AU2006204972A1

AU2006204972A1 - Removable and relayable floor covering

Info

Publication number: AU2006204972A1
Application number: AU2006204972A
Authority: AU
Original assignee: Zaxxon USA Inc
Current assignee: Zaxxon USA Inc
Priority date: 2005-01-14
Filing date: 2006-01-12
Publication date: 2006-07-20
Also published as: US20080010930A1; EP1836362A2; WO2006076487A8; KR20070062992A; WO2006076487A2; JP2008509308A; WO2006076487A3; US20060156663A1; CN101052772A

Description

WO 2006/076487 PCT/US2006/001072 Removable And Relayable Floor Covering Background Of The Invention [0001] In the need for efficiency, economy and speed in our 5 accelerated construction industry, the surface-covering business has witnessed the challenge of escalating cost incurred by the labor, material, and time associated with installation and removal procedures. The waste of time, labor, and material is particularly evident in the flooring industry where the needs for durability and replaceability co-exist as constantly conflicting 10 demands. Conventional flooring is traditionally installed on sub-floors by either pre-glue or glue applications, interlocking mechanisms, or underlayment systems. For any floor to be durable and slip-resistant, it needs to be securely installed on the sub-floor, but the more solidly it is secured, the harder and more costly it is to install the flooring and the harder and more 15 costly it is to remove it and replace it with something else. [0002] Prior to a conventional flooring installation, much labor, time and material is wasted in the removal of existing flooring and the recovery of the damaged sub-floor to ideal conditions for the re-installation of the new floor. The removal of existing flooring causes residue of glue to be stuck on the sub 20 floor. It also damages the sub-floor itself and the old flooring substrate, yielding the old flooring material to be no longer re-useable after removal. When the removal is complete, additional labor, time and material are required to install the new floor securely onto the earth. Unnecessary environmental cost is also incurred in the wasteful discarding of the old WO 2006/076487 PCT/US2006/001072 2 flooring material, and in the repeated use of another new set of the cement, adhesive or underlayment system required for the new flooring. [0003] So far, the surface-covering industry, in particular, the flooring industry, has seen innovations developed to increase the efficiency and 5 reduce the cost of the conventional installation process. Self-adhesive tiles, produced with or without release paper, have been developed to eliminate the re-application of glue when installing the flooring material. Interlocking flooring systems have been developed to eliminate the application of glue altogether by making the adjacent tiles interlock through built-in features. 10 Underlayment systems have been developed to eliminate the faulty sub-floor conditions altogether and enable the new flooring to be fastened onto the underlayment systems directly instead of the sub-floor. However, all of the existing developments, while being improvements, retain certain defects and create new ones in course. It is also notable that none of the existing 15 solutions in the field make significant progress on removal segment of use cycle. [0004] Existing self-adhesive tiles in the industry make progress by way of a pressure-sensitive glue that bonds the flooring to the earth with only a slight use of pressure, and without any additional glue application on the job 20 site. In removal, however, the self-adhesive tile damages the sub-floor easily via glue reside and delaminates and destroys the substrate of the flooring material, yielding it no longer useable. The cost of renovation and upkeep is thereby increased significantly.

WO 2006/076487 PCT/US2006/001072 3 [0005] The existing solution of interlocking flooring systems, especially those commonly found in laminates, create the defects of its own. After installation, the interlocked floor becomes a unitary and leveled surface that is locked in place against the seams of each tile or plank. As a result, an 5 interlocked floor installed wall-to-wall cannot tolerate the contraction and expansion of each of the plank or tile. Over time, a severe campering problem inevitably results. In addition, interlocked flooring also suffers from an increased level of noise pollution due to the noticeable space left to echo traffic sounds between the sub-floor and the interlocked floor. In removal, the 10 interlocked flooring solutions create extra environmental burdens and incur more material and labor cost since a significant portion of it must be destroyed in order for the entire floor to be removed. [0006] There have been floating floors developed with interconnected panels or sections to form a single unitary floor that can contract and expand 15 as a unit. This typically requires that there be a space between the periphery of the unit and the walls of a room. The interconnected panels may be tongue and groove and glued. The interconnected panel may utilize a self locking joint that does not require the use of glue. However, such types of flooring are not ideal in aesthetics due to the gaps between the floor and the walls of 20 the room. Their floating nature also make them limited and suitable for only temporary usages. [0007] Underlayment systems, pre-glued or not, are also limited in their benefits. While eliminating the need for sub-floor preparation by acting as a medium between the new flooring material and the sub-floor, underlayment WO 2006/076487 PCT/US2006/001072 4 systems are in and of itself a complicated assembly. It is costly to produce, cumbersome and complicated to install. The extra labor in applying fasteners, stables, and or other forms of structural support elements to hold the flooring in place actually end up creating additional cost in the installation process. 5 For most underlayment systems, specialized tools are also needed in the installation. [0008] Aside from the limitations mentioned above, all of the existing solutions in the market create extra environmental burdens in the installation and removal procedures (i.e. the material waste as a by-product, the messy 10 clean-up process, and the inability to recycle the used flooring after it is removed). [0009] There remains, therefore, a need for a flooring solution that is durable and slip-resistant against foot traffic in its adhesion on the sub-floor, but that can be installed and removed readily without additional investment in 15 time, labor, cost, tools or energy. There remains also a need for a flooring solution with a 100% clean removeability (will not damage the sub-floor, leave any glue residue, nor become delaminated or damaged in its removal) and that retains all of its beneficial features and original adhesion tack in place so that it can be repositioned or reused after repeated installations and removals. 20 It is also likewise advantageous and desirable to provide a method of flooring installation and replacement that is efficient and clean without the burden of glue residue removal and the creation of material waste in course. [0010] Similarly, it is desirous to provide a moisture release enhancement as an additional feature in the flooring to minimize the dirt and WO 2006/076487 PCT/US2006/001072 5 grime collection in and under the tile seams and to release the pressure built up due to moisture in the sub-floor. [0011] Additionally, it is desirous to provide a method of floor adhesion that is not "tacky" or "sticky" to the touch, does not leave a glue residue, is slip 5 resistant and suitable for both permanent and temporary tile installations. [0012] At last, it is desirous to provide a solution in flooring that can be installed, removed, and re-installed with a Do-It-Yourself "Stick, Peel, Stick" ease so the flooring can be transferred intact from one place to another by an untrained person, much like a piece of furniture. 10 Description of the Related Art [0013] U.S. Patent No. 6,623,840 discloses a rubber-surfaced protective flooring tile and method of manufacturing the same which provides a covering over hard floor surfaces. The tile consists of two layers. The top 15 has a bottom surface which has voids which extend from the bottom surface towards the top surface. The bottom layer is of granulated rubber and has a prepolymer material that binds to the voids in the top layer during the manufacture of the tile. The rubber tile provides cushion on hard surfaces to minimize injury in playgrounds, factory floors, fitness rooms, and physical 20 therapy facilities. [0014] U.S. Patent No. 6,129,967 discloses a system for securing brittle ceramic tiles to the sub-floor without a supporting adhesive substrate. A liner is used to provide structural support and an energy absorbent layer is present which allows for the tile to withstand greater forces of abrasion without WO 2006/076487 PCT/US2006/001072 6 breaking. The liner is adhered to the sub-floor and the tiles are placed inside and are anchored to the liner and an impact resistant ceramic layer. [0015] U.S. Patent No. 6,694,689 discloses a modular flooring system which utilizes a free-lay support base plate. Replaceable wear surface tiles fit 5 within the base plate. The base plate allows for the maintenance of a level floor surface when placed over a preexisting worn floor and for the removal and replacement of flooring within the base plate superstructure. The composite base plate structure permits independent temporary displacement of each of the tiles. 10 [0016] U.S. Patent No. 4,654,244 discloses a loose-lay and adhered to floor structure comprised of two layers of reinforced material suitable for use over stable and unstable sub-floors. The rigidity in the flooring is achieved by two layers of reinforced material sandwiching a cushion layer. Surface layers are placed on the outside of the reinforced layers. This reinforcement is 15 designed to prevent buckling, curling and doming under a rolled load. As an alternative, the reinforcing layer may be pre-modified such that, when used to provide a surface covering the covering will have acceptable buckling characteristics. [0017] U.S. Patent No. 6,751,917 discloses a floor tile structure without 20 an adhesive coating at the bottom. Each tiles surface layer and bottom layer are attached respectively on the upper and the lower surfaces of the soft double sided adhesive tape with pressure sensitivity. The surface layer is possibly made of rock, metal, or other hard material and the periphery is a smooth cross-section. Tiles are joined by placing the adhesive on the middle WO 2006/076487 PCT/US2006/001072 7 protruding convex layer of one tile onto the convex edge of the adjoining one and bonding the two together in the middle, leaving no need for bottom adhesion. [0018] U.S. Patent No. 6,751,912 discloses a modular interlocking tile 5 and flooring system. Each tile is adapted to be coupled to another interlocking tile. Each tile includes a body having a playing surface and two male and two female interlocking sides. The interlocking mechanism is adapted to allow the modular interlocking tiles to connect together in a staggered fashion. 10 [0019] U.S. Patent No. 6,802,159 discloses a roll-up tile system. Individual tiles lock together in a manner to form a plurality of non-bendable tile joints. The tile includes a hinge or fold line along a second axis. The hinges allow the multi-tile surface to be rolled up into a hollow tube from any direction along one of the axes. The rolled up floor panel consists of a 15 plurality of tile panels. [0020] U.S. Patent No. 6,769,217 discloses an interconnecting disengageable flooring system. The system includes two or more flooring panels comprised of a top wear surface and a bottom surface for contact with the support structure. The panels have at least three edges and all edges 20 have recesses formed therein. The system also comprises a connector having a base and a projection extending vertically from the base. The projection extending from the base is shaped to be received in a disengageable vertical connected fashion into the recesses of the panels.

WO 2006/076487 PCT/US2006/001072 8 [0021] U.S. Patent No. 6,803,099 discloses a self-adhering surface covering having a wear surface and a pressure-sensitive adhesive layer on the lower surface of the wear surface and a barrier layer disposed on the adhesive layer. The surface covering has substantially no tack at about 10 5 psi at 140 degrees F. but has tack at about 20 psi at 75 degrees F. An adhesive which is substantially non-stringing may also be employed in the adhesive layer. The barrier layer includes substantially non-adhesive particles which have a crash resistance of at least about 10 psi while disposed on the adhesive layer. The method of making the self-adhering surface 10 covering includes applying an adhesive to a substrate to from an adhesive layer having an adhesive surface, and applying a barrier layer comprising substantially non-adhesive particles to the adhesive surface to form the surface covering. The particles have a crush resistance of at least about 10 psi while disposed on the adhesive layer. 15 [0022] U.S. Patent No. 6,905,100 discloses an adhesive sheet strip, single-sidedly or double-sidedly pressure-sensitively adhering, redetachable by extensive stretching pulling on a grip tab in the direction of the bond plane, where the grip tab is such that it has a static frictional force Fs of at least 170 cN. 20 [0023] U.S. Published Patent Application No. 20040129365 discloses a preglued underlayment assembly for a floor covering system having a substantially rigid underlayment. The underlayment has an upper and a lower surface and a pressure sensitive adhesive layer disposed on the upper surface and a release layer on the adhesive layer.

WO 2006/076487 PCT/US2006/001072 9 Summary of the Invention [0024] The present invention relates to removable surface coverings that are a structural improvement of floor tiles, sheets, or planks, including 5 floor tiles, sheets, and planks or sections of varying sizes and shapes and surface types including those made from polyvinyl chloride, rubber, linoleum, polymeric resins, reinforced resins, vinyl composite, or other resilient materials, carpet, stones, ceramic, metals, glass, textiles, wood, composites thereof in desired combinations, veneers thereof in desired combinations, and 10 laminates thereof in desired combinations, all of which are hereinafter referred to as a "floor covering". [0025] More particularly, the present invention provides a floor covering having a dual backing layer comprising a foam layer and a cured adhesive layer. This dual backing layer allows the floor covering to be installed directly 15 to a sub-floor surface with only a slight application of pressure, and without any additional application of glue or underlayment systems. Significantly, this dual backing layer-enhanced floor covering can be removed readily from the sub-floor without any glue residue or any damage done to the sub-floor or to the flooring substrate. Additionally, that very same floor covering may be 20 reinstalled again without losing the effectiveness of its original tack. Thus, a loose-lay floor covering is provided that is self-adhering, removable and relayable, otherwise referred to as, "stick, peel, stick." [0026] The present invention makes such a structural improvement possible via the addition of an innovative backing layer of at least two WO 2006/076487 PCT/US2006/001072 10 varieties: without moisture-release channels and with moisture-release channels. In one embodiment, a backing layer without moisture-release channels comprises a top layer, which is adhered to the back surface of the floor covering with an adhesive. The adhesive comprises a soft, resilient 5 material, often formed from a foam, of about 0.5mm to 3.0mm in thickness. The backing layer without moisture-release channels also comprises a bottom layer that is composed of a curable adhesive that has undergone a curing or cross-linked process. The soft, resilient cushioned or foam material may be selected from the group consisting of chemical blown polyvinyl chloride 10 plastisols/organosols, acrylics, polyurethane foams, froth foams such as polyvinyl chloride plastisol, acrylics, melt processed foams such as polyvinyl chloride, polyethylene, ethylene vinyl acetate, metallocene polyolefin's, elastomeric polyolefin copolymers. Of course, other soft, resilient or cushioned materials which are non-foamed may also be employed with 15 adequate results. [0027] The curable adhesives should provide sufficient adhesion and slip resistance so that the floor covering may be removed from the sub flooring and relayed elsewhere. In one embodiment, rubber-type adhesives, PVC-type adhesives, acrylic adhesives, e-beam curable acrylic adhesives, 20 vinyl acetate-type adhesives, urethane-type adhesives, and combinations thereof have been used with the present invention with adequate results. The curable adhesive, after the curing process, may be applied onto the foam layer by a conventional coating apparatus such as a reverse roll coater, a forward roll coater, a doctor blade, an air knife, or other similar apparatus.

WO 2006/076487 PCT/US2006/001072 11 The thickness of the layer is typically around 0.1mm, but can be less or more depending on the adhesive employed. [0028] When a dual backing comprised of a foam layer and a curable adhesive is affixed to a floor covering made of any material composition, it 5 creates a loose-lay flooring system comprising a "stick-peel-stick" capability. Additional features and advantages of the invention include an increase in the floor covering's evenly distributed contact with the sub-floor as a result of the embedded foam layer providing leveling adhesion. The foam layer also makes the floor more comfortable and warm to walk on, being more shock 10 absorbent and acoustically sound. The curable adhesive is non-stringing and non-sticky to the touch before installation and after removal so that all of its original tack remains in place after the flooring removal and even more significantly, after the removed flooring is cleaned with water or a damp cloth. [0029] In another embodiment, a backing structure with moisture 15 release channels is provided that is similar in structure and composition to the foregoing backing structure without moisture-release channels, except that the soft, resilient, cushion or foam layer is molded so as to define a plurality of channels within its surface so as to override a layer of cured adhesive. This plurality of channels allows for moisture release from beneath the floor 20 covering. They also reinforce the surface tension of the floor covering's adhesion to a sub-floor and make the floor covering only removable from the sub-floor surface with a pulling force that is directed parallel to the orientation of the channels in the foam backing layer, but un-removable when pulled with a horizontal or diagonally directed pull force.

WO 2006/076487 PCT/US2006/001072 12 [0030] By this construction a floor covering formed in accordance with the present invention is capable of being installed by a loose lay application which requires no glue, release paper, underlayment systems, interlocking mechanisms and with manual and clean removeability that allows the 5 transferals and repositioning of such a floor with all of its original tack and features in place. The channel structure of the cushion layer on the backing resists horizontal or diagonal pull force of removal from the sub-floor creating a 100% recyclable, slip resistant loose lay tile. 10 Brief Description Of The Drawings [0031] These and other features and advantages of the present invention will be more fully disclosed in, or rendered obvious by, the following detailed description of the preferred embodiments of the invention, which are to be considered together with the accompanying drawings wherein like 15 numbers refer to like parts and further wherein: [0032] Figure 1 is a perspective view of a polyvinyl chloride floor tile without moisture-release channels according to the present invention. [0033] Figure 2 is a cross-sectional view of a polyvinyl chloride floor tile without moisture-release channels according to the present invention. 20 [0034] Figure 3 is a perspective view of a polyvinyl chloride floor tile with moisture-release channels according to the present invention. [0035] Figure 4 is a cross-sectional view of a polyvinyl chloride floor tile with moisture-release channels according to the present invention.

WO 2006/076487 PCT/US2006/001072 13 [0036] Figure 5 is a flowchart of the production process for the invention onto a vinyl tile. Detailed Description Of The Invention 5 [0037] This description of preferred embodiments is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description of this invention. The drawing figures are not necessarily to scale and certain features of the invention may be shown exaggerated in scale or in somewhat schematic form in the interest 10 of clarity and conciseness. In the description, relative terms such as "horizontal," "vertical," "up," "down," "top" and "bottom" as well as derivatives thereof (e.g., "horizontally," "downwardly," "upwardly," etc.) should be construed to refer to the orientation as then described or as shown in the drawing figure under discussion. These relative terms are for convenience of 15 description and normally are not intended to require a particular orientation. Terms including "inwardly" versus "outwardly," "longitudinal" versus "lateral" and the like are to be interpreted relative to one another or relative to an axis of elongation, or an axis or center of rotation, as appropriate. Terms concerning attachments, coupling and the like, such as "connected" and 20 "interconnected," refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise. The term "operatively connected" is such an attachment, coupling or connection that allows the pertinent WO 2006/076487 PCT/US2006/001072 14 structures to operate as intended by virtue of that relationship. In the claims, means-plus-function clauses, if used, are intended to cover the structures described, suggested, or rendered obvious by the written description or drawings for performing the recited function, including not only structural 5 equivalents but also equivalent structures. [0038] Referring to Figs.1-5, a floor section member 10 formed in accordance with the present invention may comprise a vinyl tile or other floor covering material of the types including, but not limited to polyvinyl chloride, rubber, linoleum, polymeric resins, reinforced resins, vinyl composite, or other 10 resilient materials, carpet, stones, ceramic, metals, glass, textiles, wood, composites thereof in desired combinations, veneers thereof in desired combinations, and laminates thereof in desired combinations, all of which are referred to hereinafter as floor section member 10. [0039] A first embodiment of the invention, shown in Figs. 1 and 2, 15 comprises a floor section 10 without moisture-releasing channels. Floor section member 10 is a self-adhesive, loose-lay installed floor surface covering which may have multiple layers including an upper wear surface 11 and an internal adhesive layer 12 that secures upper wear surface 11 to a cushion material layer 13. Another internal adhesive layer 14 is provided by a 20 backing coating of cured adhesive. Upper wear surface 11 may be made of polyvinyl chloride (PVC) or other suitable surface material. The present invention is applicable to other surface layers that are formed of a variety of materials, including polymeric resins, rubber, linoleum, reinforced resin, in-aid floors, all resilient flooring, carpet, stone, ceramic, wood, wood parquet, WO 2006/076487 PCT/US2006/001072 15 composites, veneers, and laminates or combinations thereof. Upper wear surface 11 can be of varying width, thickness, density and edge shape design, color, pattern, chemistry, or composition dependent on the specific material of which it is made. 5 [0040] Upper wear surface 11 is adhered to the thin cushioned backing of cushion material layer 13 by an internal adhesive layer 12. Upper wear surface 11 is defined by its upper surface 11 a, which forms the uppermost surface of floor section member 10, and its lower surface 11 b, the bottommost surface of floor section member 10. Internal adhesive layer 12 adheres lower 10 surface 11 lb to an surface 13a which is the uppermost surface of cushion material layer 13. Cushion material layer 13 is defined by its upper surface 13a and lower surface 13b. Lower surface 13b adheres to a backing coating of cured adhesive similar to internal adhesive layer 14. Internal adhesive layer 14 is defined by its upper surface 14a and lower surfacel4b, and forms 15 the bottommost layer of floor section member 10. [0041] Upper wear surface 11 may comprise any type of flooring material including, but not limited to polyvinyl chloride, rubber, linoleum, polymeric resins, reinforced resins, vinyl composite, or other resilient materials, carpet, stones, ceramic, metals, glass, textiles, wood, composites 20 thereof in desired combinations, veneers thereof in desired combinations, and laminates thereof in desired combinations thereof. Cushion material layer 13 often comprises a variety of soft, resilient materials including, but not limited to foamable polymers, and in particular, foam layers such as chemical blown polyvinyl chloride plastisols/organosols, acrylics, rubber foams, polyurethane WO 2006/076487 PCT/US2006/001072 16 foams, froth foams such as polyvinyl chloride plastisol, acrylics, melt processed foams such as polyvinyl chloride, polyethylene, ethylene vinyl acetate, metallocene polyolefins, elastomeric polyolefin copolymers. Additionally, any soft, resilient or cushioned material which is foamed or non 5 foamed may also be employed. The thickness of cushion material layer 13 is often about 0.5 mm to 3.0 mm. Cushioned material layer 13 provides for an evenly distributed contact between floor section member 10Oand a sub-floor. This, in-turn, significantly increases the degree of leveling adhesion of floor section member 10 onto a sub-floor, and enhances the acoustic absorption of 10 floor section member 10 while making the finished floor more comfortable to walk on and more shock-absorbent. [0042] Internal adhesive layer 14 is often formed or applied as a coating of cured -adhesive that adheres onto the sub-floor with very slight pressure, but allows lifting, removal, and repositioning of floor section member 15 10 with its original "tack" substantially unaffected, and without glue residue or delaminating the sub-floor. The cured adhesive that comprises internal adhesive layer 14 may include any adhesive that is curable, including rubber type adhesives, PVC-type adhesives, acrylic adhesives, e-beam curable acrylic adhesives, vinyl acetate-type adhesives, urethane-type adhesives and 20 combinations thereof. Lower surfacel14b of internal adhesive layer 14 must provide sufficient adhesive properties to maintain floor section member 10 in place during use. Internal adhesive layer 14 should also be releasable so that floor section member 10 can be removed and relayed repeatedly. One adhesive that has been found to provide adequate results is made of modified WO 2006/076487 PCT/US2006/001072 17 acrylate, with a viscosity of 3000-5000 cps/25 degrees Celsius, a density of 1.0-1.1 g/cm 3 , and a curing speed greater than 10 M/min/Lamp (80Wcm 1 ) with 80% active component. The coating method for this particular adhesive can be either a reverse roll coater, a forward roll coater, a doctor blade, an air 5 knife, or other similar coating apparatus. [0043] Lower surface 13b adheres to a backing coating of cured adhesive similar to internal adhesive layer 14. The criteria for the lower adhesive layer applied on the foam layer lower surface 13b, and exposed to the sub-floor, would be any curable adhesive which: (1) has undergone 10 curing or cross-linked processing; (2) has initial tack that's sufficient to bond or hold the particles to the adhesive surface and maintain the back layer in contact with the sub-floor, (3) be non-stringing and relatively resistant to penetration or compression of particles, (4) about 0.03mm to 0.05mm thick average, but can be less than 0.03 mm or greater than 0.05mm depending on 15 the adhesive used. Cushioned material layer 13 may have about 0.5mm to 3.0mm thickness, but could vary depending on the foam material used. The curable adhesive thickness can be conventionally determined, typically between 0.01mm to 0.3mm, but preferably lower than a thickness of 0.1 mm. [0044] Referring to Figs. 3 and 4, a further embodiment of the invention 20 comprises a floor section member 20, e.g., a floor tile, including a moisture releasing channel layer 24. Floor section member 20 comprises multiple layers, including a wear surface layer 21 that forms the uppermost layer that is seen and is the contact and wear surface. An internal adhesive layer 22 is adhered to a lower surface 21a of wear surface layer 21. A cushion material WO 2006/076487 PCT/US2006/001072 18 layer 23 is positioned below the wear surface layer 21, the lowermost layer of which defines moisture-releasing channel layer 24 comprising a plurality of lands 26 located between and separating a plurality of channels 27 that are arranged in regular intervals across the bottom of floor section member 20. 5 Moisture-releasing channel layer 24 is preferably formed of an adhesive layer that may be a curable, and that functions as a glue to hold floor section member 20 in place, while allowing it to be removed and relayed. Moisture releasing channel layer 24 is preferably pressure-sensitive and may be formed of rubber-type adhesives, acrylic adhesives, including e-beam curable 10 acrylic adhesives, vinyl acetate-type adhesives, urethane-type adhesives, and combinations thereof, or any other adhesives commonly used that can be curable. Moisture-releasing channel layer 24 is often pressed or embossed so as to comprise alternating lands 26 and channels 27. [0045] Wear surface layer 21 may be formed from polyvinyl chloride 15 (PVC), however, the present invention can be applied under a surface layer of a variety of materials including but not limited to polyvinyl chloride, rubber, linoleum, polymeric resins, reinforced resins, vinyl composite, or other resilient materials, carpet, stones, ceramic, metals, glass, textiles, wood, composites thereof in desired combinations, veneers thereof in desired combinations, and 20 laminates thereof in desired combinations. Wear surface layer 21 may be formed with varying width, thickness, density and edge shape design, color, chemistry, or composition, dependent on the specific material of which the surface layer is made.

WO 2006/076487 PCT/US2006/001072 19 [0046] Wear surface layer 21 is often applied to cushion material layer 23 by internal adhesive layer 22. Wear surface layer 21 is defined by its upper surface 21a which is the uppermost contact and wear surface of sample floor section member 20 and its bottom surface 21b. Internal 5 adhesive layer 22 adheres to bottom surface 21b and surface 23a which is the uppermost surface of cushion material layer 23. Cushion material layer 23 often comprises a variety of ethylene vinyl acetate foam, polyethylene foam, rubber foam, polyvinyl foam or any other soft, cushioned, resilient foam materials. The thickness of cushion material layer 23 ranges between 0.5 mm 10 and 3.0 mm, and increases floor section member 20's evenly distributed contact with the sub-floor, thereby increasing the leveling adhesion of floor section member 20 onto the sub-floor. [0047] Cushion material layer 23 is defined by its upper surface 23a and a lower surface 23b. Moisture-releasing channel layer 24 may 15 additionally comprise a curable adhesive layer 25 that is applied or glued to lower surface 23b of cushion material layer 23. Moisture-releasing channel layer 24, the bottommost layer of floor section member 20 comprises a plurality of protruding lands 26 alternated with adjacent channels 27. As shown in Fig. 3 which is a bottom view of floor section member 20, lands 26 20 and channels 27 often extend parallel to each other for the length and width of floor section member 20. Of course, other orientations and arrangements of channels and lands yield adequate results as well. [0048] Moisture-releasing channel layer 24 molds to the sub-floor upon which it is laid and reinforces the surface tension of the floor section member WO 2006/076487 PCT/US2006/001072 20 20's adhesion on the sub-floor. Such molding resists horizontal and diagonal pull forces and movement on the sub-floor. Floor section member 20 is best removed from the sub-floor with a pull parallel to the vertical structural lining on the foam backing-layer 23 because of air channels on the grids. Floor 5 section member 20 remains intact and cannot be easily displaced with a horizontal or diagonal pull. Moisture releasing channel layer 24 allows water to evaporate from its point of contact with the sub-floor, helping to maintain the floor section member's adhesion to the sub-floor and to maintain the aesthetic value of floor section member 20. This arrangement also prevents 10 unwanted particles from collecting and soiling floor section member 20 so as to distress the point of contact of moisture-releasing channel layer 24 with the sub-floor. [0049] Referring to Fig. 5, a flowchart is provided of a typical production process for a floor section member 20 in the form of a vinyl tile formed in 15 accordance with the present invention. The production process follows generally conventional means of tile manufacturing either via extrusion, calendar or heat pressure lamination. With reference to schematic 41, the process may begin with a top layer that may be a polyvinyl film that may be design printed. The polyvinyl chloride tile is then extruded into the tile by heat 20 lamination and the process shown in schematic 42. The process referenced in schematic 42 begins with a polyvinyl chloride compound mixed with calcium carbonate and processed via a Bumberly and extruded into the tile by a crushing machine. The tile surface may then be embossed, cooled, and annealed. Glue may then be applied to the tile back.

WO 2006/076487 PCT/US2006/001072 21 [0050] The foam layer, the first layer of the current invention is then combined to the tile material in accordance with the invention. Schematic 43 shows the process for incorporation of the foam layer. Schematic 43 begins with a foamable material compound processed via a Bumberly, extruded, and 5 cut to fit the tile material already produced. [0051] As referenced in schematic 41, after the foam is adhered onto the tile's backing and formed, the back surface of the tile is smoothed, and an optional ultraviolet coating may be added. The tile is then dried with ultraviolet lighting. The cured adhesive is then applied onto the foam layer 10 and followed by drying with ultraviolet lighting. The production process is then complete, and the tile is ready for packing. [0052] It is believed that the primary use of the invention would be with standard flooring. However, it also has application in analogous environment that call for the properties of the preferred embodiments. Flooring is used as 15 a covering on surfaces other than floors. [0053] It is to be understood that the present invention is by no means limited only to the particular constructions herein disclosed and shown in the drawings, but also comprises any-modifications or equivalents within the scope of the claims.

Claims

1. A self-adhesive, loose-lay installed floor surface covering comprising: an upper wear surface layer; 5 a cushioned backing adhered to the upper wear surface layer to increase the surface covering's evenly distributed contact with a sub-floor, and thereby increase the leveling adhesion of the tile onto the sub-floor; and a cured adhesive applied onto the cushioned backing's lower surface that adheres to a sub-floor to hold the floor in place during use and that 10 adheres onto a surface with very slight pressure on its own and that allows removal and repositioning with its original tack in place, without additional glue residue, damage done to the sub-floor or delaminating of the substrate so that it can be removed and relayed repeatedly. 15

2. The floor surface covering of claim 1 wherein the upper surface may be comprised of floor tile, sheet, or plank material types including those made from polyvinyl chloride, rubber, linoleum, reinforced resins, vinyl composite, or other resilient materials, carpet, stones, ceramic, metals, glass, textiles, wood, composites, veneers, and laminates and polymeric resins. 20

3. The floor surface covering of claim 1 wherein the cushioned backing may be comprised of a soft material layer including foamable material such as chemically blown polyvinyl chloride plastisols/organosols, acrylics, polyurethane foams, rubber foams, froth foams such as polyvinyl chloride WO 2006/076487 PCT/US2006/001072 23 plastisol, acrylics, melt processed foams such as polyvinyl chloride, polyethylene, ethylene vinyl acetate, metallocene polyolefins, elastomeric polyolefin copolymers. 5

4. The floor surface covering of claim 1 wherein the lower surface may comprise a curable or cross-linked adhesive material made of PVC-type adhesives, rubber-type adhesives, acrylic adhesives, including e-beam curable acrylic adhesives, vinyl acetate-type adhesives, urethane-type adhesives, and combinations thereof. 10

5. The floor surface covering of claim 1 wherein the lower adhesive layer has moisture release grid channels onto the backing layer to enhance its adhesion to a sub-floor and provide moisture-release enhancement. 15

6. The floor surface covering of claim 1 wherein the lower adhesive layer includes vertical indentations and protrusions to reinforce the surface tension of the floor surface covering's adhesion on the sub-floor.

7. The floor surface covering of claim 1 wherein the lower adhesive 20 layer comprises a self-adhesive surface covering that can be removed from a sub-flooring surface with a pull parallel to the vertical structural lining on the foam backing layer because of the air channels on the grids and which stays intact and is not easily displaced with a horizontal or diagonal pull force. WO 2006/076487 PCT/US2006/001072 24

8. The floor surface covering of claim 1 wherein the flooring can be i removed and cleaned with water and still retain its original tack for I repositionability and reinstallation. 5

9. A method of forming a self-adhesive, loose-lay installed floor surface covering comprising the steps of; applying a cushioned backing adhered to an upper wear surface to increase the surface covering's evenly distributed contact with a sub-floor, and thereby increase the leveling adhesion of the tile onto the floor; and 10 applying a cured adhesive onto the thin cushioned backing to increase the surface tension of the floor adhesion and hold it in place during use and that adheres onto a surface with very slight pressure and that allows repositioning with its original tack in place, without additional glue residue or delaminating of the substrate so that it can be removed and relayed 15 repeatedly.

10. The method of claim 9 including the step of applying the cushion backing includes applying it to the lower surface of floor tiles, sheets, and planks or sections of varying sizes and shapes and surface types including 20 those made from polyvinyl chloride, rubber, linoleum, polymeric resins, reinforced resins, vinyl composite, or other resilient materials, carpet, stones, ceramic, metals, glass, textiles, wood, composites thereof, veneers thereof, and laminates thereof. WO 2006/076487 PCT/US2006/001072 25

11. The method of claim 9 including the step of applying the cushion backing includes applying a cushion backing comprised of soft material layer including foamable material. 5

12. The method of claim 11 wherein the step of applying the cushion backing includes applying chemical blown polyvinyl chloride plastisols/organosols, acrylics, rubber foams, polyurethane foams, froth foams such as polyvinyl chloride plastisol, acrylics, melt processed foams such as polyvinyl chloride, polyethylene, ethylene vinyl acetate, metallocene 10 polyolefins, or elastomeric polyolefin copolymers.

13. The method of claim 9 including the step of applying the lower surface comprises applying a curable or cross-linked adhesive material made of PVC-type adhesives, rubber-type adhesives, acrylic adhesives, including e 15 beam curable acrylic adhesives, vinyl acetate-type adhesives, urethane-type adhesives, and combinations thereof.

14. The method of claim 9 including the step of applying the lower surface comprises applying a lower adhesive layer that has moisture release 20 grid channels onto the backing layer to enhance its adhesion to a sub-floor and provide moisture-release enhancement.

15. The method of claim 9 including the step of applying the lower surface comprises applying a lower layer that includes vertical indentations WO 2006/076487 PCT/US2006/001072 26 and protrusions to reinforce the surface tension of the floor surface covering's adhesion on the sub-floor.

16. The method of claim 9 including the step of applying the lower 5 surface comprises applying a self-adhesive surface covering that can be removed from the surface with a pull parallel to the vertical structural lining on the foam backing layer because of the air channels on the grids and which stays intact and is not easily displaced with a horizontal or diagonal pull force.