Floor tile

The present invention relates to a floor tile comprising a base substrate and a laminate layer, wherein the base substrate comprises at least one aligning member on a top surface thereof, the aligning member operable to engage with a complimentary receiver formed in the laminate layer for aligning the laminate layer on the top surface of the substrate.

This application is the U.S. National Phase of, and Applicant claims priority from, International Patent Application Number PCT/EP2016/064825 filed 27 Jun. 2016, which claims priority from GB 1511201.4 filed 25 Jun. 2015, each of which is incorporated herein by reference.

The present invention relates to a floor tile and method of forming same.

More particularly, the present invention relates to a modular flooring system comprising interconnecting floor tiles which is an improvement over that disclosed in United Kingdom Patent Specification No. GB2495790 B, the contents of which are incorporated herein by reference.

SUMMARY OF THE INVENTION

Accordingly, the present invention provides a tile comprising:a base substrate and a laminate layer,characterised in that base substrate comprises at least one aligning member on a top surface thereof, the aligning member operable to engage with a complimentary receiver formed in the laminate layer for aligning the laminate layer on the top surface of the substrate.

In another embodiment of the invention, the aligning member comprises an upstanding projection on the top surface of the base substrate, and the complimentary receiver comprises a recess formed in the underside of the laminate layer for engagement with the upstanding projection.

Preferably, the upstanding projection is an edge forming a rim that extends along the perimeter of the base substrate.

Preferably, the recess extends along the perimeter of the laminate layer.

Preferably, the recess forms a ledge in the underside surface of the laminate layer, the ledge having a complimentary fit with the rim of the base substrate to align the laminate layer on the base substrate.

In another embodiment of the invention, the aligning member comprises a plurality of upstanding projections forming raised members spaced apart on the top surface of the base substrate.

Preferably, the raised members are cuboid shaped projections.

Alternatively, the raised members are cylindrically shaped projections.

Preferably, the complimentary receiver comprises recesses formed in the underside of the laminate layer for engagement with the raised members to align the laminate layer on the base substrate.

In another embodiment of the invention, the base substrate comprises connecting means for engaging with connecting means of a substrate of a further tile to form an interconnected flooring system.

Preferably, the connecting means comprises a plurality of protruding tongues and grooves at adjacent sides of the base substrate.

Preferably, a protruding tongue or dovetail of the substrate is engaged in a groove of the substrate of another tile to connect adjacent tiles to form the flooring system.

In another embodiment of the invention, engaging the connecting means of a tile with a further tile aligns and positions a side edge of a tile with the side edge of the further tile.

Preferably, the top surface of the base substrate fully extends over the connecting means on at least one side of the substrate.

In another embodiment of the invention, the laminate layer is bonded to the substrate layer using an adhesive.

In a further aspect of the present invention there is provided a method of forming a tile comprising the steps of:forming a base substrate having features as set out above,forming a laminate layer having features as set out above;applying an adhesive to a surface of one or both of the base substrate and laminate layer;connecting the laminate layer and the base substrate so that the aligning member of the base substrate engages with the complimentary receiver formed in the laminate layer to thereby align the laminate layer on the top surface of the substrate, andbonding the laminate layer to the substrate to form the tile.

In another embodiment of the invention, the method comprises the step of: operating an injection moulding machine to form the base substrate.

In another embodiment of the invention, the method comprises the step of: removing the base substrate from the injection moulding machine and allowing the base substrate to cool.

In another embodiment of the invention, the method comprises the step of: operating a roller coater machine to apply adhesive to a surface of one or both of the base substrate and laminate layer.

In another embodiment of the invention, the method comprises the step of: applying pressure to the laminate layer on the substrate.

Preferably, the step of applying pressure to the laminate layer on the substrate comprises operating a nip-roller machine.

DETAILED DESCRIPTION

Referring to the drawings, there is shown a tile, indicated generally by the reference numeral1, comprising a base substrate, indicated generally by the reference numeral2and a laminate layer3, having a top facing surface21, and a underside surface22, which sits on a top surface5of the base substrate2to form a floor tile1. The base substrate2comprises at least one aligning member on a top surface5thereof, the aligning member operable to engage with a complimentary receiver formed in the laminate layer3for aligning the laminate layer3on the top surface5of the substrate2.

With reference toFIGS. 1 to 6, a first embodiment of the invention is shown, in which the aligning member comprises an upstanding projection4on the top surface5of the base substrate2, and the complimentary receiver comprises a recess20formed in the side edge of the underside surface22of the laminate layer3for engagement with the upstanding projection4. As shown, the upstanding projection4is an upstanding edge forming a rim4that extends along the perimeter of the base substrate2. The recess20also extends along the perimeter of the laminate layer3and forms a ledge20at the peripheral edge in the underside surface22of the laminate layer3, the ledge20having a complimentary fit to seat on the rim4of the base substrate2to align the laminate layer3on the base substrate2

In another embodiment of the invention, as shown inFIGS. 7 to 11, the aligning member comprises a plurality of upstanding projections forming raised members24spaced apart and extending upwardly on the top surface5of the base substrate2. The raised members24may be cuboid shaped projections, cylindrically shaped projections as shown inFIG. 7, or any other shape as required or as desired. There may also be any number of raised members24on the base substrate2, and although four cylindrically shaped raised members24are shown inFIG. 7, this should in no way be seen as essential or limiting on the present invention. A complimentary receiver of the laminate3comprises recesses26formed in the underside surface22of the laminate layer3for mutual complimentary engagement with the raised members24to align the laminate layer3on the base substrate2. The recesses26may have a perimeter slightly larger than the raised members24to enable a snug complimentary fit.

The base substrate2of both embodiments of the present invention also comprise connecting means, indicated generally by the reference numeral6, for engaging with connecting means6of a base substrate2of a further tile1to form an interconnected flooring system (seeFIGS. 12 and 13). The connecting means6as shown is a dovetail type connection system comprising a plurality of protruding tongues7and grooves8at adjacent sides of the base substrate2, and the top surface5of the substrate2extends over connecting means6on at least one side of the base substrate2, and preferably on two sides of the base substrate2.

As shown inFIGS. 12 and 13, the embodiments ofFIGS. 1 to 11comprise the same type of connection system, whereby a protruding tongue7of the base substrate2of one tile1is engaged in a groove8of the base substrate layer2of another tile1′ to connect adjacent tiles1,1′ to form a flooring system10. InFIGS. 12 and 13, for exemplary purposes, the laminate3of the tiles1,1′ is shown removed so that the connecting means6of the substrates2,2′ can be clearly illustrated, and it should be understood that when tiles1,1′ are being interconnected they may be done so with or without the laminate3bonded to the substrate layer2.

FIGS. 14 and 15show respectively two and four tiles joined together. As shown, the portion of the top surface5of the substrate layer2that extends over the connecting means6of tile1will cover the connecting means6of the adjacent tile1′ when the two tiles1,1′ are interconnected. In this way engaging the connecting means6of adjacent tiles1,1′ aligns and positions a side edge30of the tile1with the side edge30′ of a further adjacent tile1′ in a side by side arrangement. Notable is that there is no grout line visible between adjacent joined tiles1,1′ of floor system10, and a smooth near seamless interconnection is achieved between the side edges30,30′ of adjacent connected floor tiles1,1′ according to the present invention. Any number of tiles1may be joined to form the required flooring system10.

There is also provided a method of forming a tile1comprising the initial step of forming a base substrate2according to the embodiments shown. An injection moulding tool may be fitted to an injection moulding machine an appropriately operated to form the base substrate2and the base substrate2removed from the machine when formed and allowed to dry. Such a tool is fitted to the machine between the machine plates and secured using mould clamps. Flexible PVC in any of various colours is then vacuum fed to a hopper of the moulding machine and gravity feed into a barrel of the machine where it is melted at between 180-190 degrees Celsius. The injection moulding machine is set to allow a screw inside the barrel to pick up sufficient melted material that is then injected through a nozzle of the barrel and into the closed mould at pre-set speeds and pressures. The mould remains closed for a pre-set time to allow cooling. The mould then opens and the base substrate with a moulded aligning member, that is, with an either upstanding rim or raised members, is manually or automatically ejected from the mould. This moulded interlocking tile substrate2is then stacked on cooling racks for about 24 hours. It will be understood that the dimensions for the base substrate may be moulded as required or as desired. The laminate layer3according to the invention, with either a recess ledge22, according to the embodiment ofFIGS. 1 to 6, or raised member receiving recesses26, according to the embodiment ofFIGS. 7 to 11may also be formed using the same process.

Next, an adhesive is applied to a bottom surface of a laminate layer3. Such a step may be performed by operating a roller coater machine to apply adhesive to the laminate layer. The adhesive may be a hot melt polyurethane adhesive or any other suitable adhesive and the laminate layer3may comprise a PVC backing layer, a printed middle layer having a desired surface finish or effect for the tile1, such as wood, porcelain, plastic etc, and a clear PVC top layer. The laminate layer3is sized as appropriate to sit in the nest on the substrate.

Next, the laminate layer3is oriented as required and placed onto the base substrate so that the aligning member4,24of the base substrate2engages with the complimentary receiver22,26formed in the laminate layer3to thereby align the laminate layer3on the top surface5of the substrate2. Pressure is then applied to the laminate layer3on the substrate2, such as by operating a nip-roller machine, so that the laminate layer3is bonded to the substrate2to form the tile1. The completed interlocking tile1is then stacked flat on a cooling rack for a further 24 hours before packaging.

Aspects of the present invention have been described by way of example only and it should be appreciated that additions and/or modifications may be made thereto without departing from the scope thereof as attached in the appended claims.