Abstract:
A method for installing flooring boards is provided. The method comprises laying down a two layer pad on a floor, applying a band of adhesive, laying a flooring board on the top of the two shifted-layer pad and the edge of the floor board occupying one half of the width of the band, and laying an adjacent floor board, which covers the remaining of the band of the adhesive.

Description:
FIELD OF THE INVENTION 
       [0001]    The invention relates to flooring, and more particularly, to method of installing padded flooring tiles. 
       BACKGROUND OF THE INVENTION 
       [0002]    Stone tiles, ceramic tiles, and porcelain tile are normally installed on cement board with mortar and grout. The installation process generally involves the following steps. First, previous floor needs to be removed and cleaned, and then the mortar must be mixed and applied onto the floor. After the mortar is applied and before it cures, a cement board is laid on the top of the floor and a layer of mortar is applied on the top of the cement board. Tiles are placed on the top of the cement board before the mortar is cured. After the tiles are firmly attached to the concrete board, grout can be applied to fill the gaps between the tiles. After the grout is applied, the excess of grout needs to be removed and the tiles are then cleaned. Grout sealant is applied to make the grout stain resistant. If the tiles are installed on a plywood subfloor instead of the concrete floor, the cement board can be nailed instead of affixed using the grout. 
         [0003]    The process above is wet and requires experience; it could not be easily mastered by a DIY installer. For professional installer, the process described above is laborious and lengthy. Most time is spent waiting for mortar to cure and grout to dry, especially for small job such as bathroom. Therefore, there is a need for a process that enables easy and quick installation of tiles, and it is to this method the present invention is primarily directed. 
       SUMMARY OF THE INVENTION 
       [0004]    The present invention provides a method for installing floor covering. The installing process is broken into two stages. First pre-assembled pads with ceramic floors are prepared, then these pre-assembled pads are used to cover the floor. The invention introduces use of a pad covered with restickable glue. 
         [0005]    In another embodiment of the invention there is provided a method for installing a flooring covering. The method comprises laying a band of adhesive on the top of a pad with a resticakable glue layer, the band of adhesive having a width and laying a first flooring element on the pad. The first flooring element has a first edge, the first edge being placed on the band of adhesive, and the first edge does not occupy more than half of the width of the band of adhesive. The method further comprises laying a second flooring element on the pad. The second flooring element has a second edge and the second edge is placed on the band of adhesive and adjacent to the first edge. Finally the pad is placed on a floor. 
         [0006]    In another embodiment, the present invention provides a pre-assembled pad with flooring elements. The pre-assembled pad comprises a pad with a top side and a bottom side, a layer of restickable glue placed on the bottom side of the pad, a plurality of bands of adhesive on the top side of the pad, and a plurality of flooring elements placed on the top side of the pad, each element being placed between two bands. 
         [0007]    In yet another embodiment of the present invention there is provided a method for installing a wall covering. The method comprises the steps of attaching a pad with a restickable glue layer on both sides of the pad on a wall, laying a band of adhesive on the top of a pad, the band of adhesive having a width, and laying a first flooring element on the pad. The first flooring element has a first edge, the first edge being placed on the band of adhesive, and the first edge does not occupying more than half of the width of the band of adhesive. Finally the method comprises the step of laying a second flooring element on the pad, the second flooring element having a second edge, the second edge being placed on the band of adhesive and adjacent to the first edge. 
         [0008]    In yet another embodiment, the present invention provides a method for installing a floor covering. The method comprises the steps of covering a pad with a layer of resticakable glue, laying a first flooring board on the pad, the first flooring board having a first tongue and a first groove, placing an adhesive on the first tongue, sliding a second flooring board with a second tongue and second groove on the pad, the second groove being engaged to the first tongue, and placing the pad on a floor. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]    Features and advantages of embodiments of the invention will become apparent as the following Detailed Description proceeds, and upon reference to the Drawings, where like numerals depict like elements, and in which: 
           [0010]      FIG. 1  is a cross section view of a padded ceramic tiles installed on a floor; 
           [0011]      FIG. 2A  is a cross-section illustration of an alternative embodiment of a pad for installing ceramic pads; 
           [0012]      FIG. 2B  illustrates an alternative embodiment for the groove; 
           [0013]      FIG. 2C  illustrates yet another alternative embodiment of the invention for glue down installation; 
           [0014]      FIG. 2D  illustrates yet another alternative embodiment of the invention with a wood veneer; 
           [0015]      FIG. 3  illustrates a cross-section view of an alternative embodiment with a double layer pad; 
           [0016]      FIG. 4  is a cross-section view of an alternative embodiment of a double layer pad with ceramic tiles; 
           [0017]      FIG. 5  is an illustration of a double layer pad of  FIG. 4 ; 
           [0018]      FIG. 6  illustrates an alternative embodiment of the present invention; 
           [0019]      FIG. 7  is a top view of a floor installed with ceramic tiles and wooden boards; 
           [0020]      FIG. 8  illustrates an embodiment for wall installation; 
           [0021]      FIG. 9  illustrates an installation method of the present invention for hardwood floor boards with tongue and groove; 
           [0022]      FIG. 10  illustrates two hardwood floor boards after installation; 
           [0023]      FIG. 11  illustrates an alternative way to install the hardwood floor boards; 
           [0024]      FIG. 12  illustrates an easy way to engage two adjacent floor boards; and 
           [0025]      FIG. 13  is a flowchart of a method for installing ceramic floor according to the invention 
           [0026]      FIG. 14  illustrates an alternative embodiment of the present ion; 
           [0027]      FIGS. 15 and 16  illustrate yet another alternative embodiment of the present invention; 
           [0028]      FIGS. 17-19  illustrate alternative methods of installation. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0029]    The present invention provides a method for installing padded floor tiles and/or floor boards. The method eliminates use of cements to affix tiles and user of grout for filling gaps between the tiles. The installed floor offers soft sensation to users who walk on this floor and also reduces noises generally associated with the ceramic or wood floors. The installed ceramic floor also offers some flexibility, thus preventing cracks that often are associated with ceramic/stone tiles. The ceramic/stone tiles the present invention are pre-assembled on a soft and flexible pad with use of restickable glue and this pad serves as a cushion that provides soft feeling for people who walk on it. The flexible pad also eliminates the need for preparation of the underlayment or subfloor, which means that the ceramic tiles can be installed on top of the subfloor that is not perfectly leveled. Because of the pre-installed flexible pad comes with a layer of restickable glue, there is no need for application of additional glue during the installation time; consequently, the installation process can be made easy and fast. The flexible pad also prevents spilled liquid to reach the underlayment and subfloor easily and thus preventing damage to the underlayment or subfloor. The subfloor in the context of this application can be wood surface or a cement slab. The restickable glue is not liquid glue; it is a high viscosity polymer based glue. One example of restickable glue is EVA (ethylene vinyl acetate) class of glue. 
         [0030]      FIG. 1  is a cross section view  100  of a padded ceramic tiles  102  installed on a floor  110 . The pad  104  is affixed onto the floor  110  and the ceramic tiles  102  are first secured to the pad  104  through a layer of restickable glue  112  and then firmly attached with a band adhesive/grout  106 . The band of the adhesive/grout  106  is laid on the top of the pad  104  and the edge of a ceramic tile  102  is placed on the top of the adhesive/grout  106 . The adhesive/grout  106  can be epoxy grout, urethane grout, urethane glue, liquid nail, for stone and tile, or other type of glue that can be used with stone or tile. The width of the band is preferably 1 cm-3 cm. 
         [0031]    The ceramic tiles  102  are preferably gauged tiles, gauged marble, or granite tiles, i.e., their edges have been through the grinding process, thus having a perfect sizing and no grout line is needed. The gauged tiles can be aligned easily and have a better presentation; however, they are not necessary. In the case of non gauged tiles are used, then flexible grout, such as urethane grout or epoxy grout, is recommended. The flexible grout will mask out the imperfections on the tile edges. 
         [0032]    The adhesive  106  plays several functions in the installation of ceramic tiles. The adhesive  106  glues two adjacent ceramic tiles  102  together and also glues the ceramic tiles to the pad  104 . The adhesive  106  provides certain flexibility to the ceramic tiles  102 , such that the ceramic tiles  102  are flexible in relation to the pad  104 . The adhesive  106  also provides mechanical support for the ceramic tiles  102 , so that the ceramic tiles  102  act like one single piece once installed on the pad  104 . The adhesive  106  also serves the role of grout and seals the “grout” line, so that no water will leak between the ceramic tiles  102 . In the case of the tiles are joined by epoxy grout, the epoxy grout will serve as mortar, grout, and grout sealer. The adhesive  106  can also be polymer modified grout, which is a grout (sanded or unsanded) mixed with some glue and additive such as PVA. 
         [0033]    The pad  104  plays several functions in the installation of ceramic tiles. The pad  104  being soft and flexible enables greater gripping force between the pad  104  and the ceramic tiles  102 . The pad  104  also serves as cushion that absorbs shock and other impact forces, thus reducing the breakage of ceramic tiles  102 . Because of the cushion effect, when a user walks on the installed ceramic tiles, the user feels the softness generally associated with expensive tapestry. The pad  104  serves also as a moisture barrier, preventing the water from reaching the sub-floor. The pad  104  is also a good insulator of coldness and helps to keep the floor warm. The restickable glue  112  helps to hold the tiles  102  during the installation and also helps to prevent water spreading. The pad  104  is stretchable, the pad also serve as membrane that prevents tiles from cracking when the subfloor moves. The pad  104  can be made from EVA foam, non woven cloth, urethane foam, rubber pad, PE foam, PVC tiles, foam, plastic films/membranes, wood veneer, laminate veneer, carpet, etc. The weakness of softness of the pad  104  is overcome by the flexibility of adhesive/epoxy grout. The tiles do not have to be installed on the hard board, where stress often cracks, and the installation procedure is complicated and cost is high. The concept of the tile installed on a soft pad eliminates the stress, and allows the soft pad to absorb stress and impact. 
         [0034]    As shown in  FIG. 1 , a band  108  of the adhesive is spread on the top of the pad  104 , and a tile  102  is placed on the top of this band  108  of adhesive. As two adjacent tiles are placed, the adhesive is squeezed to fill the gap between the ceramic tiles  102 . The adhesive also is also pushed down onto the pad  104 , forming a little depression as shown in adhesive  106 . The pad  104  with tiles  102  are placed on the top of the subfloor  110 . The pad  104  is preferably not firmly attached to the subfloor  110  and the pad  104  “floats” over the subfloor  110 . The floating pad  104  reduces the possibility of tiles  102  cracking because of different expansion rate between the subfloor  110  and the ceramic tiles  102 . The pad  104  can be also attached firmly to the subfloor as well. The attachment can be done by glue, adhesive, restickable glue, staple, etc. 
         [0035]      FIG. 2A  is a cross-section illustration  200  of an alternative embodiment of a pad  204  for installing ceramic pads  102 . The pad  204  has multiple longitudinal grooves  206  that run along its width. The groove  206  can be made by heat pressing down the pad  204  or adding an additional layer (not shown) on top of the pad  204 . A band of the adhesive  208  is deposited onto the groove  206 . As tiles  102  are placed on the top of the pad  204 , the adhesive  208  is squeezed between the ceramic tiles  102 , and a film  210  of adhesive  208  fills up the gap between the ceramic tiles  102 . The groove  206  enables formation of a strip  202 , which provides a thick and firm link between the ceramic tiles  102 . The strip  202  of inverted T shape fills the joint between the two ceramic tiles  102  and the pad  204 . The strip  202  serves support for connecting the ceramic tiles  102  and the pad  204  together. This connection reduces the vertical movement and forces between two adjacent tiles as one tile is being stepped on and another tile is not. This also reduces the potential disconnection/cracking between the two adjacent tiles. In case of grout is used between tiles, this inverted T connection will stabilize the grout line. The strip  202  also provides certain flexibility to the floor formed by the ceramic tiles  102  and the pad  204 . When the pad  204  with the ceramic tiles  102  is placed on a subfloor  110 , the pad  204  serves as a cushion providing sensation of softness to a user walking on the top of the finished floor. 
         [0036]      FIG. 2B  illustrates an alternative embodiment  220  for the groove. The groove  226  can have different shapes: such as rectangle, oval, triangle, or stair shapes.  FIG. 2B  also shows ceramic tiles  102  placed over double pads  224 ,  230 . The pad  230  can be one layer of plastic film, enforced fiber cloth, or non weave cloth.  FIG. 2C  illustrates yet another alternative embodiment  250  for the invention. In the embodiment  250 , the tile floor is not floating, but glued down. The pad  252  is a net that allows the glue to penetrate onto the subfloor  110  and the tiles are glued down onto the subfloor  110 . This embodiment is suitable for shower usage. This embodiment is also useful for wall tile installation since the net can be stapled onto the plywood before grout application. This eliminates the need for cement board because the tiles are sealed with glue and epoxy grout.  FIG. 2D  illustrates another alternative embodiment  280  where the groove can be further strengthened with a wood veneer, a plastic sheet, or a laminate sheet. The wood veneer  282  is strong mechanically and can be glued down. on stone or tile. The wood veneer  282  is installed in a perpendicular direction relative to the tiles  102 . This improved the structure may further stabilize the grout or two pieces of tile after installation. Though the pad is a soft cushion, but at joint, it could be stabilized as a solid substrate. 
         [0037]      FIG. 3  illustrates a cross-section view of an alternative embodiment  300  with a double layer pad  302 . The pad  302  has two layers  308 ,  310  of sub-pads. Two layers of sub-pads  308  and  310  are offset of each other. The ceramic tiles  102  are attached to first sub-pad  310  of the pad  302  through adhesive  306 . There is an over-hang portion  312  of the first sub-pad  310  that extends beyond the second sub-pad  308  and there is a trailing portion  314  of the second sub-pad  308  that extends beyond the first sub-pad  310 . When two double layer pads  302  are placed adjacent to each other, the over-hang portion  312  of one pad  302  is placed on the top of the trailing portion  314  of another pad  302 . The adhesive can be used to glue two adjacent pads  302  together. Because the sizes of the tiles are often slight different from their standard size, with this double layer, the portion of the pad over hangs can be adjusted to allow the groove distance between two adjacent tiles. 
         [0038]      FIG. 4  is a cross-section view of an alternative embodiment  400  of a double layer pad  402  with ceramic tiles  304 . In this embodiment, adhesive  404  is placed on a semi-circular groove.  FIG. 5  is an illustration  500  of a double layer pad of  FIG. 4 . The double layer pad is formed by a lower layer  504  and a top layer  506  and a plurality of semi-circular grooves  502  are distributed on the top layer  506 . The grooves  502  may have other shapes. The top layer  506  is shifted from the lower layer  504  and the top layer  506  is partially over hang from the lower portion  504 . 
         [0039]      FIG. 6  illustrates an alternative embodiment  600  of the present invention. In this embodiment  600 , ceramic tiles  606  interlaced with wooden boards  604  are placed on a pad  602 . The ceramic tiles  606  and wooden board  604  may have similar dimensions and are attached onto the pad  603  through adhesive as described above. The ceramic tiles  606  may have different dimensions from the wooden board  604  as shown in  FIG. 7 . 
         [0040]      FIG. 7  is a top view of a floor  700  installed with ceramic tiles  704  and wooden boards  702 . In the floor  700 , the ceramic tiles  704  are placed on a pad and separated from each other by wooden edges  702 . In the traditional tile installation, this mix of wood board and ceramic tile is not easy to handle because wood board is not able to be attached with mortar or grout. The water in mortar will warp the wood and it will not firmly bond the wood boards. With this method, tile and wood board can be easily installed on the same pad with same adhesive or epoxy grout. For floor board  700  shown in  FIG. 7  and embodiment  600  shown in  FIG. 6 , other non-wooden boards such as porcelain tiles and stone tiles may also be used. 
         [0041]    The present invention may also be applicable for wall installation as shown in  FIG. 8 .  FIG. 8  illustrates an embodiment  800  for wall installation. The ceramic tiles  804  are attached onto a pad  802 . Both sides of the pad  802  are covered with restickable glue  808  that helps to secure the pad  802  on the wall and also helps to secure the ceramic tiles  804  in place while adhesive  806  that glues two adjacent ceramic tiles  804  together cures. The pad  802  can be secured onto the wall by glue, screws, staples, nails, or other attaching means. The pad is mounted on a mesh net where the net allows the restickable glue to directly glue the pad onto the wall. The restickable glue also temporary holds the tile at a wall position, while the glue on the groove after cure will hold the tile permanently. 
         [0042]    The present invention can also be applied to installation of hardwood floor boards. Normally, hardwood floor boards are glued or nailed onto a subfloor and more recently they can also be installed “floating” with mechanical locks. However, these installation methods are less than desired for the following reasons. The glued down floor made from engineered wood boards often experience delamination because of different expansion rate of materials and the floating floor is prone to water leakage. 
         [0043]    The present invention provides an easy way for installing floor boards. Generally, a first row of floor boards is placed and pressed onto a pad with a pressure sensitive glue. Pressure sensitive glue/adhesive adheres to most surfaces with very slight pressure. They are available in solvent and latex or water-based forms. They adhere with just finger or hand pressure and do not require activation by water, solvent or heat. The pressure sensitive glue will not take effect until a pressure is applied. The second row of the floor board will be slid into their position. The floor board will not stick to the pad because the pressure is not applied yet. After the second row of floor boards is well positioned, installer can simply step on the second raw floor boards, which will glue to pad firmly. The glue on the pad is pre-manufactured glue, which can be used directly to hold the floor board securely. Floor boards can be hardwood, laminate, bamboo, vinyl, or engineered material. The floor board bottom can be coated, treated, or covered a layer of material, such as laminate floor boards and plastic films, that have strong bonding with restickable glue. The floating hardwood floor installation for pressure sensitive pad:
       1: The floor board is pressed down (stepped on) onto a pressure sensitive glue covered pad. The pad is not glued unless the press is applied.   2. Slide next row of the floor boards. The glue does not stick to the boards because the pressure is not applied yet. The board can be hand press/slide in, or hammered into the position.   3. Press down (step on) the newly installed the boards onto the glue such that the pad firmly grip the new boards.
 
The floating hardwood floor installation for laminate floor:
   1. The laminate board is pressed down (stepped on) to a pressure sensitive glue covered pad. The pad is not glued until the pressure is applied.   2. Laminate flip down, and slide next row the floor boards. The glue does not stick to the boards because the pressure is not applied yet. The boards can be hand press/slide in, or hammered into the position.   3. Press down (step on) the newly installed the board to all the glue pad firmly grip the new board.       
 
         [0050]      FIG. 14  is an illustration  1400  of the floor boards installed according to the above process. Each floor board  1404 ,  1406  is equipped with a pressure sensitive glue covered pad  1402 ; one floor board can be slid next to another floor board. The system can further be improved with glue to bond the floor boards. The glue applied could be a permanent glue, which better enforcement for the floor system. The glue can glue two boards, it can also be used to glue them to the pad. For wood floor, White Glue (PVA), Yellow Glue, most wood glue can be applied for this case. Liquid nail, polyurethane glue can also be used for this case as well. Most of glues are easy to cleaned with water or wet mop/sponge if the glue surfaced to surface of the wood floor. The floor boards are firmly held by the restickable glue, the board will not move or shift as the applied glue cures. 
         [0051]      FIGS. 15 and 16  illustrate another floor board installed according to the present invention. Hardwood floating installation method based on pressure sensitive pad:
       1. The floor board  1502  is laid down on a pressure sensitive glue pad  1506 . The pad does not stick until the pressure is applied.   2. The wood glue is applied to groove the floor board, some excessive glue  1508  may be applied to allow the wood board to glue to the pad.       
 
         [0054]    3. Slide next row  1504  the floor board. The glue does not stick to this board because the pressure is not applied yet. The board can be hand press/slide in, or hammered into the position. No gap is left between the boards.
       4. Press down (step on) the newly installed the board to allow the glue pad firmly grip the new board.       
 
         [0056]      FIG. 17  illustrates an alternative embodiment with a net  1706  for the pad, which allows the floor to glue onto the subfloor. The pad still uses the pressure sensitive glue. Directly glue down method can also be used as shown in  FIGS. 18 and 19 . The pad is attached to floor boards, which are smaller than the floor board. The glue can applied at the joint area; the glue will glue floor boards together and, at the same time, glue them to the subfloor. The floor pad also holds the floor in the position. The floor pad also uses a pressure sensitive glue and allow the 2 nd  raw floor slide to position then press down to secure the position. The glue can also be temperature sensitive glue; temperature sensitive glue will become adhesive when it is heated up to a certain temperature. 
         [0057]    The installation method of the present invention can be used with hardwood floor boards with tongue and groove features as shown in  FIG. 9 . A pad  902  covered with a layer of restickable glue is placed on a floor, a first floor board  904  with a tongue  912  and a groove  914  are placed on the top of the pad  902 . The restickable glue holds the floor board  904  in place while an adjacent floor board  904  is placed. An adhesive  906  is placed on the tongue  912  of the first floor board  904  before the groove  914  of the second floor board  904  is slid onto the tongue  912  of the first floor board  904 . The adhesive  906  is compressed between the two floor boards and glues them together preventing liquid from penetrating between the two floor boards as shown in  FIG. 10 . Because the pad  902  is flexible, the pad  902  expands and contracts with the floor boards  904 . 
         [0058]      FIG. 13  is a flowchart  1300  of a method for installing a floor covering according to the invention. The installation is made easy by dividing the installation into two stages. The pad is covered with a layer of restickable glue and a band of adhesive is spread on the top of the pad, step  1302 . After the band of adhesive is placed, a ceramic tile is laid on the pad with an edge of the ceramic tile on the top of the band of adhesive, step  1304 . Preferably the edge of the ceramic the does not occupy more than half of the width of the band of the adhesive. A second ceramic tile is placed adjacent to the first ceramic tile. The edge of the second ceramic tile is also placed on the top of the band of adhesive and the second ceramic the is pressed against the first ceramic tile, step  1306 . The compression between two ceramic tiles forces the band of adhesive to fill up the gap between two ceramic tiles with part of the band of adhesive attached to the underside of two ceramic tiles and to the pad. The placement of ceramic tiles is repeated until the pad is filled with ceramic tiles. With multiple pads assembled with ceramic tiles, an installer can then place the pads on the floor, step  1308 . The pads are placed adjacent to each other, thus covering the floor. The resulting floor is covered with “floating” ceramic tiles. If the pad is a double layer pad as described above, during the installation of the pads, the over-hang of a pad is placed on the top of the trailing portion of another pad. Though the above installation process is described based on ceramic tiles, the process is equally applicable for installing other flooring elements such hardwood floor boards described above. 
         [0059]    The terms and expressions which have been employed herein are used as terms of description and not of limitation, and there is no intention, in the use of such terms and expressions, of excluding any equivalents of the features shown and described (or portions thereof), and it is recognized that various modifications are possible within the scope of the claims. Other modifications, variations, and alternatives are also possible. Accordingly, the claims are intended to cover all such equivalents. Dimensions in the drawings here presented are not to the scale unless otherwise indicated. It is intended that different features shown in different figures in this specification may be combined interchangeably.