Patent Abstract:
Described herein is a method of installing a flooring system overlying a subfloor comprising laying a plurality of liners having a grid pattern printed thereon on the subfloor such that longitudinal edge portions of adjacent liners are adjacent or overlapping; and adhering a plurality of tiles to the liners with an adhesive such that the tiles are substantially aligned with the grid pattern, and edges of adjacent tiles substantially abut, whereby some of the tiles overlie the longitudinal edge portions of at least two of the adjacent liners and are adhered thereto.

Full Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuation of U.S. application Ser. No. 13/679,742, filed on Nov. 16, 2012, which is a continuation of U.S. application Ser. No. 11/643,409, filed on Dec. 21, 2006 and now issued as U.S. Pat. No. 8,322,100, which claims the benefit of U.S. provisional application Ser. No. 60/752,430, filed Dec. 21, 2005, which are hereby incorporated by reference in their entireties. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates generally to the field of flooring including tiles and more particularly to a flooring system that enables the tiles to be easily installed and removed. Still more particularly the present invention relates to resilient tiles and a flooring system comprising a plurality of tiles, a plurality of liners having a grid pattern printed thereon and adhesive to adhere the tiles to the liners. 
       BACKGROUND OF THE INVENTION 
       [0003]    The floor replacement cycle for resilient flooring tile is long because among other reasons residential resilient tile is often difficult to remove and replace. The removability of fully adhered tile varies—sometimes it comes up with great difficulty, a small piece at a time—at best tile is removed with moderate difficulty in larger pieces or entire tile. 
         [0004]    Further, residential resilient tile can be difficult to repair. Repair usually involves removing the tile in multiple pieces, scraping the floor, and respreading adhesive. 
         [0005]    Also, residential tile can be difficult to recycle, since it usually comes up in pieces. These pieces are not easily collected and contained for shipping to a recycling plant. Additionally, as small pieces they are not easily identified as safely recyclable tile, possibly being non-vinyl tile or tile containing hazardous materials. The residential tile to be recycled may include an underlayment comprising materials not normally used to make tile. 
         [0006]    With prior art residential tile, replacing the tile that has been removed requires additional subfloor preparation. This usually involves manual adhesive scraping, patching, and/or the installation of ¼″ plywood. 
         [0007]    Another disadvantage of prior art resilient tile is that it is not easily customizable or themed. 
         [0008]    An issue for the average do-it-yourselfer is that planning the tile job can be confusing. It may be difficult for the average homeowner to properly center and balance the tile in the room. Also, positioning and centering a rolled-out underlayment on the floor can be difficult if the room center marks are covered by an opaque underlayment. 
         [0009]    Further, water can get trapped under the tile in wet areas. This is especially true when using adhesive tabs, i.e. discontinuous adhesive, to install the tile. 
         [0010]    In order to make a floor that floats, the flooring pieces must be attached to each other. Inexpensive tile is usually thin and weak and not easily locked together via the edges. Tiles that are not affixed to the subfloor with full-spread glue can be prone to shifting due to foot pivoting and due to furniture movement. 
         [0011]    Another issue with a floating floor is that installing tile on a floating underlayment on plywood or on an existing floor can lead to fatigue failure under chair wheels due to repeated flexing of the tile. Also, fatigue failure due to repeated flexing of the tile under chair wheels is enabled by and manifested at the tile joints. Further, dragging appliances over floating tile system can result in the tile or underlayment being torn. 
         [0012]    Changing seasons cause the subfloor in typical residential construction to move with changing moisture levels. This movement can cause flooring to buckle due to shrinkage of the subfloor or tearing due to expansion of the subfloor. 
       SUMMARY OF THE INVENTION 
       [0013]    The present invention is directed to a method of installing a flooring system overlying a subfloor comprising: laying a plurality of liners having a grid pattern printed thereon on the subfloor such that longitudinal edge portions of adjacent liners are adjacent or overlapping; and adhering a plurality of tiles to the liners with an adhesive such that the tiles are substantially aligned with the grid pattern, and edges of adjacent tiles substantially abut, whereby some of the tiles overlie the longitudinal edge portions of at least two of the adjacent liners and are adhered thereto. 
         [0014]    Other embodiments of the present invention are directed to a method of installing a flooring system overlying a subfloor comprising: laying a plurality of liners having a grid pattern printed thereon on the subfloor such that longitudinal edge portions of adjacent liners are adjacent or overlapping and the grid pattern of adjacent or overlapping liners are substantially; and adhering a plurality of tiles to the liners such that the tiles are substantially aligned with the grid pattern, whereby some of the tiles overlie the longitudinal edge portions of at least two of the adjacent liners and are adhered thereto. 
         [0015]    Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0016]      FIGS. 1 to 7  are schematic representations showing installation steps of the present installation method. 
           [0017]      FIG. 8  is a bottom plan review showing the location of the adhesive tabs. 
           [0018]      FIGS. 9 to 12  are schematic representations showing further installation steps of the present installation method. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0019]    The installation of the system involves rolling out the liner, using the printed grid as a centering aid. First the center run of liner is rolled out then side runs of liner are rolled out to reach the wall. Next adhesive dots are applied to each corner of the tile, or adhesive is sprayed over the selected liner area or tile and allowed to dry. The tile is then laid onto the grid. 
         [0020]    Individual tiles can be replaced by prying with a knife blade in a corner or edge of the tile and slowly prying up the tile, continuing to pull by hand as soon as the corner can be gripped. Then a new tile can be installed in its place. 
         [0021]    Removal of the entire installation involves pulling up the tile/liner starting at a corner or edge, cutting the liner at the tile perimeter, and restacking the tile for disposal/recycle. 
         [0022]    The liner may be a 32″ wide, 4 mil clear, matt finish, rigid vinyl film. To enable positioning and centering the tile the liner should have grid lines the size of the tile to be installed printed on the liner. In one embodiment, a row of squares are centered longitudinally on the liner and two rows of half tile sized rectangles are printed adjacent the edges of the liner. The width of the liner can be a multiple of the tile width, with the row of tiles centered or the seam between the rows of tiles centered, in which case the liners are laid with the edges of adjacent liners adjacent. If the width of the liners is somewhat greater than a multiple of the tile width, the edge portions of adjacent liners are overlapped when the liners are laid. 
         [0023]    The modulus of elasticity, tensile strength, grid layout, and moisture resistance of the film are important to the proper functioning of the liner during installation and afterwards. The liner should be stiff enough to reduce the degree of flexing and deter buckling. 
         [0024]    In one embodiment, the tiles are 16″×16″×0.125″ modular vinyl tile. The adhesive may be adhesive dots applied to each of the corners of the tile, or pressure sensitive adhesive, or a spray adhesive applied to the tile or liner. The tiles can have other dimensions, such as a 12″×12″ tile or 18″×18″ tile or be self-adhering Place‘n’Press tile of any size. The tile can be of different shapes such as rectangles, triangles, parallelograms. Different tile compositions can include non-PVC tile and liner, or any tile with a degree of conformability. The concept can likely be used with a variety of adhesive types including full adhesive on the back of the tile, dots of various kinds of adhesive, and spray adhesive. 
         [0025]    The liner can either float on the substrate or be adhered to the substrate with an adhesive or other means that does not damage the substrate and is easy to remove. The tile can be laid over the entire substrate or form an island on the substrate. If an island is formed, it is preferred that the tile overlying the edge of the liner extend beyond the edge of the liner and is adhered to the substrate. 
         [0026]    Olsen Stiffness values are obtained on a Tinius Olsen Stiffness Tester with a range of 0 to 6 inch-pounds or 0 to 50 inch-pounds depending on the sample stiffness. The protocol described in ASTM D-747 was followed to measure the values with the exception that the values reported were obtained at an angle of 20 degrees and sample run on the 50 in-pound machine were 2″ wide as opposed to 1″ wide. The stiffness test is a measure of the force in inch-pounds needed to bend the material 20 degrees. 
         [0027]    Olsen stiffness at 73.4 degrees F., 5 degree, 2 inch width, 1 inch span of no greater than 10 in-lb yields a tile that will conform sufficiently to the substrate on which it is laid. Preferably, the Olsen stiffness is no greater than 5 in-lb. 
         [0028]    The Liner Specification for one embodiment of the tile, in which the liner is 36″ wide allowing for a 4″ overlap on each edge with 16″ tile, is set forth in Table I below: 
         [0000]    
       
         
               
               
               
             
               
               
               
             
           
               
                   
                 TABLE I 
               
               
                   
                   
               
               
                   
                 Thin, non-glass option 
                 Glass option 
               
               
                   
                   
               
             
             
               
                   
               
             
          
           
               
                 Composition 
                 rigid vinyl film 
                 vinyl plastisol saturated 
               
               
                   
                   
                 glass scrim 
               
               
                 Thickness 
                 0.0025″ to 0.008″ prefer 
                 0.025″ +/− 0.003″ or thinner 
               
               
                   
                 0.004″ +/− 0.0005″ 
                 if all other properties can be met 
               
               
                 Width 
                 36″ +/− 0.030″ 
                 36″ +/− 0.030″ 
               
               
                 Modulus Prefer 
                 200,000 psi minimum 
                 40,000 psi minimum 
               
               
                 Thickness 
               
               
                 times 
               
               
                 Modulus = 400 
               
               
                 to 1000 lb/in 
               
               
                 Yield Load 
                 5 lbs/inch minimum, 
                 5 lbs/inch minimum, 
               
               
                   
                 prefer 14 lbs/inch minimum 
                 prefer 14 lbs/inch minimum 
               
               
                 Gloss-60 
                 20-40 preferred - full gloss 
                 20-40 preferred - full gloss 
               
               
                 degree 
                 is acceptable 
                 is acceptable 
               
               
                 Resistance to 
                 growth 0.3% maximum, 
                 growth 0.3% maximum, 
               
               
                 Moisture 
                 prefer 0.1% maximum 
                 prefer 0.1% maximum 
               
               
                 Immersion Test 
                 prefer 0.1% maximum 
               
               
                   
                 absorption up to 5% acceptable 
               
               
                 Dimensional 
                 0.3% change maximum, prefer 0.1% 
                 0.3% change maximum prefer 0.1% 
               
               
                 Stability, 6 
                 change maximum 
                 change maximum 
               
               
                 weeks @115 
               
               
                 degrees F. 
               
               
                 Camber 
                 Ten meters of material cut from a 
                 Ten meters of material cut from a 
               
               
                   
                 roll and laid on a flat, smooth 
                 roll and laid on a flat, smooth surface 
               
               
                   
                 surface shall lay flat overall, with 
                 shall lay flat overall, with minimal 
               
               
                   
                 minimal puckering and baggy edge 
                 puckering and baggy edge effect. 
               
               
                   
                 effect. Prefer vary no more than 15 mm 
                 Prefer vary no more than 15 mm 
               
               
                   
                 from a straight line, with overlap 
                 from a straight line, with overlap 
               
               
                   
                 may vary 150 mm, without overlap 
                 may vary 150 mm, without overlap 
               
               
                   
                 may vary 40 mm. 
                 may vary 40 mm. 
               
               
                 Plastisol (Glass 
                   
                 Minimal migration, butyl benzyl 
               
               
                 Option Only) 
                   
                 phthalate (BBP) preferred plasticizer. 
               
               
                   
               
             
          
         
       
     
         [0029]    The Liner Specification for one embodiment of the tile, in which the liner is 36″ wide allowing for a 4″ overlap on each edge 
         [0030]    The liner can also be formed from other materials, such as PET, PETG or Mylar. PETG can be successfully recycled into vinyl tile. Polyethylene likely cannot be recycled into vinyl tile. 
         [0031]    Installation 
         [0032]    The tile installation method provides an easy do-it-yourself system for consumers to install their favorite tile patterns. It takes the guesswork out of planning the tile layout and allows for a durable installation without the use of messy adhesives that can damage existing flooring. If desired, it can be easily removed or replaced as fashion and room use needs change. The installation method with adhesive tabs is not intended for bathrooms, laundries and other places where surface water and spills are likely to occur on a regular basis. The use of spray adhesive, in place of the adhesive tabs, provides added protection against surface water penetration. 
         [0033]    Materials Needed: 
         [0034]    Modular tile, Layout grid liner, Adhesive tabs, and Tape measure, pencil, hammer, pry bar, saw, household transparent tape, utility knife, scissors, carpenter&#39;s square or straight edge, and some cardboard or craft paper if a pattern needs to be made to fit to an irregular shaped object. 
         [0035]    Preparation: 
         [0036]    Remove furniture and appliances from the room. The tile can be fit directly to existing baseboard and trim moldings, however removing the baseboard molding and replacing it after the tile is in place will make the perimeter fitting much easier. Undercut doorframes (optional) to allow the tile to slip underneath and make fitting tiles around doorframes easier. Use a tile and hand saw, as known in the art. The tile is laid adjacent the doorframe and the saw is positioned with the blade resting on the surface of the tile with the teeth adjacent the doorframe and the handle of the saw extending past the edge of the tile. With the saw in this position, the doorframe is cut to remove the lower portion and permit the tile to be slid under the door frame. 
         [0037]    All subfloors must be smooth, flat, clean and dry. Irregularities in the subfloor can telegraph through to the tile. Damaged areas in the subfloor should be repaired to create a structurally sound and firm base. 
         [0038]    Suitable Substrates: 
         [0039]    Old Vinyl Flooring: Must be a single layer and not be cushioned-backed or foam-backed. The vinyl must be firmly bonded. Loose vinyl, gapped seams, cuts, tears, rips or other damage need to be repaired. 
         [0040]    Wood Floors: Must be structurally sound, meet applicable building codes and show minimal deflection. The tile can go over most types of wood subfloors and underlayments except for particleboard. Loose vinyl, gapped seams, cuts, tears, rips or other damage need to be repaired. 
         [0041]    Concrete/Ceramic/Terrazzo/Marble: 
         [0042]    Must be clean, dry and dust-free. Cracks, unevenness and other damage need to be repaired. If installing over ceramic, terrazzo, or marble tile, the ceramic, terrazzo or marble tile must be firmly bonded. 
         [0043]    Do Not Install Over: 
         [0044]    Carpet, Existing cushioned (foam-backed) vinyl flooring, or existing resilient tile floors that are on or below grade. 
         [0045]    The layout grid liner serves several purposes. It is an aid to planning the layout in the room and “balancing” the installation to avoid small pieces of tile at the perimeter walls. It protects the existing floor surfaces from damage and when it is decided to change flooring, makes removal and replacement much easier. 
         [0046]    The layout grid is only to be used as an aid. After starting to lay tile on top of the grid (as described in succeeding steps) each tile must butt neatly and squarely to adjoining the tile, even if the tile edges start to wander slightly from the gridlines. 
         [0047]    Step  1  ( FIG. 1 ). In most rooms  1 , there will be one or two walls  2  and  3  that are relatively longer and straighter than other walls. In these instructions such walls are referred to as prominent walls. Find the midpoint of the room between the two most prominent parallel walls  2  and  3  and place a small piece of masking tape  4  and  5  with a pencil mark at two spaced locations. 
         [0048]    Step  2  ( FIG. 2 ). Slightly unroll the layout grid liner  6  and trim the leading edge  7  the first grid mark G running across the liner using scissors. Measure the overall length of the room (Y) in the direction parallel to your two prominent walls. Unroll the layout grid  6  and, measuring from the leading edge  7 , cut the first length of layout grid liner  6  at the grid mark past the measured distance Y. 
         [0049]    Step  3  ( FIG. 3 ). Align one long edge  8  of the layout grid liner  6  with the midpoint marks  4  and  5  on the floor, allowing the ends to be flashed up the walls. Do a test layout of the tiles by positioning a tile (shown shaded in  FIG. 3 ) on the layout grid lines and butting additional tile (shown shaded in  FIG. 3 ) against each other, working towards one of the prominent walls. If the distance between the last full tile and the prominent wall is at least one-half the width of the tile, go directly to step  5 . 
         [0050]    Step  4  ( FIG. 4 ). If the distance between the last full tile and the prominent wall is less than one-half the width of the tile, then it is recommended that the layout grid liner  6  be shifted (toward the center of the room) by one-half the width of the tile so the tile at the prominent walls will be greater than one-half of a tile. This can be done by moving the original pencil marks or by shifting the layout grid liner  6  so that one of the long grid lines  9  fall on top of the original marks  4  and  5 , as shown in  FIG. 4 . The prominent walls will now be balanced for equal-sized pieces larger than one-half tile. 
         [0051]    Step  5  ( FIG. 5 ). Next, visually balance the grid to the remaining ‘end’ walls  9  and  10  or obstructions, such as cabinet  12 . A small amount of the grid liner  6  should flash up the walls, so there will be good-sized pieces of tile at these walls. It is almost impossible to do this in every room, but try to avoid cut pieces at the perimeter areas that are less than 5 or 6 inches in width. Shift the layout grid liner  6  in the long direction to accomplish this but make sure the edge  8  of the grid liner  6 , or one of the long grid lines  9 , remains on top of the marks  4  and  5  as determined in the previous step to maintain balance at the prominent walls  2  and  3 . 
         [0052]    Step  6  ( FIG. 6 ). Tape the “balanced” starting grid liner  6  to the subfloor  14  using common household transparent tape  13 . Start near the middle of the grid liner  6 , and gently push out any wrinkles or distortions. Tape the liner  6  to the subfloor  14  by placing a small amount of tape (about 1″ piece) along both edges of the liner  6 . Use tape  13  at every other grid line running across the sheet. The ends of the liner may now be cut with scissors or a utility knife to fit to the end walls  10  and  11  or cabinet  12 . Do not fit too tight. Try to stay about ⅛″ to ¼″ away from the walls so there is no fullness. An easy way to mark the liner  6  for cutting is to press it into the corner where the floor and wall meet and mark it using a pen or pencil. It may then be folded back on itself and cut along the mark with scissors. 
         [0053]    Step  7  ( FIG. 7 ). Measure, cut and lay adjoining pieces of grid liner  6  on both sides of the starting piece that is taped to the subfloor  14 . Carefully align the grid pattern so that the liner edges are butt together. Full widths of liners should all be running the same direction as the starting piece. When properly aligned and laying flat, use transparent tape  13  to fasten the adjoining edges of the new pieces of grid liner  6  to the preceding grid liner  6  that is already taped to the subfloor  14 . If the liner is somewhat greater than a multiple of the tile width, overlap the edge portions width the grid marks aligned of overlapping. Tape the leading edges  8  of the new pieces of grid liner  6  to the subfloor  14  as done with the starting grid liner  6 . 
         [0054]    Cut and install subsequent pieces of the layout grid liner  6  to fill in the remainder of the room. Stay about ⅛″ to ¼″ away from the walls  2 ,  3 ,  10  and  11 . There is no need to tape the perimeter edges of the liner  6  to the subfloor  14  at walls as long as the perimeter liners  6  are taped to the previous liner  6 . 
         [0055]    Installing The Tile With Adhesive Tabs 
         [0056]    Step  8  ( FIG. 8 ). In preparation for bonding the tile  15  to the liner, four adhesive tabs  16  must be placed on the back of each tile  15 , one close to each of the corners. The adhesive tabs  16  are applied by pressing the sticky side of the tab  16  against the back of the tile  15  and rubbing the release liner side of the tab  16 . Then, the release liner is simply peeled off. The tabs  16  should be placed about ¼″ in from the actual edges of the tile  15 . 
         [0057]    Step  9  ( FIG. 9 ). Install the first tile  15  inside the grid liner section closest to the center of the room. Line up the edges of the first tile as perfectly as possible within the grid. 
         [0058]    Step  10  ( FIG. 10 ). Place adhesive tabs on successive tile and continue to install in “step fashion” (tile a, then tile b, then tile c, etc.), preferably in one quadrant, or one half of the room at a time. Butt the edges of each tile against the preceding tile. 
         [0059]    Step  11  ( FIG. 11 ). Complete the remaining quadrants until all tiles are installed in the room. The installed tiles are shown as shaded in  FIG. 11 . 
         [0060]    Cutting Border Tile 
         [0061]    Step  12  ( FIG. 12 ). For straight cuts at walls and cabinets, place a loose tile (I) face up exactly on top of the last full tile in that row. Place another full tile (II) on top of tile (I) with its edge against the wall (W). Using tile (II) as a guide, mark the face of tile (I) with a pencil (P). 
         [0062]    Using a carpenter&#39;s square or a straight edge as a guide, carefully score the face of the tile I (about ⅓ thickness) along at the mark with a utility knife Bend at the score mark to snap the tile I into two pieces. 
         [0063]    For irregular cuts, make a pattern out of craft paper or cardboard and transfer it to the tile. Score along the markings and snap small pieces off. Pliers or a coping saw are often useful in making more intricate cutouts for complicated fitting. 
         [0064]    Tile should slip underneath the undercut door jambs for a neat fit. Do not fit tile too snug as some lifting or buckling off of the subfloor could develop. 
         [0065]    Place adhesive tabs  16  at corners of cut pieces I and fasten in place on top of the grid liner  6 . Keep cut edges towards the wall. 
         [0066]    Finishing The Job 
         [0067]    Replace baseboard and trim moldings. Replace furniture and appliances. 
         [0068]    As used throughout, ranges are used as shorthand for describing each and every value that is within the range. Any value within the range can be selected as the terminus of the range. In addition, all references cited herein are hereby incorporated by referenced in their entireties. In the event of a conflict in a definition in the present disclosure and that of a cited reference, the present disclosure controls.

Technology Classification (CPC): 4