JP2020530533A - Easy installation of ceramic or stone tile products - Google Patents

Abstract

Hard tile products and systems that are useful for covering floors, walls, and other surfaces, both that are easy to install and remove, are provided.

Description

Cross-reference to related applications This application claims the benefit of priority to US Patent Provisional Application No. 62/486674 filed April 18, 2017, the disclosure of which is hereby incorporated by reference in its entirety. Incorporated into the specification.

Ceramic tiles are one of the most widely installed flooring in the world. However, installing ceramic tiles is labor intensive and the installation cost per square foot is very high compared to vinyl or wood planks that can be installed using click techniques. ..

Various thermoplastic slabs, including cores, printed layers, and optionally overlays, are described, for example, in US Pat. Nos. 6,617,009, 6,986,934, 7,21,310, 310. It is disclosed in Nos. 7,419,717, 7,763,345, and 8,021,741. In these planks, the core is composed of at least one thermoplastic and the printing layer is preferably aminoplast resin impregnated printer paper. If desired, the edges of these thermoplastic slabs may have tongue and groove designs for attachment to each other within a floating floor system.

Various alternative configurations of plank mounting for plank flooring systems include, for example, US Pat. Nos. 7,770,350, 7,866,115, 8,099,919, and 8. , 875,465, and US Patent Applications 2003/0024199, 2004/0016196, and 2005/007860.

In addition, floor planks with cores modified to include sound absorbing or cork layers that provide sound insulation and insulation are disclosed in U.S. Pat. Nos. 8,234,829 and 8,171,691, respectively. There is.

A two-layer laminate of flexible plastic sheet material laminated together in an offset relationship so as to define offset edges layer by layer, U.S. Pat. No. 7,155. , 871.

Layered wood composites for flooring are disclosed in US Pat. Nos. 7,544,423 and 7,261,947.

In addition, floor coverings with protective aluminum oxide on the outermost surface are disclosed in US Patent Application Publication No. 2002/0025446, while a wear layer containing fibers, binders, and abrasion resistant particles. A building panel having a decorative surface with is disclosed in US Pat. No. 8,431,054.

Work waterproof plastic composite flooring and wall covering planks with veneer layers, extruded plastic composite cores, click-lock edge fastening systems, and optional base layers are disclosed in US Pat. No. 9,234,357. .. Various veneer layers are disclosed, including stone or tile veneer. However, such veneers are less than 3 mm thick according to industry standards. World Wide Web wikipedia. See the definition of veneer with the "en." Extension of org / wiki / wood veneer. Stone or tile veneers less than 3 mm thick can break easily and do not provide a robust flooring. Further, the adhesive layer that binds the veneer to the core is described as a water resistant hot melt adhesive and is applied at temperatures above 200 ° F. during the manufacture of the work floor material. Therefore, it is very difficult to remove this tile from the substrate if necessary. Moreover, even if the tile is removed, there is a high probability of damage to the tile or substrate, which prevents reuse.

In addition, commercially available polymer cores can easily dent and provide improper support for rigid ceramic tiles at the top. In addition, the polymer core has a coefficient of thermal expansion significantly higher than the coefficient of thermal expansion of the ceramic tile, which can lead to damage to the joints, cracks in the core, and buckling of the floor itself.

A modular tile assembly with a substantially rigid substrate, at least one sealant layer, and at least one stone, ceramic, or porcelain tile is disclosed in US Pat. No. 7,993,731. Sealant layers that bond stone, ceramic, or porcelain tiles to the following substrates are described as hot glue or polyurethane resin adhesives. Conventional adhesives such as one-component thermosetting urethane adhesives are described. The use of these adhesives makes it very difficult to remove the tile from the substrate. Moreover, even if the tile is removed, there is a high probability of damage to the tile or substrate, which prevents reuse.

A floating floor system that uses real porcelain tiles is SnapStone. The system uses real porcelain tiles that are permanently attached to the crafted tray, where the tabs are clicked together and the tabs are then snapped together to create a grout line. The system is described as being able to be installed on most existing hard surfaces without the need for a thin set of backer boards and mortar. However, the plastic frame is specific to the size of the tile, which increases the number of inventory management units in this system. In addition, the tolerances must be very tight, so the tiles must be adjusted. This limits product offerings and increases costs.

Therefore, there is a need for a cost-effective, easy-to-install hard tile product that allows each component being assembled to be easily removed, replaced, or reused as needed. This will allow homeowners to replace damaged tiles or refurbish their flooring with newly designed tiles.

The present disclosure relates to the easy installation of hard tile products that significantly reduce installation effort and time, and facilitate removal and replacement as needed, and thus create consumer value.

One aspect of the present disclosure is intended for work thick plates. This plank connects to a mineral or metal with a Mohs hardness scale of 4 or higher, a composite core with a Mohs hardness scale of less than 4, a mounting system that attaches hard tiles to the composite core, and adjacent work planks. Includes a connection system for, and hard tiles. In some non-limiting embodiments, the mounting system is a removable mounting system, so that hard tiles are not permanently mounted on the composite core. Non-limiting examples of hard tiles that can be used in these work planks include metal alloys such as ceramics, porcelain, natural stones, glass, metals, or steel. The present disclosure allows such rigid tiles to be easily assembled via composite cores, mounting systems, and connecting systems. In addition, embodiments with removable mounting systems allow easy removal without damaging hard tiles or composite cores.

In one non-limiting embodiment of the work planks of the present disclosure, the thickness of the hard tile is greater than 3 mm.

In one non-limiting embodiment of the work planks of the present disclosure, the mounting system for attaching hard tiles to the composite core comprises an adhesive. Non-limiting examples of adhesives include removable hot melt adhesives, pressure sensitive adhesives, moisture resistant adhesives, and combinations thereof.

In another non-limiting embodiment of the work planks of the present disclosure, the mounting system for attaching hard tiles to the composite core is magnetic.

In one non-limiting embodiment, the composite core of the machined plank has a core expansion coefficient in the range of 5 × ^10-6 to 30 × ^10-6 inches / inch / Fahrenheit.

In one non-limiting embodiment, the composite core of the workpiece is such that the long-term dent according to ASTM F970 is less than 0.005 inch and / or the short-term dent according to ASTM F1914 is less than 0.005 inch. Has dent resistance.

In one non-limiting embodiment, the composite core of the workpiece is high density polyethylene, polypropylene, polyethylene, low density polyethylene, polyamide, polyester, polyvinyl chloride, polylactic acid, or copolymers of these, recycled polymers, or Contains polymers selected from blends. In one non-limiting embodiment, the composite core may further comprise a filler and / or an additive.

In some non-limiting embodiments, the work planks may further comprise a second mounting system on a composite core to which the underlay layer can be adhered. In some non-limiting embodiments, the work slab may further comprise an underlay layer adhered to the composite core.

Another aspect of the present disclosure relates to a system for covering floors, walls, and other hard surfaces having these work planks. The system comprises two or more work planks connected adjacently via a connection system.

In one non-limiting embodiment, hard tiles are inserted from the edges of the composite core to provide a gap when connected to adjacent work planks. In this embodiment, when the gap is filled with grout, caulking, or sealant, it prevents any water on the hard tile from reaching the click joint, potentially penetrating the joint and the underlying floor. Can be prevented from reaching, and accordingly mold / white mold and odor problems are prevented.

In one non-limiting embodiment, the gaps between the hard tiles of the connected planks are grouted using, for example, acrylic, urethane, epoxy, or cementum grout. In one non-limiting embodiment, any gap between the hard tiles of the connected planks is filled with removable caulking or sealant, such as acrylic latex, silicone, or butyl rubber. In addition to preventing water penetration, this embodiment allows the caulking or sealant to be removed from the grout wire, allowing the planks to be moved and replaced as needed.

FIG. 5 is a photograph of a cross-sectional view showing the results of a short-term dent test in a commercial product having a composite core with a PVC print layer and a wear layer on top. Significant dents in the polymer core occurred within 15 minutes of load application. FIG. 5 is a photograph of a cross-sectional view showing the results of a short-term dent test in a commercial product having a composite core with a PVC print layer and a wear layer on top. Significant dents in the polymer core still occurred 5 days after the initial dents (shown in FIG. 1). In FIG. 2, the PVC layer at the top was restored, but the core was not. It is a photograph of a non-limiting embodiment of the present disclosure having a ceramic tile adhered to a thick vinyl plank. It is a photograph of a non-limiting embodiment of the present disclosure, two of the planks of FIG. 3 are connected together with a connection system of click joints of a composite core, thereby two plank assemblies. Is producing. It is a photograph of a non-limiting embodiment of the present disclosure, in which the two such assemblies of FIG. 4 are connected together with a click joint connection system to form four plank assemblies. As shown in FIG. 5, the space between the clicked joints can be filled with sealant / caulking. It is a photograph of a non-limiting embodiment of the present disclosure depicting a composite core having a magnetic mounting system for depositing hard tiles on the composite core. It is a photograph of a non-limiting embodiment of the present disclosure depicting a work slab of ceramic tile magnetically attached to a composite core.

This specification discloses a system of work planks and connected work planks for use as coatings on floors, walls, and other hard surfaces.

The work planks of the present disclosure include hard tiles having a Mohs hardness of 4.0 or higher. Such hard materials are not flexible enough to create a watertight seal when the joint is assembled during installation and therefore cannot be easily joined to, for example, tongue and groove type joints. Traditionally, such hard tiles, such as ceramic, porcelain, and natural stone tiles, are installed with grout, which is extremely laborious and costly to install.

In the work planks of the present disclosure, hard tiles with a Mohs hardness of 4.0 or higher are assembled on a composite core with a Mohs hardness of less than 4 and have a connection system that allows easy joining during installation. ..

The hard tiles used in the work planks of the present disclosure include minerals or metals having a Mohs hardness scale of 4 or higher. Non-limiting examples include metal alloys such as ceramics, porcelain, natural stones, glass, metals, and / or steel, with a Morse hardness of 4.5 for standard steel and 5.5 for glass. In the case of ceramic, the range is 7.0, and in the case of hardened steel, the range is 7.5 to 8.0. Hard tiles preferably have a thickness of 3 mm or more. In one non-limiting embodiment, hard tiles can range in thickness from 3 mm to 30 mm. In another embodiment, the hard tile can range in thickness from 3 mm to 25 mm. In yet another embodiment, the hard tiles can be in the thickness range of 3 mm to 15 mm, or 3 mm to 12 mm, or 3 mm to 10 mm, or 3 mm to 8 mm, or 3 mm to 6 mm. Non-limiting examples of such hard tiles are commercially available, both of which are Crossville Inc. (Crossville, TN) Crossville and Laminam tiles, Dal-tile (Dallas, TX), Crossville Inc. (Crossville, TN), and tiles made by Marazzi (Sunnyvale, TX) and the like are included.

In one non-limiting embodiment, the edges of the hard tile are sloped to create a grouted appearance.

In one non-limiting embodiment, hard tiles can be coated for easier cleaning. In one non-limiting embodiment, the hard tiles may contain, for example, additives to enhance antimicrobial effects.

In one non-limiting embodiment, hard tiles are inserted from the edges of the composite core to provide a gap when connected to adjacent work planks. In this embodiment, when the gap is filled with grout, caulking, or sealant, it prevents water on hard tiles from reaching the click joint, potentially penetrating the joint and reaching the underlying floor. Prevents mold / white mold and odor problems associated with it.

The work plank further comprises a composite core. The thickness of the composite core varies from about 2 mm to about 20 mm.

In one non-limiting embodiment, the composite core has a Mohs hardness rating of less than 4.0.

In one non-limiting embodiment, the composite core is a water resistant high density or medium density fiberboard.

In one non-limiting embodiment, the composite core comprises a polymer. Non-limiting examples of polymers useful for the composite cores of the present disclosure include high density polyethylene, polypropylene, polyethylene, low density polyethylene, polyamide, polyester, polyvinyl chloride (PVC), polylactic acid, or these. Any copolymer of, or recycled polymer, or blend of.

In one non-limiting embodiment, the composite core further comprises a filler. Non-limiting examples of useful fillers in composite cores are limestone, talc, calcium carbonate, wood dust, bamboo dust, cork, pearlite, fiberglass, polyamide fibers, cellulose fibers, wood fibers, polymer fibers, glass. , Sand, synthetic fiber, fly ash, flax fiber, hemp fiber, kaolin clay, mica, wollastonite (CaSiO3), carbon black, or any combination thereof.

The composite core can have densities in the range of 1.0 to 2.4 gm / cc, preferably 1.3 to 2.1 gm / cc.

In one non-limiting embodiment, the filler-to-polymer ratio of the composite core ranges from about 5:95 to about 95: 5 by weight.

In addition, the composite core may further contain additives. Non-limiting examples of additives that can be used are colorants, anti-UV agents, UV absorbers, flame retardants, antifungal agents, anti-microbial agents, coupling agents, reinforcing agents, interfacial adhesion promoters, stabilizers. , Antibacterial agents, lubricants, plasticizers, and recycled additives, and any combination thereof.

In the present disclosure, composite cores may have dent resistance such that long-term dents according to ASTM F970 are less than 0.005 inches. In addition or alternatives, the composite core may have dent resistance such that short-term dents according to ASTM F1914 are less than 0.005 inches.

A non-limiting example of a core complex with acceptable dent resistance (dent less than 0.005 inches according to ASTM F970) is STAINMASTER® 5.74 "x 47.74" Washed Oak. , STAINMASTER® 12 "x 24" Light Brown Stone, and such commercial products.

In one non-limiting embodiment, the composite core has a core expansion coefficient that is closer to the expansion range of the hard tile. For example, porcelain tiles have a coefficient of expansion of 2 x ^10-6 inches / inch / Fahrenheit, clay tiles have a coefficient of expansion of 3.5 x ^10-6 inches / inch / Fahrenheit, and marble It has an expansion coefficient of 3.1 × 10 ^{-6 to} 7.9 × 10 ^-6 to 30 × 10 ^-6 inches / inch / Fahrenheit. World Wide Web extension. com / thermal-expansion-coe. See Americanelents with html. A typical high-end vinyl core is the extension of the World Wide Web. com / thermal-expansion-coe. It has PVC (approximately 28 x ^10-6 inches / inch / Fahrenheit expansion) and limestone (4.4 x ^10-6 inches / inch / Fahrenheit expansion) according to Americanelents with html. Increasing the filler content tends to reduce the coefficient of thermal expansion (see: Wood Plastic Composites, Analoge A Klyosov, p. 362). In one non-limiting embodiment, the composite core used in the present disclosure has a core expansion coefficient in the range of 5 × ^10-6 to 30 × ^10-6 inches / inch / Fahrenheit. This reduction in coefficient of expansion reduces joint damage, core cracking, and / or buckling of any dressing, including planks.

The work planks are further equipped with a mounting system for attaching hard tiles to the composite core. In one non-limiting embodiment, the mounting system is a removable mounting system that allows the tiles mounted on the composite core to be removed, removed, and / or replaced without damaging the tile or composite core. Is.

In one non-limiting embodiment, the working plank mounting system comprises an adhesive that adheres hard tiles to the composite core. Various adhesives can be used that can adhere hard tiles such as stone, ceramic, or porcelain tiles to the composite core. Non-limiting examples include hot melt adhesives such as ethylene vinyl acetate copolymers, ethylene acrylate copolymers, ethylene n-butyl acrylates, ethylene acrylates, ethylene ethyl acetates, polyurethanes, and amorphous polyolefins; styrene-ethylene / propylene. , Styrene-isoprene-styrene (SIS), acrylate polymers, bio-based acrylates, thermoplastic elastomers, natural rubbers, pressure sensitive adhesives such as silicone rubbers; and Polyacrylic products from Base King in Dalton, GA. Examples thereof include commercially available EnviroSTIX ™ adhesives, polyvinyl acetate, epoxy resins, resorcinol-formaldehyde, and moisture resistant adhesives such as polyurethane. Removable adhesives made from acrylic copolymer emulsions such as Covinax211-15, Covinax211-01, Covinax225-00, and removable pressure sensitive adhesives such as Franklin International's Covinax SMA-01 from Columbus, Ohio, are used for tiles. Suitable when removal may be desirable. Detachable hot melt adhesives such as 3M 3798 LM from 3M, St Paul, MN are also suitable.

In an alternative, non-limiting embodiment, the work planks further comprise a mounting system that magnetically attaches stone, ceramic, or porcelain tiles to the composite core. See Examples 5 and 6 for embodiments of the present disclosure that depict the magnetic attachment of hard tiles to a composite core. In one non-limiting embodiment, magnetic properties are built within tiles and composite cores. This allows tiles and composite cores to be attached and removed if necessary. In another non-limiting embodiment, the magnetic properties are part of the stripped polymer sheet material, which is attached to the bottom of the hard tile and the top of the composite core and has the ability to be removed if necessary. To enable. In another non-limiting embodiment, the magnetic properties are part of a stripped polymer sheet material that is attached to the bottom of a hard tile and the bottom of a composite core. This allows the attachment of hard tiles to composite cores and provides the ability to remove them if necessary. In another non-limiting embodiment, the magnetic properties are part of a stripped polymer sheet material that is attached to the bottom of a hard tile, and the composite core is constructed within or from the stripped polymer sheet. It rests on an underlay layer that has any of the magnetic properties of being made. This allows the attachment of hard tiles to composite cores and provides the ability to remove them if necessary.

In addition, the work planks of the present disclosure include a connection system for connecting to adjacent work planks. Various methods for connecting to adjacent workpieces via the core are known and can be used in the present disclosure. In one non-limiting embodiment, the composite core has ridges raised using currently available click-locking techniques to have tongue and groove type joints. Various designs of this click-locking technique have been described and are available from Unilin (Wielsbeke, Belgium), Valinge (Viken, Sweden), or Classsen (Kaisersesch, DE). Such techniques are widely used in the hard surface flooring industry. Alternatively, lock grip strip technology can be used. Similar methods of connection that may be routinely adapted for use in the present disclosure are described in US Pat. Nos. 7,770,350, 7,866,115, 8,099,919, and the same. Nos. 8,875,465, and U.S. Patent Applications 2003/0024199, 2004/0016196, and 2005/097860, the teachings of which are on adjacent work planks. Incorporated herein by reference, along with a connection system for connecting. In this non-limiting embodiment, the composite core is flexible and soft enough to seal the joint when assembled.

The work planks of the present disclosure may further comprise a second mounting system on the core composite opposite the hard tiles, with an underlay layer optionally adhered. The non-limiting second mounting system can be magnetic or can include an adhesive as described herein. Non-limiting examples of underlay layers include layers of cork, rubber, foam, and paper. Such an underlay layer can be added to provide a gripping effect of the planks on the surface to which it is applied, as well as a sound damping effect.

The planks of the present disclosure are machined by subjecting hard tiles to the core composite via a mounting system. If desired, a second mounting system can be applied to the core composite on the opposite side of the tile to adhere to the underlay layer. The planks of the present disclosure can be machined to various shapes and sizes. In one non-limiting embodiment, the planks are rectangular in shape with a thickness of up to about 1.25 inches, a width of about 2 to about 12 inches, and a length of about 4 to 96 inches. Alternatively, the planks can be polygonal, such as squares, pentagons, hexagons, or, but not limited to, they can be joined together in a herringbone or French pattern, for example.

Thus, it is possible to provide an easy installation system for easily connecting two or more of the planks via a connecting system and, accordingly, covering floors, walls, and other hard surfaces. ..

Accordingly, the present disclosure also provides a system for covering floors, walls, and other hard surfaces comprising two or more of work planks connected adjacently via a connecting system. Work planks can be cut to size and shape by well-known methods used to cut ceramics, porcelain, or natural stones or metals. Equipment for cutting ceramic, porcelain, or natural stone tiles includes wet / dry saws such as the SKIL 7-inch wet table top saw or Ryobi 4-inch handheld wet tile saw, or BOSCH Multi-X tools. Metal tiles can be cut using bench scissors, electric saws, or gold saws.

In one non-limiting embodiment, the system of the present disclosure may include slanted hard tiles.

In one non-limiting embodiment, hard tiles are inserted from the edges of the composite core to provide a gap when connected to adjacent work planks.

In one non-limiting embodiment, the connected planks are then grouted using, for example, acrylic, urethane, epoxy, or cementum grout. In one non-limiting embodiment, the groove between the connected tiles is a removable caulk, such as, for example, acrylic latex, silicone, butyl rubber, oil-based asphalt caulking, polyurethane, caulking cord, or cementitious grout. Or it is filled with sealant. In this embodiment, when the gap is filled with grout, caulking, or sealant, it prevents water from reaching the click joint from above and potentially penetrates the joint to reach the underlying floor. And, accordingly, prevent mold / mildew and odor problems. If the planks (s) need to be replaced or moved, they can be removed by peeling the caulking / sealant from the grout wire and the click joints can be removed and need to be replaced or moved. Any plank (s) can be removed and / or replaced or reassembled.

In the case of a magnetic assembly between a hard tile and a composite core, the replacement or movement of the hard tile of the work plank (s) is easily facilitated by pulling the hard tile away from the magnetic assembly and replacing it with a new hard tile. be able to. Alternatively, the entire work slab (s) can be removed by stripping it from the grout wire and removing the connecting system that connects to the adjacent slab.

The work planks and systems of the present disclosure can be installed as easily as high grade vinyl using click or grip lock stick technology and are typically required to install grouted ceramic and stone floors. Does not require a skilled labor force. Assemblies as shown in FIGS. 3-5 and 7 can be mixed and matched for high surface coverage. It will be appreciated that either uniform or different hard tiles can be mixed and matched for the desired flooring pattern or aesthetic appearance and finish. In addition, rigid tiles, as well as planks and systems, including composite cores and connecting systems, are highly resistant to water and therefore cost-effective and durable coatings on floors, walls and other surfaces. I will provide a.

The following test methods and examples demonstrate the disclosure and its availability. The present disclosure may be in other and different embodiments, some of which details may be modified and / or replaced in various obvious ways without departing from the spirit and scope of the present disclosure. is there. Therefore, the examples should be considered as properties and non-limiting examples.

Test Methods The following are standard tests well known to experts in the hard surface industry.

Long-term dent test ASTM F970-Simulates potential dents caused by furniture or static loads.

Short-term dent test ASTM F1914-Simulates dents caused by high loads applied to small areas (eg, high heels, sharp objects).

Solidity test of caster joints of chair EN425-Simulates the impact of stress due to moving loads and stress on click joints of assembled panels.

Water Absorption Test ASTM EN13329 Appendix G-Measure the thickness that expands with exposure to water. Any significant expansion can create strain and warpage of the panel assembly.

Edge curl test ASTM F2199: This test method is used to measure the ability of floor tiles to retain their original dimensions after exposure to heat, which simulates a long service life at reasonable and expected temperatures.

Dimensional stability test EN 434-Dimensional stability after exposure to heat.

The additional tests given below are specifically designed to assess the properties of a particular flooring material.

Temperature Cycle Test: A small assembled panel is placed in the environmental chamber and, for example, cycled over a temperature range of 40 to 120 degrees Fahrenheit so that the assembled flooring is free of warpage and strain. , Confirm the ability to withstand fluctuations in indoor temperature.

Mohs hardness test: The Mohs scale of mineral hardness is a quantitative sequential scale that characterizes the scratch resistance of various minerals through the ability of harder materials to scratch softer materials. The scale is in the range of 1-10.

Installation test: Use this test to determine the relative ease of installation. The time to install the flooring by a professional installer is measured for both the test and control samples. The relative ease of cutting control, as well as the test sample, is also recorded.

(Example 1)
Short-term dent testing was performed on a commercially available composite core product with a polymer core, a top PVC printed layer and a wear layer.

FIG. 1 is a cross-sectional photograph showing the results of a short-term dent test. As shown, significant dents in the polymer core occurred within 10-15 minutes of load application. Such dents will be a serious problem when hard tiles such as stone or ceramic tiles are used on the top of this polymer core.

FIG. 2 is a photograph showing a cross-sectional view showing the results of a short-term dent test on a commercially available polymer core product having a PVC printed layer and a wear layer on top several days after the test. Significant dents in the polymer core were still observed 5 days after the initial dents. The PVC layer at the top was restored, but the core was not. Furthermore, this dent will present a serious problem when hard tiles such as stone or ceramic are used at the top of such polymer cores, especially at the joints.
(Example 2)

The work planks of the present disclosure were prepared. Ceramic hard tiles measuring 6.9 inches x 19.7 inches x 9 mm thick (Adison Oak wood plank ceramic tiles commercially available from Floor & Depot), using double-sided adhesive tape, 7 Assembled on a core composite of a 5.5 inch x 47.6 inch x 5 mm thick vinyl plank, Traffic Master Allure Ultra (commercially available from Home Depot) (see Figure 3). The ceramic tile was successfully removed by pulling it from the top. However, as those skilled in the art will understand when reading this disclosure, hots such as ethylene vinyl acetate copolymers, ethylene acrylate copolymers, ethylene n-butyl acrylates, ethylene acrylic acids, ethylene ethyl acetates, polyurethanes, and amorphous polyolefins. Melt adhesives; pressure sensitive adhesives such as styrene-ethylene / propylene, styrene isoprene styrene (SIS), acrylate polymers, bio-based acrylates, thermoplastic elastomers, natural rubbers, silicone rubbers; and Base King from Dalton, GA. Alternative adhesives can be used, including commercially available EnviroSTIX ™ adhesive products, moisture resistant adhesives such as polyvinyl acetate, epoxy resins, resorcinol-formaldehyde, and polyurethane. Removable adhesives made from acrylic copolymer emulsions such as Covinax211-15, Covinax211-01, Covinax225-00, and removable pressure sensitive adhesives such as Franklin International's Covinax SMA-01 from Columbus, Ohio, are used for tiles. It is suitable when removal is desirable. Detachable hot melt adhesives such as 3M 3798 LM from 3M, St Paul, MN are also suitable.

The core complex had a click joint connection system. The gaps between the ceramic tiles were kept uniform across all sides to create space for caulking. The two planks were assembled together to first create the two plank assemblies (see Figure 4). Two such assemblies are made and joined together with the click joints to form four plank assemblies, and the space between the clicked joints in this assembly is DAP 3.0 Advanced All-Purpose Sealant /. It was filled with caulking (suitable for the temperature range of 20-120 degrees Fahrenheit) and dried (see FIG. 5).

After 24 hours, the four plank assemblies of FIG. 5 were tested for leakage at any joint by applying a small amount of water to the joint. No leaks were observed.

The four plank assemblies of FIG. 5 were stored indoors and any changes due to dimensional stability issues typically occurring in residential installations were observed. No visible cracking or expansion of caulking, no strain, or warpage of the assembly was observed on visual inspection for up to 16 months from the start of this test. This test demonstrates the dimensional stability of planks and systems.

A large surface coverage can be obtained by similarly connecting a plurality of such plank assemblies of FIG. It will be appreciated that either uniform or different ceramics, porcelain, or natural stones can be mixed and matched for the desired flooring pattern or aesthetic appearance and finish.
(Example 3)

Various commercially available flooring samples were tested for dent resistance. ASTM F970 for a long-term dent resistance test and ASTM F1914 for a short-term dent resistance test were performed. The results are shown in Table 1 together with the connection types. A substrate as a core with a dent resistance of less than 0.005 inches would be preferred for the purposes outlined in the present disclosure.

(Example 4)

Hard ceramic tiles sized to 6.9 inches x 19.7 inches x 9 mm thick (Adison Oak wood planks ceramic tiles commercially available from Floor & Decor) are used in Magnetic Building Solutions, Dalton, GA. It was assembled with a stripped magnetic receiving layer (MBR030S004PS-MagneBuild PS Receptive) supplied by LLC (see FIG. 6). 7.5 inch x 47.6 inch x 5 mm thick vinyl plank, Traffic Master Allure Limited (commercially available from Home Depot) top of composite core with double-sided tape, Magnetic Building, Dalton, GA It was coated with a piece of a 1.0 mm thick magnetic underlayment (MBU100R100-MagneBilledUnderlayment (Base)) supplied by Solutions LLC.

A ceramic tile with a magnetic receiving layer of FIG. 6 was placed on top of a vinyl plank with a magnetic underlayment to create a robust and stable magnetic attachment. This one plate assembly, in which the ceramic tiles are evenly inserted from the edges of the plate, is shown in FIG. It was observed that the ceramic tiles were firmly attached by the magnetic underlayment. It was possible to separate the ceramic tiles from the underlying core, thereby demonstrating the ability to replace or move the tiles as needed.

In this embodiment, the individual vinyl planks have click joints and two or more such planar assemblies (as in FIG. 7) are connected via a connecting system for connecting adjacent work planks. Can be connected together. See, for example, similar assemblies in FIGS. 3-5. The gap between the ceramic tiles can be maintained evenly across all sides to create space for caulking. Two planks as shown in FIG. 7 can be assembled together to create the first two planks (as in FIG. 4). Two such assemblies can be made and joined together with the click joints to form four plank assemblies. The space between the clicked joints in such an assembly may be grouted, caulked, or sealed. Grouts, caulks, or sealants can be selected from the group consisting of acrylics, urethanes, epoxies, acrylic latexs, silicones, butyl rubbers, oil-based asphalt caulks, polyurethanes, caulking cords, and cementitious grouts. One example is DAP 3.0 Advanced All-Purpose Sealant / Caulking (suitable for the temperature range of 20-120 degrees Fahrenheit). As in a similar embodiment of FIG. 5, the four plank assemblies can be dried to obtain a higher surface coverage. A large surface coverage can be obtained by similarly connecting a plurality of such plank assemblies of FIG. 7.

Claims (39)

It is a work plank
a) A hard tile having a top and a bottom, wherein the hard tile contains a mineral or metal having a Mohs hardness scale of 4 or more.
b) A composite core having a top and a bottom, wherein the composite core has a Mohs hardness scale of less than 4.
c) A mounting system that attaches (a) to (b),
d) A work plank comprising a connection system for connecting adjacent work planks. The work plank according to claim 1, wherein the hard tile comprises ceramic, porcelain, natural stone, glass, metal, or a metal alloy. The work thick plate according to claim 1, wherein the thickness of the hard tile is 3 mm to 30 mm. The work thick plate according to claim 1, wherein the thickness of the hard tile is 3 mm to 25 mm. The work thick plate according to claim 1, wherein the thickness of the hard tile is 3 mm to 15 mm. The work plank according to claim 1, wherein the mounting system is a removable mounting system. The work plank according to claim 6, wherein the removable mounting system comprises a removable adhesive. The work sheet according to claim 7, wherein the removable adhesive is selected from a removable hot melt adhesive, a pressure sensitive adhesive, a moisture resistant adhesive, and a combination thereof. The removable adhesive is selected from the group consisting of ethylene vinyl acetate copolymer, ethylene acrylate copolymer, acrylic copolymer emulsion, ethylene n-butyl acrylate, ethylene acrylic acid, ethylene ethyl acetate, polyurethane, and amorphous polyolefin. The work thick plate according to claim 8, which is a possible hot melt adhesive. The removable adhesive is from vinyl acrylic copolymer emulsions, acrylics, modified acrylics, styrene-ethylene / propylene, styrene isoprene styrene (SIS), acrylate polymers, biobased acrylates, thermoplastic elastomers, natural rubbers, and silicone rubbers. The work thick plate according to claim 8, which is a removable pressure-sensitive adhesive selected from the group. 8. The removable adhesive is a removable moisture resistant adhesive selected from the group consisting of polyvinyl acetate, epoxy resin, resorcinol-formaldehyde, polyacrylic polymer, acrylic, modified acrylic, and polyurethane. Work planks described in. The work plank according to claim 1, wherein the mounting system is magnetic. 12. The work plank according to claim 12, wherein the magnetic mounting system comprises magnetic properties built within the rigid tile and the composite core and / or underlying layer. 12. The magnetic attachment system comprises a stripped polymer sheet material attached to either the bottom of the hard tile and the top of the composite core, the bottom of the composite core, or the underlay layer. Work planks described in. The work thick plate according to claim 1, wherein the composite core is a water-resistant high-density or medium-density fiberboard. The work sheet according to claim 1, wherein the composite core has a density in the range of 1.0 to 2.4 gm / cc. The work sheet according to claim 1, wherein the composite core has a density in the range of 1.3 to 2.1 gm / cc. The work plan according to claim 1, wherein the composite core has a core expansion coefficient in the range of 5 × 10 ^-6 to 30 × 10 ^-6 inches / inch / Fahrenheit. The work sheet according to claim 1, wherein the composite core has dent resistance such that the long-term dent according to ASTM F970 is less than 0.005 inch. The work plan according to claim 1, wherein the composite core has dent resistance such that short-term dents according to ASTM F1914 are less than 0.005 inches. The work plan according to claim 1, wherein the composite core has dent resistance such that long-term dents according to ASTM F970 are less than 0.005 inches and short-term dents according to ASTM F1914 are less than 0.005 inches. The composite core comprises a polymer selected from high density polyethylene, polypropylene, polyethylene, low density polyethylene, polyamide, polyester, polyvinyl chloride, polylactic acid, or any copolymer, recycled polymer, or blend thereof. The work plank according to 1. 22. The work plank according to claim 22, wherein the composite core further comprises a filler. The fillers are limestone, talc, calcium carbonate, wood dust, bamboo dust, cork, pearlite, glass fiber, polyamide fiber, cellulose fiber, wood fiber, polymer fiber, glass, sand, synthetic fiber, fly ash, flax fiber, 23. The work plank according to claim 23, which is selected from hemp fibers, kaolin clay, mica, wollastonite (CaSiO ₃ ), carbon black, or any combination thereof. 23. The work plank according to claim 23, wherein the filler-to-polymer ratio is in the range of 5:95 to 95: 5 by weight. 22. The work plank according to claim 22, wherein the composite core further contains an additive. The additives are colorants, anti-UV agents, UV absorbers, flame retardants, antifungal agents, anti-microbial agents, coupling agents, reinforcing agents, interfacial adhesion promoters, stabilizers, antioxidants, lubricants, plasticizers. The working plank according to claim 26, which is selected from the agent and a recycled additive thereof or any combination thereof. The work plate according to claim 1, wherein the hard tile is inserted from the edge of the composite core b) so as to provide a gap when connected to an adjacent work plate. The work plate according to claim 1, wherein the connection system for connecting to an adjacent work plate includes a grip lock strip technique or a click lock technique. The work plate according to claim 1, further comprising a second mounting system under the composite core of the plate for attachment of the underlay layer. 30. The work plank according to claim 30, wherein the second mounting system is magnetic or comprises an adhesive. 30. The work plank according to claim 30, further comprising an underlaying layer adhered to the additional adhesive layer. 32. The work plank according to claim 32, wherein the underlay layer comprises cork, rubber, foam, or paper. The work thick plate according to claim 1, wherein the hard tile includes unadjusted ceramic or porcelain or stone tile. The work plank according to claim 1, wherein the hard tile has an inclined edge. Claims 1-35, a system for covering floors, walls, and other surfaces, wherein the system is adjacently connected via the connection system for connecting to adjacent work planks. A system comprising two or more work planks according to any one of the above. 36. The work plank according to claim 36, wherein the hard tiles of the work plank are inserted from the edge of the composite core so as to provide a gap when connected to the adjacent work plank. 36 or 37. The system of claim 36 or 37, wherein the connected work planks are caulked or sealed. 38. The system of claim 38, wherein the caulking or sealant is selected from the group consisting of acrylic, urethane, epoxy, acrylic latex, silicone, butyl rubber, oil-based asphalt caulking, polyurethane, and caulking cords.