Patent Description:
Flooring panels are used to form a floor over a support surface, such as a sub-floor. Such panels are made from a variety of materials (e.g., vinyl, wood, etc.). Various methods have been used for attaching flooring panels to support surfaces.

The present invention provides a flooring panel as defined in claim <NUM>.

A flooring panel according to the present invention includes an upper floor layer having an upper side and a lower side. The flooring panel also includes an adhesive layer comprising an elastic layer having an upper first side, which is attached to the lower side of the upper floor layer, and a lower second side, which is located opposite the upper side of the elastic layer and which defines a lower surface of the elastic layer. The elastic layer is made from a foam material and includes a plurality of open holes formed in the lower side of the elastic layer. The open holes are sized and shaped for applying suction against a support surface when the flooring panel is applied thereto. A sealing material is applied to the entire urface of the lower side of the elastic layer for enhancing the suction applied by the holes to the support surface. At least some of the holes retain hollow spaces therein so as to apply the suction to the support surface. The sealing material does not completely fill the open holes so as to maintain the hollow spaces.

In one embodiment, the sealing material is configured to form a substantially air-tight seal around outer edges of the at least some of the holes when the flooring panel is applied against the support surface.

In one embodiment, the sealing material includes polyurethane.

In the drawing figures, which are not to scale, and where like reference numerals indicate like elements throughout the several views:.

Embodiments are now discussed in more detail referring to the drawings that accompany the present application. In the accompanying drawings, like and/or corresponding elements are referred to by like reference numbers.

Various embodiments are disclosed herein; however, it is to be understood that the disclosed embodiments are merely illustrative of the disclosure that can be embodied in various forms. In addition, each of the examples given in connection with the various embodiments is intended to be illustrative, and not restrictive. Further, the figures are not necessarily to scale, and some features may be exaggerated to show details of particular components (and any size, material and similar details shown in the figures are intended to be illustrative and not restrictive). Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the disclosed embodiments.

Subject matter will now be described more fully hereinafter with reference to the accompanying drawings, which form a part hereof, and which show, by way of illustration, specific example embodiments. Subject matter may, however, be embodied in a variety of different forms and, therefore, covered or claimed subject matter is intended to be construed as not being limited to any example embodiments set forth herein; exemplary embodiments are provided merely to be illustrative. Among other things, for example, subject matter may be embodied as methods, devices, components, or systems. The following detailed description is, therefore, not intended to be taken in a limiting sense.

Throughout the specification and/or claims, terms may have nuanced meanings suggested or implied in context beyond an explicitly stated meaning. Likewise, the phrase "in one embodiment" as used herein does not necessarily refer to the same embodiment and the phrases "in another embodiment" and "other embodiments" as used herein do not necessarily refer to a different embodiment. It is intended, for example, that covered or claimed subject matter include combinations of example embodiments in whole or in part.

For example, terms, such as "and", "or", or "and/or," as used herein may include a variety of meanings that may depend at least in part upon the context in which such terms are used. Typically, "or" if used to associate a list, such as A, B, or C, is intended to mean A, B, and C, here used in the inclusive sense, as well as A, B, or C, here used in the exclusive sense. In addition, the term "one or more" as used herein, depending at least in part upon context, may be used to describe any feature, structure, or characteristic in a singular sense or may be used to describe combinations of features, structures or characteristics in a plural sense.

<FIG> illustrate an adhesive or suction sheet <NUM> which may be used for the present invention. The adhesive sheet <NUM> is adapted to be releasably attached to a support surface (e.g., any non-porous, substantially flat surface). The adhesive sheet <NUM> has a bonding side <NUM> adapted to be attached to the flooring panel, so that it can be releasably attached to the support surface via the adhesive sheet <NUM>. An adhesive side <NUM> of the adhesive sheet <NUM>, which is located opposite the bonding side <NUM>, is adapted to be removably attached to the support surface. In one embodiment which does not form part of the claimed invention, the adhesive sheet <NUM> may be used as a stand-alone product. That is, the adhesive sheet <NUM> may be applied to the support surface by itself such that the item may be subsequently attached to the adhesive sheet <NUM>, as will be discussed in greater detail below. According to the present inveniton, an upper floor layer of a flooring panel is pre-laminated to the bonding side <NUM> of the adhesive sheet <NUM> and then applied to the support surface as a single unit. The construction and use of the adhesive sheet <NUM> are discussed in greater detail below. The adhesive sheet <NUM> includes an elastic and/or flexible layer <NUM> having a plurality of holes <NUM> (see <FIG>) provided throughout the elastic layer <NUM>. In one embodiment, the elastic layer <NUM> is made from a foam material composed of ethylene vinyl acetate (EVA), which is a copolymer of ethylene and vinyl acetate. In other embodiments, the foam can be made from any suitable elastic material, such as rubber, plastic, urethane, polyurethane (PU), polyethylene (PE), polystyrene, vinyl, silicone, latex rubber, etc., or mixtures thereof.

In one embodiment, the elastic layer <NUM> may be formed from a mixture of EVA (e.g., in about <NUM>%-<NUM>% by weight), PE (e.g., in about <NUM>%-<NUM>% by weight) and/or PU (e.g., in about <NUM>%-<NUM>% by weight). This mixture may optionally include other components, such as a filler (e.g., calcium carbonate and/or talcum powder) in about <NUM>%-<NUM>% by weight, a foaming agent (e.g., azodicarbonamide), a crosslinking agent (e.g., dicumyl peroxide), a foaming promoter (e.g., zinc oxide) and/or a lubricating agent (e.g., stearic acid). In one embodiment, the mixture is chemically blended by heat and pressure in a mixer using at a suitable temperature and pressure to create a paste-like substrate. The paste-like substrate is then fed through an extruder and conveyor to form a substantially flat sheet of the blended material. Thereafter, the flat sheet is subjected to a foaming process by feeding same into a mold foaming vulcanizing machine at a suitable temperature and pressure. The flat sheet undergoes a vulcanization process to form a foamed sheet with a desired density, thickness, etc..

In one embodiment, the elastic layer <NUM> of the present invention provides a rubber foam-like in softness and flexibility. The material has low-temperature toughness, stress-crack resistance, waterproof properties, resistance to UV radiation, foam recovery from compression.

According to the invention, the holes (<NUM>) are distributed throughout the entire elastic layer <NUM>. The holes <NUM> can be distributed randomly or uniformly in the elastic layer <NUM>. According to the invention, the holes <NUM> positioned in the interior of the adhesive sheet <NUM> (see, e.g., the holes labeled as "18a" in <FIG>) are formed as closed cells such that air or other gas is encapsulated or trapped in the holes 18a. On the other hand, the holes positioned on the surfaces of the Bonding and adhesive sides <NUM>, <NUM> of the elastic layer <NUM> (see, e.g., the holes labeled as "18b" in <FIG>) are open to the exterior of the elastic layer <NUM>. According to the invention, the holes 18b positioned on the adhesive side <NUM> of the elastic layer <NUM> each have a concave shape extending inwardly into the elastic layer <NUM> and are treated as discussed below such that they can provide and maintain suction against the support surface for releasably attaching the adhesive sheet <NUM> to same. In one embodiment, the holes 18b are spread substantially throughout the entire surface of the adhesive side <NUM> of the elastic layer <NUM>.

In one embodiment, the holes <NUM> have random sizes. In one embodiment, at least some or substantially all of the holes <NUM> have a diameter greater than approximately <NUM>. In another embodiment, at least some or substantially all of the holes <NUM> have a diameter greater than approximately <NUM>. In another embodiment, at least some or substantially all of the holes <NUM> have a diameter greater than approximately <NUM>. In another embodiment, at least some or substantially all of the holes <NUM> have a diameter greater than approximately <NUM>. In another embodiment, at least some or substantially all of the holes <NUM> have a diameter greater than approximately <NUM>. In another embodiment, at least some or substantially all of the holes <NUM> have a diameter greater than approximately <NUM>. In another embodiment, at least some or substantially all of the holes <NUM> have a diameter greater than approximately <NUM>. In another embodiment, at least some or substantially all of the holes <NUM> have a diameter greater than approximately <NUM>. In another embodiment, at least some or substantially all of the holes <NUM> have a diameter greater than approximately <NUM>. In another embodiment, at least some or substantially all of the holes <NUM> have a diameter greater than approximately <NUM>.

In one embodiment, at least some or substantially all of the holes <NUM> have a diameter less than approximately <NUM>. In another embodiment, at least some or substantially all of the holes <NUM> have a diameter less than approximately <NUM>. In another embodiment, at least some or substantially all of the holes <NUM> have a diameter less than approximately <NUM>. In another embodiment, at least some or substantially all of the holes <NUM> have a diameter less than approximately <NUM>. In another embodiment, at least some or substantially all of the holes <NUM> have a diameter less than approximately <NUM>. In another embodiment, at least some or substantially all of the holes <NUM> have a diameter less than approximately <NUM>. In another embodiment, at least some or substantially all of the holes <NUM> have a diameter less than approximately <NUM>. In another embodiment, at least some or substantially all of the holes <NUM> have a diameter less than approximately <NUM>. In another embodiment, at least some or substantially all of the holes <NUM> have a diameter less than approximately <NUM>. In another embodiment, at least some or substantially all of the holes <NUM> have a diameter less than approximately <NUM>.

In one embodiment, at least some or substantially all of the holes <NUM> have a diameter ranging from approximately <NUM> to approximately <NUM>. In another embodiment, at least some or substantially all of the holes <NUM> have a diameter ranging from approximately <NUM> to approximately <NUM>. In another embodiment, at least some or substantially all of the holes <NUM> have a diameter ranging from approximately <NUM> to approximately <NUM>. In another embodiment, at least some or substantially all of the holes <NUM> have a diameter ranging from approximately <NUM> to approximately <NUM>. In another embodiment, at least some or substantially all of the holes <NUM> have a diameter ranging from approximately <NUM> to approximately <NUM>. In another embodiment, at least some or substantially all of the holes <NUM> have a diameter ranging from approximately <NUM> to approximately <NUM>. In another embodiment, at least some or substantially all of the holes <NUM> have a diameter ranging from approximately <NUM> to approximately <NUM>. In another embodiment, at least some or substantially all of the holes <NUM> have a diameter ranging from approximately <NUM> to approximately <NUM>. In another embodiment, at least some or substantially all of the holes <NUM> have a diameter ranging from approximately <NUM> to approximately <NUM>. In another embodiment, at least some or substantially all of the holes <NUM> have a diameter ranging from approximately <NUM> to approximately <NUM>.

The elastic layer <NUM> can have a varying density, depending an various factors and variables, such as the number and size of the holes <NUM>. In one embodiment, the density of the elastic layer <NUM> ranges from about <NUM>/m<NUM> to about <NUM>/m<NUM>. In other embodiments, the density of the elastic layer <NUM> can be less than about <NUM>/m<NUM> or greater than about <NUM>/m<NUM>.

The elastic layer <NUM> can also have a thickness that can vary depending on various factors, such as types of item for attachment to the adhesive sheet <NUM>. In one embodiment, the elastic layer <NUM> ranges in thickness from about <NUM> to about <NUM>. In other embodiments, the thickness of the elastic layer <NUM> can be greater than about <NUM> or smaller than about <NUM>. In another embodiment, the thickness of the elastic layer <NUM> is greater than the largest diameter or radius of the holes <NUM> so as to ensure that the interior surfaces of the holes 18b provided on the adhesive side <NUM> of the elastic layer <NUM> are completely closed or sealed.

A coating of sealing material <NUM> is applied to the outer surface of the elastic layer <NUM> on the adhesive side <NUM> of the adhesive sheet <NUM>. The sealing material can be any suitable sealing material capable of providing a substantially air-tight seal to the interior surfaces of the holes 18b and/or around edges or lips <NUM> (see <FIG>) surrounding the holes 18b. In this manner, the holes 18b are adapted to function as micro-suction holes for releasably attaching the adhesive sheet <NUM> to a non-porous, substantially flat surface. In one embodiment, the sealing material includes polyurethane ("PU").

In one embodiment, the adhesive sheet <NUM> also includes a primer coating <NUM> applied to the outer surface of the elastic layer <NUM> on the bonding side <NUM> of the adhesive sheet <NUM>. More particularly, the primer coating <NUM> can be any suitable material known to persons of ordinary skill in the art. A layer of bonding material <NUM> is also applied to the primer coating <NUM>. The Bond layer <NUM> can be any suitable material known to persons of ordinary skill in the art for securely or fixedly bonding the adhesive sheet <NUM> to another item. Optionally, protective films <NUM>, <NUM> (e.g., peel-off paper liners) are applied over the bonding layer <NUM> and the sealing coating <NUM>, respectively, to protect same during storage and/or transportation.

In the following, a method is provided for making the adhesive sheet <NUM>. The adhesive sheet <NUM> is made from a foam <NUM> (see <FIG>), such as an EVA foam, which is made in a manner known in the art. In one embodiment, the foam <NUM> may be purchased from a foam manufacturer, such as Foamtech LTD, located Shanghai City, China. The foam <NUM> is then cut into a plurality of sheets <NUM> in desired thicknesses, as indicated by dotted-line representation in <FIG>. The sheets <NUM> are then attached (e.g., glued) to each other in an end-to-end fashion so as to create a substantially continuous foam sheet rolled into a roll for easy storage and/or transportation. At this stage, the sheet <NUM> has a construction similar or corresponding to that of the elastic layer <NUM> shown in <FIG>. That is, the sheet <NUM> has a plurality of open holes 18b formed an each outer side or surface thereof (see <FIG>). The sealing layer <NUM>, the primer coating <NUM> and the bonding layer <NUM> are applied to the sheet <NUM> in the following manner.

With reference to <FIG>, the rolled foam sheet <NUM> is fed to a first roller applicator <NUM>, which applies a primer coating <NUM> to one side of the sheet <NUM>. The sheet <NUM> then passes through a first oven <NUM> so as to cure the primer coating <NUM> at a suitable temperature (e.g., at <NUM>). Thereafter, the sheet <NUM> is fed to a second roller applicator <NUM>, which applies a bonding agent over the cured primer coating <NUM>, and then passes through a second oven <NUM> to cure the bonding agent to form a bonding layer <NUM> over the primer coating <NUM>. A third roller applicator <NUM> applies a coating <NUM> of sealing material (e.g., PU) to the opposite side of the sheet <NUM> (see also <FIG>), while a third oven <NUM> cures the sealing coating <NUM> at a suitable temperature (e.g., at <NUM> - <NUM>). Thereafter, protective films <NUM>, <NUM> are sequentially applied to the bonding layer <NUM> and the sealing coating <NUM>, respectively, via one or more applicators <NUM>. The processed sheet <NUM> is then formed into a roll for storage, transportation and/or further processing.

In one embodiment, which does not form part of the claimed invention, the adhesive sheet <NUM> may be used for attaching one or more flooring or wall panels P (see <FIG>) to a support surface, such as a floor, a sub-floor or a wall (not shown in <FIG>). The adhesive layer <NUM> may be used as a stand-alone underlayment layer. With the protective film <NUM> removed, the bonding layer <NUM> is applied to the support surface (e.g., a sub-floor or a wall) so as to securely and fixedly attach the adhesive sheet <NUM> to the support surface. The protective film <NUM> is then removed from the adhesive sheet <NUM>, exposing the suction holes 18b in the adhesive side <NUM> of the adhesive layer <NUM>. The flooring panel P is then attached to the adhesive sheet <NUM> via the suction holes 18b to secure same to the support surface. Sufficient pressure (as indicated by the arrow in <FIG>) is applied manually and/or with the use of a tool over the flooring/wall panel P, at least partially compressing the holes 18b. When the applied pressure is released, the holes 18b return to their original shapes (see <FIG>), creating negative pressure or partial vacuum therewithin and releasably attaching the flooring/wall panel P to the adhesive sheet <NUM> and hence the support surface. The negative pressure is maintained within the holes 18b by the sealing layer <NUM>, which creates a substantially air-tight seal between the holes 18b and the bottom surface of the flooring/wall panel P. The flooring/wall panel P may be detached from the adhesive sheet <NUM> and hence the support surface by peeling same away from the adhesive sheet <NUM> and releasing the negative pressure created by the suction holes 18b. Once the flooring/wall panel P is removed, another flooring/wall panel of a different design, pattern and/or type may be installed an the adhesive layer <NUM>. Multiple adhesive layers <NUM> may be installed as an underlayment layer so as to allow a user to easily and readily change the look and/or feel of his/her floor.

In one embodiment, the flooring/wall panel P may be any flooring or wall panel having a substantially non-porous bottom, such as luxury vinyl tiles ("LVT"), carpet tiles, hard wood or engineered wood panels, laminates, rubber tiles, vinyl composition tiles, decorative wall panels, wood plastic composites, rigid vinyl, sheet vinyl, multilayer flooring, stones/tiles, carpet rolls, non-polyvinyl chloride (PVC) tiles and planks, etc. In other embodiments, any item, such as other construction or decorative products, may be used in conjunction with the adhesive sheet <NUM> for removably attaching same to a suitable support surface.

According to the present invention, the adhesive sheet <NUM> is pre-laminated to a prefabricated flooring plate <NUM> to form a composite flooring panel <NUM> adapted to be releasably attached to a non-porous sub-floor or over an existing floor (see <FIG>, in which only certain components of the adhesive sheet <NUM> are shown). The flooring plate <NUM> has a construction similar to that of a conventional flooring panel. If a conventional LVT is used for constructing the flooring panel <NUM>, the flooring plate <NUM> may be provided with a top polyurethane layer <NUM>, a wear layer <NUM> below the polyurethane layer <NUM>, a pattern layer <NUM> below the wear layer <NUM>, a stabilization layer <NUM> below the pattern layer <NUM>, and a load bearing layer <NUM> below the stabilization layer <NUM>. As will be readily apparent to a person skilled in the art, one or more layers <NUM>, <NUM>, <NUM>, <NUM>, <NUM> may be eliminated, or one or more additional layers may be added.

The flooring plate <NUM> is pre-laminated to the bonding layer <NUM> of the adhesive sheet <NUM>. Accordingly, the protective film <NUM> is not present in the flooring panel <NUM>. In one embodiment, the protective film <NUM> is present in the flooring panel <NUM>, to safeguard the adhesive side <NUM> of the adhesive sheet <NUM>.

Claim 1:
A flooring panel (P, <NUM>) comprising
- an upper floor layer (<NUM>) having an upper side and a lower side; and
- an adhesive layer (<NUM>) comprising
- an elastic layer (<NUM>) having a first side (<NUM>), and a second side (<NUM>), which is located opposite said first side (<NUM>) of said elastic layer (<NUM>) and which defines a surface of said elastic layer (<NUM>),
said elastic layer (<NUM>) being made from a foam material and including a plurality of holes (<NUM>) distributed throughout said elastic layer (<NUM>), wherein said holes (<NUM>) positioned in the interior of said elastic layer (<NUM>) are formed as closed cells (18a) and open holes (18b) are formed in said surface of said elastic layer (<NUM>), said open holes (18b) being sized and shaped for applying suction against a support surface when said adhesive layer (<NUM>) is applied thereto;
characterized by
- a sealing material (<NUM>) applied to the entire surface of said second side (<NUM>) of said elastic layer (<NUM>) for enhancing the suction applied by said open holes (18b) to the support surface; and
- a bonding layer (<NUM>) applied to said first side (<NUM>) of said elastic layer, wherein said open holes (18b) each have a concave shape extending inwardly into said elastic layer (<NUM>) and are treated with said sealing material (<NUM>),
wherein said sealing material (<NUM>) does not completely fill said open holes (18b) so as to maintain hollow spaces, said first side (<NUM>) of said adhesive layer (<NUM>) being attached to said lower side of said upper floor layer (<NUM>).