Patent Abstract:
A removable interior building surface-covering section member such as a floor tile, sheet, or plank is provided that can be laid without the use of adhesives and which can be removed and relayed repeatedly. The removable floor section member has multiple layers including an top surface, an intermediate cushion layer and a lower adhesive layer. The lower adhesive layer may have alternating raised and lowered channels to increase adhesion moisture conditions.

Full Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]     This application is a continuation-in-part of, and claims priority from, co-pending patent application Ser. No. 11/036,907, filed Jan. 14, 2005, and entitled Removable And Relayable Floor Covering. 
     
    
     FIELD OF THE INVENTION  
       [0002]     The present invention generally relates to floor coverings and their installation and, more particularly to a removable and repositionable tile floor coverings.  
       BACKGROUND OF THE INVENTION  
       [0003]     There is always a need for efficiency, economy and speed in the construction industry. The surface-covering portion of the construction industry has also had the challenge of escalating costs incurred by the labor, material, and time associated with flooring installation and removal procedures. This waste of time, labor, and materials is particularly evident in the flooring industry where the need for durability and replaceability are constant conflicting requirements. 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. However, the more solidly it is secured to the sub-floor, the more difficult and costly it will be to install or remove the flooring.  
         [0004]     Prior to a conventional flooring installation, much labor, time and material is wasted in the removal of existing flooring and the return of the damaged sub-floor to ideal conditions for the installation of the new floor. The removal of existing flooring often causes glue residue to remain on the top surface of the sub-floor. The process of removal of existing flooring or the residual, hardened glue also often damages the sub-floor. When the removal is complete, additional labor, time and material are required to install the new floor securely to the sub-floor. Unnecessary environmental cost is also incurred in the wasteful discarding of the old flooring material, and in the repeated use of another new set of the cement, adhesive or underlayment system required for the new flooring.  
         [0005]     Self-adhesive tiles, produced with or without release paper, are known in the art and may help to eliminate the re-application of glue when installing new flooring materials. Interlocking flooring systems have also been developed to eliminate the application of glue altogether by making the adjacent tiles interlock. Underlayment systems have been developed in the art to eliminate faulty sub-floor conditions and enable new flooring to be fastened onto the underlayment systems directly instead of on to a sub-floor.  
         [0006]     For example, in U.S. Pat. No. 6,129,967 a system for securing brittle ceramic tiles to a sub-floor without a supporting adhesive substrate is disclosed. A liner is used to provide structural support and an energy absorbent layer is present which allows the tile to withstand greater forces of abrasion without breaking. The liner is adhered to a sub-floor and the tiles are placed inside and are anchored to the liner and an impact resistant ceramic layer.  
         [0007]     U.S. Pat. No. 6,694,689 discloses a modular flooring system which utilizes a free-lay support base plate into which replaceable wear surface tiles fit. The base plate provides for 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.  
         [0008]     U.S. Pat. No. 4,654,244 discloses a loose-lay floor structure including two layers of reinforced material that are suitable for use over stable and unstable sub-floors. 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 designed to prevent buckling, curling and doming under a rolled load.  
         [0009]     U.S. Pat. No. 6,751,917 discloses a floor tile structure without an adhesive coating at the bottom. Each tile surface layer and bottom layer are attached respectively, on the upper and the lower surfaces of 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 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.  
         [0010]     U.S. Pat. No. 6,751,912 discloses a modular interlocking tile 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.  
         [0011]     U.S. Pat. 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 an 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 plurality of tile panels.  
         [0012]     U.S. Pat. No. 6,769,217 discloses an interconnecting disengageable flooring system. The system includes two or more flooring panels including a top wear surface and a bottom surface for contact with the support structure. The panels have at least three edges and all edges 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.  
         [0013]     U.S. Pat. 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 psi at 140° F. but has tack at about 20 psi at 75° 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 covering includes applying an adhesive to a substrate to form 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.  
         [0014]     U.S. Pat. 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 of at least 170 cN.  
         [0015]     U.S. Published Patent Application No. 20040129365 discloses a pre-glued 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.  
         [0016]     None of the foregoing prior art flooring systems and methods are completely satisfactory. There remains a need for a flooring systems that is durable and slip-resistant against foot traffic when adhered to a sub-floor, but that can be installed and removed readily without additional investment in time, labor, cost, tools or energy. In addition, there is a need in the art for a flooring system with a nearly 100% clean removeability (i.e., that will not damage a sub-floor, leave appreciable 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. It is 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. Also, it is desirous to provide a moisture release enhancement as an additional feature in the flooring to minimize the dirt and grime collection in and under the tile seams and to release the pressure built-up due to moisture in the sub-floor. 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 resistant and suitable for both permanent and temporary tile installations. Furthermore, 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.  
       SUMMARY OF THE INVENTION  
       [0017]     The present invention relates to removable flooring and surface coverings that are a structural improvement of floor tiles, sheets, or planks, including 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 laminates thereof in desired combinations, all of which are hereinafter referred to as a “floor section, floor covering, or floor tile”.  
         [0018]     More particularly, the present invention provides a floor covering having a dual backing layer comprising a foam layer coated with a repositionable, pressure sensitive adhesive layer. This dual backing layer allows the floor covering to be installed directly 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 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.” 
         [0019]     In one embodiment, a floor covering is provided including a top surface or wear layer often having a backing layer arranged below the wear layer. A cushion layer is arranged below the backing layer which includes a bottom-most embossed surface that defines a plurality of channels that are separated one from another by a plurality of lands. A repositionable, pressure sensitive adhesive that has an initial tack is applied onto the bottom-most surface of the cushion layer so that the cushion layer (i) adheres to a surface thereby to hold the cushion layer in place after application of a pressure, but (ii) allows removal of the cushion layer from the surface absent a substantial diminution of the initial tack so that the floor covering may be repositioned on the sub-floor.  
         [0020]     In another embodiment, floor covering is provided that includes a top surface or wear layer. A divided cushion layer is located below the backing layer which has a bottom-most embossed surface that defines a plurality of intersecting channels that are separated one from another by a plurality of lands wherein each of the lands comprises a top surface. A repositionable, pressure sensitive adhesive that has an initial tack is applied to the top surface of the lands so that the divided cushion layer (i) adheres to a surface thereby to hold the cushion layer in place after application of a pressure, and (ii) allows removal of the cushion layer from the surface absent a substantial diminution of the initial tack so that the floor covering may be repositioned on the sub-floor.  
         [0021]     A method for adjusting the surface contour of a floor covering is also provided in which a divided cushion layer is formed on a bottom surface of a self-adhesive, loose-lay tile so as to define a plurality of removable pad segments. In order to compensate for a prominence or depression on a sub-floor, e.g., a nail or portion of a floor board or a hole or low spot, at least one of the pad segment is removed from its position of the bottom-most surface of the floor covering thereby forming a void in the divided cushion layer that is suitable for accepting and receiving the prominence.  
         [0022]     In another method for adjusting the surface contour of a floor covering, a divided cushion layer is formed on a bottom surface of a self-adhesive, loose-lay tile so as to define a plurality of removable pad segments. In order to compensate for a prominence or depression on a sub-floor, e.g., a nail or portion of a floor board or a hole or low spot, at least one of the pad segment is removed from its position of the bottom-most surface of the floor covering thereby forming a void in the divided cushion layer that is suitable for accepting and receiving the prominence, and the removed pad segment is positioned atop a portion of the divided cushion layer that corresponds to the position of the depression in the sub-floor. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0023]     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 numbers refer to like parts and further wherein:  
         [0024]      FIG. 1  is a perspective view of a floor covering without moisture-release channels according to the present invention;  
         [0025]      FIG. 2  is a cross-sectional view of a floor covering without moisture-release channels according to the present invention;  
         [0026]      FIG. 3  is a perspective view of a floor covering with moisture-release channels according to the present invention;  
         [0027]      FIG. 4  is a cross-sectional view of a floor covering with moisture-release channels according to the present invention;  
         [0028]      FIG. 5  is a flowchart of one typical production process according to the invention;  
         [0029]      FIG. 6  is a perspective view of an alternative embodiment of floor covering formed in accordance with the present invention.  
         [0030]      FIG. 7  is a bottom perspective view of the floor covering shown in  FIG. 6 ;  
         [0031]      FIG. 8  is a broken-away and enlarged view of a corner portion of the floor covering shown in  FIG. 7 ;  
         [0032]      FIG. 9  is a cross-sectional view of a portion of the floor covering shown in  FIG. 7 ; a floor covering formed in accordance with the alternative embodiment of the present invention;  
         [0033]      FIG. 10  is a broken-away and enlarged view of the floor covering shown in  FIGS. 7, 8 , and  9 , showing an individual pad segment, lands, and channels in accordance with the present invention;  
         [0034]      FIG. 11  is a broken-away perspective view showing the top surfaces of pad segments on the bottom-most surface of a floor covering formed in accordance with the present invention;  
         [0035]      FIGS. 12 and 13  are a broken-away perspective views similar to that of  FIG. 11 , showing a pad segment being removed from the floor covering;  
         [0036]      FIG. 14  is a perspective view of a portion of a workman&#39;s hand holding a pad segment formed in accordance with the present invention;  
         [0037]      FIG. 15  is a broken-away illustration of a floor covering formed in accordance with the present invention being applied to a sub-floor;  
         [0038]      FIG. 16  is a perspective view of a broken-away corner portion of a floor covering showing a first pad segment being applied over top of a second pad segment so as to increase the thickness of the floor covering in that region;  
         [0039]      FIG. 17  is a perspective view of a bottom of a floor covering formed in accordance with the present invention showing an edge strip with pad segments removed to accommodate a prominence on a sub-floor;  
         [0040]      FIG. 18  is a perspective view of a bottom of a floor covering formed in accordance with the present invention showing a central void formed by the selective removal of pad segments so as to accommodate a prominence on a sub-floor and portion of the floor covering bottom having additional pad segments added so as to compensate for unevenness or depressions in the sub-floor;  
         [0041]      FIG. 19  is a perspective view of a bottom of a floor covering formed in accordance with the present invention showing a corner pad segment removed to accommodate a prominence on a sub-floor and a corner having a doubled pad segment to compensate for a corresponding depression in the sub-floor;  
         [0042]      FIG. 20  is a broken-away, perspective view of a corner portion of a floor covering formed in accordance with the present invention showing a double-thickness of pad segments on the bottom portion of a floor section acting to compensate for a depression in the sub-floor;  
         [0043]      FIGS. 21 and 22  are cross-sectional views of a pair of side-by-side floor tiles formed in accordance with the present invention where a portion of one of the floor tiles sits atop a recess in a sub-floor; and  
         [0044]      FIGS. 23 and 24  are cross-sectional views of floor tiles formed in accordance with the present invention where a portion of the floor tile sits atop a prominence in a sub-floor. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0045]     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 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 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 “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.  
         [0046]     The term “operatively connected” is such an attachment, coupling or connection that allows the pertinent 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 equivalents but also equivalent structures.  
         [0047]     Referring to  FIGS. 1-5 , a floor section  10  that is formed in accordance with a first embodiment of the present invention may be formed, at least in part from any one of the following floor covering material types 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 laminates thereof in desired combinations, all of which are referred to hereinafter as a “floor section”.  
         [0048]     Floor section  10  often comprises a self-adhesive, loose-lay installed floor covering which may have multiple layers or be homogenous, i.e., natural stone or wood, 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 adhesive layer  14  is provided by a backing coating of cured or non-cured adhesive. More particularly, upper wear surface  11  is preferably formed from polyvinyl chloride (PVC), ceramic, stone, or other suitable surface materials, and 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. Upper wear surface  11  is defined by its upper surface  11   a , which forms the uppermost wear surface of floor section  10 , and its lower surface  11   b , the bottommost surface of floor section  10 .  
         [0049]     Cushion material layer  13  is defined by its upper surface  13   a  and lower surface  13   b . 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 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-foamed may also be employed. The thickness of cushion material layer  13  is often about 0.1 mm to 1.0 mm, with about 0.2 mm often preferred. Cushioned material layer  13  provides for an evenly distributed contact between floor section  10  and a sub-floor. This, in-turn, significantly increases the degree of leveling adhesion of floor section  10 , and enhances the acoustic absorption of floor section  10  while making the finished floor more comfortable to walk on and more shock-absorbent.  
         [0050]     Upper wear surface  11  is adhered to cushion material layer  13  by an internal adhesive layer  12 . Internal adhesive layer  12  adheres lower surface  11   b  to an uppermost surface  13   a  of cushion material layer  13 . A repositionable, pressure sensitive adhesive layer  14  is often formed or applied as a coating of cured or non-cured adhesive that adheres onto the sub-floor with very slight pressure, but allows lifting, removal, and repositioning of floor section  10  with its original “tack” substantially unaffected, and without glue residue or delaminating the sub-floor. The repositionable, pressure sensitive adhesive that comprises internal adhesive layer  14  may include many of the adhesives that are non-curable or curable, including rubber-type adhesives, PVC-type adhesives, acrylic adhesives, e-beam curable acrylic adhesives, vinyl acetate-type adhesives, urethane-type adhesives and combinations thereof. Lower surface  14   b  of repositionable, pressure sensitive adhesive layer  14  must provide sufficient adhesive properties to maintain floor section  10  in place during use, but also be releasable so that floor section  10  can be removed and repositioned, sometimes repeatedly. In other words, repositionable, pressure sensitive adhesive layer  14  advantageously adheres to a surface with an initial tack that holds the cushion layer in place after application of a pressure, but allows for the removal of the cushion layer from the surface (e.g., sub-floor) absent a substantial diminution of its initial tack. One adhesive that has been found to provide adequate results is made of modified acrylate, with a viscosity of 3000-5000 cps/25° C., a density of 1.0-1.1 g/cm 3 , and a curing speed greater than 10 M/min/Lamp (80 Wcm −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 knife, or other similar coating apparatus. Of course, repositionable, pressure sensitive adhesives that do not need to be cured, as are well known in the art, may also be used in connection with the present invention.  
         [0051]     Lower surface  13   b  adheres to a backing coating of cured adhesive layer  14 . In one embodiment, the criteria for the repositionable, pressure sensitive adhesive layer applied on foam layer lower surface  13   b , would be any curable adhesive which: (1) has undergone curing or cross-linked processing; (2) has initial tack that&#39;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 0.03 mm to 0.05 mm thick average, but can be less than 0.03 mm or greater than 0.05 mm depending on the adhesive used. Cushioned material layer  13  may have about 0.5 mm to 3.0 mm thickness, but could vary depending on the foam material used. The repositionable, pressure sensitive adhesive thickness can be conventionally determined, typically between 0.01 mm to 0.3 mm, but preferably lower than a thickness of 0.1 mm.  
         [0052]     Referring to  FIGS. 3 and 4 , another embodiment of the invention comprises a floor section  20  that includes a moisture-releasing channel layer  24 . More particularly, floor section  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. Wear surface layer  21  is defined by its upper surface  21   a  which is the uppermost contact and wear surface of sample floor section member  20  and its bottom surface  21   b . An internal adhesive layer  22  is adhered to a lower surface  21   b  of wear surface layer  21 . Wear surface layer  21  is preferably formed from polyvinyl chloride (PVC), ceramic, stone, or other suitable surface materials, and 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. Wear surface layer  21  is often applied to cushion material layer  23  with an internal adhesive layer  22 . Internal adhesive layer  22  adheres to bottom surface  21   b  and surface  23   a  which is the uppermost surface of cushion material layer  23 .  
         [0053]     When cushion material layer  23  is positioned below wear surface layer  21 , the lowermost portion of it defines moisture-releasing channel layer  24 . Moisture-releasing channel layer  24  comprises a plurality of lands  26  that are located between and separate a plurality of troughs or channels  27  that are arranged in regular intervals across the bottom of floor section  20 . Moisture-releasing channel layer  24  is preferably formed by pressing or embossing the bottom-most surface of cushion material layer  23  so as to compress portions of cushion material layer  23  to form troughs or channels  27  while maintaining the portions of cushion material layer  23  adjacent to troughs or channels  27  at or near to their original thickness so as to define lands  26 . Additionally, depending upon embossing conditions, lands  26  can also be compressed to less than their original thickness. Repositionable, pressure sensitive adhesive layer  14   b  is applied to lower surface  23   b  of cushion material layer  23 . In one embodiment, ( FIG. 3 ) lands  26  and channels  27  may extend parallel to each other for the length and width of floor section  20 . Repositionable, pressure sensitive adhesive layer  14   b  advantageously adheres to a surface with an initial tack that holds the cushion layer in place after application of a pressure, but allows for the removal of the cushion layer (i.e., the tile) from the surface (e.g., sub-floor) absent a substantial diminution of the initial tack.  
         [0054]     Cushion material layer  23  may comprise any one or combination of soft, resilient materials including, but not limited to foamable polymers or foam such as 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 polyolefins, elastomeric polyolefin copolymers, so long as they are susceptible to taking a set after being compressed or other wise embossed in accordance with that aspect of the invention. Additionally, any soft, resilient or cushioned material which is foamed or non-foamed may also be employed. The thickness of cushion material layer  23  and lands  26  is often about 0.1 mm to 1.0 mm, with about 0.2 mm being often preferred, with those portions of cushion material layer  23  that define troughs or channels  27  having an embossed thickness of about 0.2 mm or less.  
         [0055]     Repositionable, pressure sensitive adhesive layer  14   b  is applied over the bottom-most surface of moisture-releasing channel layer  24 , and functions as a releasable glue to hold floor section  20  in place on a sub-floor, while advantageously allowing floor section  20  to be removed, repositioned, and then relayed onto the sub-floor. Repositionable, pressure sensitive adhesive layer  14   b  may be formed of rubber-type adhesives, acrylic adhesives, including e-beam curable acrylic adhesives, vinyl acetate-type adhesives, urethane-type adhesives, and combinations thereof, or any other pressure sensitive adhesives that are curable or non-curable as are well known in the art.  
         [0056]     Moisture-releasing channel layer  24  molds to the sub-floor upon which it is laid and reinforces the surface tension of the floor section&#39;s adhesion on the sub-floor. Such molding resists horizontal or diagonal pull forces and movement on the sub-floor. Floor section  20  is best removed from a sub-floor with a pull parallel to the vertical structural lining on the cushion material layer  23  as a result of the provision of channels  27 . Floor section  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&#39;s adhesion to the sub-floor and to maintain the aesthetic value of floor section  20 . This arrangement also prevents unwanted particles from collecting and soiling floor section  20  or distressing the point of contact of moisture-releasing channel layer  24  with the sub-floor.  
         [0057]     Referring to  FIG. 5 , a flowchart is provided of a typical production process for a floor section  20  in the form of a vinyl tile formed in 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 also include a printed design. The polyvinyl chloride film is then extruded into a tile by heat lamination according to 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 tile by a crushing machine. The tile surface may then be embossed, cooled, and annealed. Glue is then applied to the tile back. 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 cut to fit the tile material already produced.  
         [0058]     As referenced in schematic  41 , after the foam is adhered onto the tile&#39;s backing and formed, the back surface of the tile is smoothed, embossed to yield lands  26  and channels  27 , and then the adhesive is applied onto the foam layer and followed, in some embodiments, by drying/curing with ultraviolet light. The production process is then complete, and the tile is ready for packing.  
         [0059]     Referring to  FIGS. 6-24 , a further embodiment of the present invention provides for removal and readjustment of a cushion layer to accommodate unevenness in the sub-floor. More particularly, a floor section  50  comprises multiple layers including wear surface layers  52 , a backing layer  54  and a dividable cushion material layer  56 . Wear surface layers  52  include an upper-most clear film surface  58  and often a print film layer  60  that form the uppermost layers that are seen and that form the contact and wear portion of floor section  50 . Backing layer  54  may be formed from polyvinyl chloride (PVC), ceramic, stone, or other suitable support materials, and can be of varying width, thickness, density and edge shape design. An internal adhesive layer  62  is adhered to a lower layer surface of wear surface layers  52  so as to adhere an uppermost surface of backing layer  54  and another internal adhesive layer  63  (a repositionable, pressure sensitive adhesive layer, such as adhesive layer  14   b ) is adhered to a bottom surface of backing layer  54  so as to adhere an uppermost surface of dividable cushion material layer  56 . Internal adhesive layer  63  advantageously adheres to the bottom surface of backing layer  54  with an initial tack that holds dividable cushion material layer  56  in place after application of a pressure, but allows for the removal of dividable cushion material layer  56  from the bottom surface of backing layer  54  absent a substantial diminution of an initial tack.  
         [0060]     Dividable cushion material layer  56  comprises a plurality of removable pad segments  70 , i.e., cushion material layer  56  is arranged and constructed so as to be separated or split into a plurality of separate and discrete segments. Each pad segment  70  is separated from its adjacent pad segments by score lines  72  that allow for removal of individual pad segments  70  from floor section  50  ( FIG. 12 ) i.e., a grid of intersecting incisions or cuts through the thickness of cushion material  56  so as to render it capable of being split into a plurality of separate and discrete pad segments. The bottom-most surface of each pad segment  70  is also pressed or embossed so as to define a plurality of lands  76  that are located between and separate a plurality of troughs or channels  77  that are arranged in regular intervals across the bottom surface of floor section  50 . In particular, bottom-most surface of each pad segment  70  is preferably formed by pressing or embossing the bottom-most surface of so as to compress portions of dividable cushion material layer  56  to form troughs or channels  77  while maintaining the portions of dividable cushion material layer  56  adjacent to troughs or channels  77  at or near to their original thickness so as to define lands  76 . Dividable cushion material layer  56  may additionally comprise a repositionable, pressure sensitive adhesive layer  80  substantially similar to repositionable, pressure sensitive adhesive layer  14   b  ( FIG. 10 ) that is applied to the bottom-most surface of each pad segment  70 . Depending upon process conditions, repositionable, pressure sensitive adhesive layer  80  can be applied to the bottom surface of lands  26  as shown in  FIGS. 8-24 , or it can be applied to the entire bottom surface of cushion layer  56 , including the surface that defines the bottom of channels  77 . Repositionable, pressure sensitive adhesive layer  80  advantageously adheres to a sub-floor surface with an initial tack that holds each pad segment  70  in place after application of a pressure, but allows for the removal of any one or more of pad segments  70  from the surface of the sub-floor absent a substantial diminution of an initial tack ( FIGS. 12, 13 ,  14 , and  16 ).  
         [0061]     Dividable cushion material layer  56  may comprise any one or a combination of soft, resilient materials including, but not limited to foamable polymers or foam such as 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 polyolefins, elastomeric polyolefin copolymers. Additionally, any soft, resilient or cushioned material which is foamed or non-foamed may also be employed. The thickness of dividable cushion material layer  56  and lands  76  is often about 0.5 mm to 3.0 mm, with those portions of dividable cushion material layer  56  that define troughs or channels  77  having an embossed thickness of about 1 mm or less.  
         [0062]     Repositionable, pressure sensitive adhesive layer  80  is applied over the bottom-most surface of dividable cushion material layer  56  and is often curable, and functions as a releasable glue to hold floor section  50  in place on the sub-floor, while advantageously allowing floor section  50  (or one or more pad segments  70 ) to be removed, repositioned, and relayed onto the sub-floor. Repositionable, pressure sensitive adhesive layer  80  may be formed of rubber-type adhesives, acrylic adhesives, including e-beam curable acrylic adhesives, vinyl acetate-type adhesives, urethane-type adhesives, and combinations thereof, or any other pressure sensitive adhesives that are curable or non-curable as are well known in the art.  
         [0063]     Floor section  50  may be applied to a sub-floor  85  in the following manner. Referring to  FIGS. 11-24 , floor section  50  is applied to sub-floor  85  by first arranging dividable cushion material layer  56  in spaced confronting relation to the top surface of sub-floor  85 . Once in this position, floor section  50  is moved toward the top surface of sub-floor  85  until adhesive layer  80  engages the sub-floor. If sub-floor  85  is uneven, i.e., there are both depressions  87  ( FIGS. 21 and 22 ) and prominences  90  (FIGS.  23  and  24 ) within the sub-floor surface to be covered by floor section  50 , one or more pad segments  70  may be removed and/or stacked one atop another so as to compensate for the uneven surface features of the sub-floor. Of course, pad segments  70  would be removed from floor section  50  to form a complementary void  92  on its back surface so as to compensate for a prominence  90  that projects from the surface of sub-floor  85 . Alternatively, pad segments  70  from the same or any other floor section  50 , or as provided separately packaged, may be applied over top of other pad segments  70  on the back surface of floor section  50  so as to compensate for depressions  87  that are formed in the surface of sub-floor  85  ( FIGS. 17, 18 ,  19 , and  20 ).  
         [0064]     More particularly, one or more individual pad segments  70  may be peeled from backing layer  54  ( FIGS. 12, 13 , and  14 ) thereby creating a void  92  defined by the surrounding, remaining pad segments  70  adjacent to that section of dividable cushion material layer  56 . The number of pad segments  70  to be removed will correspond to the amount of surface area required to accept prominence  90  to be compensated for on the surface of sub-floor  85  ( FIGS. 23 and 24 ). In addition, the removed pad segments  70  may be stacked one atop another so as to build up the thickness in any region of dividable cushion material layer  56  so as to compensate for corresponding depressions  87  located on sub-floor  85 .  
         [0065]     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.

Technology Classification (CPC): 4