unit price of calcium carbonate is typically much lower than ilmenite powder, iron powder, or PVC, or most if not all of the components used in the base layer 506. In contrast, in the known prior art, floor planks or tiles are made as light as possible to keep down costs of transporting the floor planks and tiles. In the known prior art light calcium carbonate is used, whereas in at least one embodiment of the present invention “heavy” calcium carbonate is used. Typically there are two types of calcium carbonate. One is light weight or “light” calcium carbonate, which may be used for the base layer 506 of an embodiment of the present invention, and; another is heavy weight or “heavy” calcium carbonate, which is commonly used in paint or other industries. but which is typically not used for base layer 506 or for base layers of floor planks or tiles of the prior art. It is possible, that heavy weight or “heavy” calcium carbonate may be used for a base layer 506 in an alternative embodiment of the present invention.
The base layer 506, in accordance with an embodiment of the present invention also may include an additional plasticizer, which may be made of 5% DOA (Bis(2-ethylhexyl) adipate) and 95% DINP (Di-isononyl phthalate) and which may be used in PVC in the base layer 506 as a plasticizer. This particular plasticizer has low temperature resistance and may create better flexibility for the base layer 506, than using DINP (Di-isononyl phthalate) alone, which is typically done for known base layers for known planks and tiles. In at least one embodiment of the present invention, the base layer 506 may be made of PVC, ilmenite powder, calcium carbonate, DOA, a plasticizer (such as DINP, typically used in the PVC), lubricant and some other additives.
The plasticizer used for the base layer 506 may be a Flexidone plasticizer (instead of DINP) from International Specialty Products Inc., (ISP), located in Wayne, N.J., (internet address: ispplastics.com). These Flexidone plasticizers are typically based on N-alkyl pyrrolidone chemistry.
The backing layer 508 may have a bottom surface 8e shown in
In at least one embodiment of the present invention, in order to form the plank or tile 501 of
It is known in the art to place PVC film on a bottom surface of a floor plank or tile, in order to keep the floor plank or tile flat, to prevent cupping or pillow-up, and also to isolate moisture from an underlayment or subfloor. However, PVC film was not typically used to provide an adhesive free anti-slip surface. It is known in the art to use PU (polyurethane) on the top surface of a floor plank or tile, for the purpose of durability and easy cleaning.
In at least one embodiment of the present invention, PU (polyurethane) is better than PVC for use as an anti-slip film to surround the backing layer 508 and the devices 510, because PU is more environmentally friendly and is better at preventing moisture buildup. In at least one embodiment a PU anti-slip film surrounding the backing layer 508 and the devices 510 isolates moisture coming from the underlayment or subfloor, under a floor plank or tile, such as under floor plank or tile 501 of
Instead of PU, the anti-slip backing film placed on the bottom surface 508e and on the outer surfaces of each device or devices 510, such as outer surfaces 511a and 511b, may be an aluminum oxide infused Polyurethane, a synthetic rubber, a plastic, or a material embedded with carborundum, however PU anti-slip film is preferred particularly in combination with ilmenite powder filler for the base layer 506 and honeycomb bottom texture or devices 510 for the backing layer 508. However, for other types of base layers or backing layers, other types of anti-slip backing films may be better. For example, for rubber floor base layers or replace all of layers 502, 504, and 506 with rubber (to rubber tile, base layer 506 typically has to be rubber or rubber synthetics0. Layer 502 & 504 can still be PVC or other plastic synthetics. A rubber floor sometimes does need layers, similar to layers 502 and 504. A rubber floor can be solid-colored or simply spread pigment in solid-colored base to create random pattern, by for example spreading colorful chips through the rubber material. Synthetic rubber for an anti-slip film may be better than PU, in one or more embodiments.
Each of the plurality of devices 510 may have the same, or substantially the same, hexagonal, six sided shape, as shown by
Typically a cutting die would be used to form the edges of the floor plank or tile 501, such as edges at the front 502b, right side 502a, rear 502c, and left side 502d, shown in
The base layer 506 may be made in advance by calendering (sophisticated, base layer will be thin) or by sets of rollers (simple, base layer will be thicker). The wear layer 502, pattern layer 504 and base layer 506 may then be properly aligned, so that each layer has substantially the same length and width, is aligned with the other layers, and does not extend substantially beyond the other layers. After cutting, the aligned layers 502, 504, and 506 may then be sent to a hot press machine for lamination to add the backing layer 508 and the devices 510.
A cutting die can be installed with a calendering machine or extrusion machine, so the entire production process may be made to be automatic and continuous. But due to technique bottleneck or budget limit, factory can also cut lamination sheet into slab, then send to independent, or standoff, cutting die to shape into piece or floor plank or tile 501.
The wear layer 502 is transparent, and typically has a thickness of from 0.03 millimeters to 1.2 millimeters. The base layer 506, can itself be comprised of more than one layer, such as one, two, or three layers, typically depending on the thickness T2 of the plank or tile 501, shown in
The wear layer of the layer 504 of the plank, tile or piece 501, may be pure PVC, with greater pulling power (upward) when temperature goes down (for example, a relatively higher processing temperature versus relatively lower room temperature), and for such a PVC wear layer, typically a balance layer as part of the base layer 506 of the plank, tile or piece 501 is used to offset the pulling power of the wear layer 504. A leveling layer or in this case the devices 510 (and anti-slip surface) of the base layer 506 of the floor plank or tile 501, would be the bottommost layer and is placed in contact with a subfloor or underlayment surface 600a of subfloor 600, shown by dashed lines in
A fiber glass layer may optionally be placed between the pattern film layer 504 at the bottom and the base layer 506 (or may be placed between a leveling layer and balance leveler), however alternatively, fiber glass materials can be mixed in with the base layer 506 of the floor plank 501. Fiber glass materials mixed in with the base layer 506.
For the lowest (price wise) end product for residential uses, a pattern may be printed on the back of the wear layer 502, then a pure white film may be paved underneath the pattern (on the non-pattern side) layer 504, which is called a “feature layer/film”. The combination wear layer 502 (with pattern on back) and “feature layer/film” may then be laminated onto a base layer 506, and thereafter a large slab or sheet including the combination wear layer 502 and the base layer 506 may be die cut to form a plurality of pieces each identical or similar to piece or floor plank 501. For better anti-scratch, anti-cuff and better durability of the surface or top 502e shown in
On the back of the floor plank or tile such as on outer surfaces 511a and 511b shown in
The base layer 506, following cutting away portions of a raw material piece to form the plank 1 may be comprised of one or more of the following materials: polyvinyl chloride (PVC), calcium carbonate (filler), DOP or DINP, a lubricant, a stabilizer, and/or various additives. DOP (Dioctyl Phthalate) is a combustible non-toxic colorless oily liquid with slight odor. Disononyl phthalate (DINP) has similar functions and properties as DOP but is more environmental-friendly. The lubricant may be resin oil or rosin. The wear layer 502, the pattern film layer 504, and the base layer 506 may be laminated to each other through heat (can also be laminated by adhesive or cement). The plank 501 of
Instead of die cutting to initially form a raw material piece, another method such as water jet, and CNC, Computer numerical control, which utilizes the commands of numerical control program (compiled by computer) to drive a motor of machine can be used.
In the prior art diagram of
Each of the magnetic base layers, such as layer 810 may have a thickness or depth T4 which may range from 0.25-0.75 millimeters. Alternatively only one magnetic base layer (such as one of layers 808, 810, and 812) can be provided and may have a depth T4, which may be between 0.25 and 0.75 millimeters.
Each of the magnetic base layers, such as each of layers 808, 810, and 812 shown in
Each of floor planks 800 and 850 may have a length, width, and a depth. Each of floor planks 800 and 850 may have a rectangular or square appearance as viewed from the top as shown for example in
As shown by
The floor planks 800 and 850 are placed on a floor or subfloor 870, so that the anti-slip PVC/PU film layers 814 and 864 are in contact with the floor or subfloor 870, and so that corresponding layers of the floor planks 800 and 850 are aligned with each other. Optional coating 802 is aligned with and adjacent to optional coating 852; wear layer 804 is aligned with and adjacent to wear layer 854; pattern films 806 and 856 are aligned with and adjacent to one another; first magnetic base layers 808 and 858 are aligned with and adjacent to one another; second magnetic base layers 810 and 860 are aligned with and adjacent to one another; third magnetic base layers 812 and 862 are aligned with and adjacent to one another; and PVC/PU film layers 814 and 864 are aligned with and adjacent to one another.
In
The magnetic base layers, such as 808, 810, and 812 may be purchased from various sources. The magnetic base layers, such as 808, 810, and 812, may be made substantially of or entirely of iron powder or inmenite powder. An impulse magnetizer machine, known in the art, can be used to make the iron powder or inmenite powder magnetic or give the iron powder or inmenite powder its magnetic polarity. The impulse magnetizer machine can be used before or after the base layers 808, 810, and 812 are laminated as part of the floor plank 800. An “IMPULSE MAGNETIZER T-SERIES” from “MAGNET-PHYSICS INC.” can be used to create the magnets or magnetic polarity in base layers 808, 810, and 812.
The embodiment of
For example,
In at least one embodiment the base layer 1001c may be comprised substantially or entirely of a magnetic-powdered layer, and an iron-powdered layer. In at least one embodiment of the present invention, the order does not matter, i.e. either the magnetic layer or the iron-powdered layer may be closer to the surface 1001a then the other layer.
The layer 1001c may have more than one magnetic base layer, similar to or identical to base layers 808, 810 and 812 shown in
In at least one embodiment, a magnetic layer, iron layer, or a layer which is non magnetic and contains no iron and no ilmenite (such as a polyvinyl chloride layer, calcium carbonate layer, DINP/DOP layer, or some combination of these materials) can be added onto layer 1001c of
Then, similar to the manner in which piece 100 of
The floor plank 1000a shown in
The layer 1002c and the portion 1003 shown in
The floor plank 1000a may further include slots or channels 1004, 1006, 1008, and 1010 shown in
The floor plank 1000a may include a base layer which may be comprised of layer 1002c and portion 1003. The base layer may include a balance layer and a leveling layer. Typically, in at least one embodiment, only a base layer comes out of a calendering machine or extruder machine. The base layer is then immediately laminated, first with a pattern film and then with a wear layer, or with the pattern film and the wear layer at the same time, to form the piece 1000 shown in
The wear layer is transparent, is part of the layer 1002b, and is on the surface 1002a of the floor plank 1000a shown in
Typically a cutting die would be used to form the edges of the piece 1000 which may be in the form of a conventional known plank or tile. A bevel machine or some other type of machine can be used to cut, bevel, etch, sculpt, carve, chisel out or otherwise form the slots or channels such as, slots or channels 1004, 1006, 1008, 1010, shown in
Each of the floor planks 1100 and 1200 may be identical to or substantially the same as the floor plank 1000a of
The floor plank 1100 may also include grooves or further channels 1106a-b and 1112a-b in
There are “+” signs and “−” signs shown on the planks 1100 and 1200 in
In accordance with one embodiment of the present invention, a piece, such as 1000 in
In at least one embodiment a sign may be embossed on the bottom of a plank to show where magnetic material. For example, magnetic material may be used on the bottom of floor plank 501 shown in
Although the invention has been described by reference to particular illustrative embodiments thereof, many changes and modifications of the invention may become apparent to those skilled in the art without departing from the spirit and scope of the invention. It is therefore intended to include within this patent all such changes and modifications as may reasonably and properly be included within the scope of the present invention's contribution to the art.
The present application is a continuation in part of and claims the priority of U.S. patent application(s) Ser. No. 12/769,736, titled “METHOD AND APPARATUS FOR FLOOR PLANKS”, filed on Apr. 29, 2010 now U.S. Pat. No. 8,268,110 and Ser. No. 12/950,546, titled “METHOD AND APPARATUS FOR FLOOR TILES AND PLANKS”, filed on Nov. 19, 2010.
| Number | Name | Date | Kind |
|---|---|---|---|
| 2932596 | Rayner | Apr 1960 | A |
| 20100281810 | Ruland | Nov 2010 | A1 |
| Number | Date | Country |
|---|---|---|
| 02000328759 | Nov 2000 | JP |
| Number | Date | Country | |
|---|---|---|---|
| 20110265409 A1 | Nov 2011 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 12769736 | Apr 2010 | US |
| Child | 13044587 | US | |
| Parent | 12950546 | Nov 2010 | US |
| Child | 12769736 | US |
