System for modular tile installation

• US 9,402,496 B2
• Filed: 04/29/2013
• Issued: 08/02/2016
• Est. Priority Date: 09/19/2000
• Status: Expired due to Term

• Current Assignee: Interface Incorporated
• Original Assignee: Interface Incorporated
• Inventors: Scott, Graham A. H., Oakey, David D., Bradford, John P., Gray, Keith N.
• Primary Examiner(s): Nguyen, Chi Q
• Application Number:
  US13/872,576
• Publication Number:
  US 20130232900A1
• Time in Patent Office: 1,191 Days
• Field of Search: 525/060.5, 523/112, 523/85, 523/91, 527/450.5, 527/471.1, 428/86, 428/100, 428/99, 428/101, 428/356, 428/354
• US Class Current: 1/1
• CPC Class Codes: A47G 27/0243 Features of decorative rugs or carpets
• CPC Class Codes: A47G 27/0475 Laying carpet tiles
• CPC Class Codes: E04F 15/02 Flooring or floor layers composed of a number of similar elements of webs E04F15/16
• CPC Class Codes: E04F 2201/07 with connections using a special adhesive material
• CPC Class Codes: Y10T 428/23914 Interlaminar
• CPC Class Codes: Y10T 428/24008 including fastener for attaching to external surface
• CPC Class Codes: Y10T 428/24017 Hook or barb
• CPC Class Codes: Y10T 428/24025 Superposed movable attached layers or components
• CPC Class Codes: Y10T 428/2848 Three or more layers
• CPC Class Codes: Y10T 428/2857 including metal or compound thereof or natural rubber

Abstract

Connectors for joining adjacent modular floor covering units. The connectors include a film and an adhesive layer coated on one side of the film. To install tiles using the connectors, a first tile is placed on the floor and a connector is positioned so that the adhesive layer faces upward and does not contact the floor. The connector is typically positioned so that only a portion of the adhesive layer adheres to the underside of the tile, leaving the remainder of the connector extending from the underside of the tile. Tiles are then positioned adjacent the first tile so that a portion of the connector adheres to the adjacent tiles. In this way, the connectors span adjacent tile edges. The tiles are assembled on a underlying flooring surface without the need to attach them to the floor surface. Rather, the tiles are linked to each other with the connectors, so that the tiles create a floor covering that “floats” on the underlying floor surface.

Claims

1. A floorcovering system for installation on an underlying surface, the floorcovering system comprising:

a plurality of modular tiles, wherein each modular tile comprises an underside; and

a plurality of connectors for connecting the plurality of modular tiles without extending along entire adjacent edges of adjacent modular tiles, wherein each of the plurality of connectors is sized to extend along less than entire adjacent edges between adjacent modular tiles, each connector comprising;

a film having two sides; and

a layer of adhesive located on a side of the film, wherein the adhesive on a portion of a connector is capable of forming a bond between the film and the undersides of adjacent modular tiles and has a sufficient shear strength to prevent the adjacent modular tiles from moving relative to the connector or each other thereby creating gaps between the adjacent modular tiles after installation when the connector spans adjacent edges of the adjacent modular tiles and extends along less than the entire adjacent edges without abutting another connector and when the portion has a surface area that is no more than approximately 5% of the modular tile surface area of each of the adjacent modular tiles.

2. The system of claim 1 wherein the film comprises a plastic material sufficiently stiff for a connector positioned partly in contact with an underside of a modular tile to project beyond the edge of the modular tile in roughly the same plane as the underside of the modular tile.

3. The system of claim 2 wherein the plastic material comprises a polyolefin, a polyamide, or polyester.

4. The system of claim 1 wherein the film exhibits a tensile strength between 160 and 270 MPa, inclusive, in at least one direction.

5. The system of claim 1 wherein at least one of the plurality of connectors has a surface area of approximately 9 inches square.

6. The system of claim 1 wherein at least one of the plurality of connectors has a surface area of at least 9 inches square, wherein 9 inches square of the surface is sufficient to stabilize adjacent tiles connected by the at least one of the plurality of connectors, wherein a portion of the surface area greater than the 9 square inches does not meaningfully contribute to stability of adjacent tiles connected by the at least one of the plurality of connectors.

7. The system of claim 1 wherein at least one of the plurality of connectors has a film that comprises a thickness between approximately 0.0005 and 0.015 inches, inclusive.

8. The system of claim 1 wherein at least one of the plurality of connectors has a film that comprises a thickness between approximately 0.003 and 0.01 inches, inclusive.

9. The system of claim 1 wherein the layer of adhesive comprises a releasable adhesive.

10. The system of claim 1 wherein the film comprises a dimension and wherein the film is capable of being stretched at least 120% of the dimension before breaking.

11. The system of claim 1 wherein the connector is adapted to connect the adjacent modular tiles together without adhering the modular tiles to the underlying surface on which the tiles are positioned.

12. The system of claim 11 wherein the plurality of connectors are provided on release material.

13. The system of claim 1 wherein the plurality of connectors are provided in a roll.

14. The system of claim 1 wherein the plurality of connectors are provided on a strip of release material folded into an accordion shape.

15. The system of claim 1 wherein the plurality of connectors are provided in a stack.

16. The system of claim 1 wherein the system further identifies that, to install the modular tiles using the connectors, a first modular tile is placed on the underlying surface;

a connector is then positioned so that only a first portion of the connector adheres to the underside of the first modular tile leaving a second portion of the connector extending from the underside of the first modular tile, and an adjacent modular tile is then positioned adjacent to the first modular tile on the underlying surface so that the second portion of the connector adheres to the adjacent tile.

17. The system of claim 1 wherein the modular tiles are carpet tiles.

18. A floorcovering system for installation on a surface, the floorcovering system comprising:

a plurality of modular tiles, wherein each modular tile comprises an underside and a modular tile surface area; and

a plurality of modular tile connectors for connecting the plurality of modular tiles without extending along entire adjacent edges of adjacent modular tiles, wherein each of the plurality of modular tile connectors is sized to extend along less than entire adjacent edges between adjacent modular tiles, each modular tile connector comprising;

a film having two sides, each side having a connector surface area that is no more than approximately 5% of the modular tile surface area of each of the plurality of modular tiles to allow each modular tile connector to adhere to adjacent modular tiles without extending along the entire adjacent edges between the adjacent modular tiles; and

a layer of adhesive less than 0.010 inches thick on a side of the film.

19. The system of claim 18 wherein the modular tiles are carpet tiles.

20. The system of claim 18 wherein the layer of adhesive is sufficiently thin to be incapable of migrating beyond a connector edge and into contact with the surface.

21. The system of claim 18 wherein the layer of adhesive is sufficiently viscous to be incapable of migrating beyond a connector edge and into contact with the surface.

22. The system of claim 18 wherein the layer of adhesive is more than 0.0005 inches thick.

23. The system of claim 18 wherein the layer of adhesive is about 0.002-0.008 inches thick.

24. The system of claim 18 wherein each of the plurality of modular tiles has a textile backing surface on the underside, and wherein the layer of adhesive is about 0.005-0.008 inches thick.

25. The system of claim 18 wherein each of the plurality of modular tiles has a relatively flat backing surface, and wherein the layer of adhesive is about 0.002-0.003 inches thick.

26. The system of claim 18 wherein each of the plurality of modular tiles has a shallow embossed backing surface on the underside, and wherein the thickness of the layer of adhesive of each connector is about 0.002-0.003 inches.

27. The system of claim 18 wherein each of the plurality of modular tiles is a hard back tile, and wherein the thickness of the layer of adhesive of each connector is about 0.002-0.003 inches.

28. The system of claim 18 wherein each connector surface area is approximately 1% of the modular tile surface area of each of the plurality of modular tiles.

29. The system of claim 18 wherein each connector surface area is approximately 2-5% of the modular tile surface area of each of the plurality of modular tiles.

30. The system of claim 18 wherein the layer of adhesive of each connector comprises a sufficient shear strength so that, when a connector spans adjacent edges of the adjacent modular tiles so that the layer of adhesive contacts the undersides of the adjacent modular tiles, the connector prevents adjacent tiles from moving relative to the connector or each other thereby creating gaps between the adjacent tiles after installation.

31. The system of claim 18 wherein the film of each connector comprises a plastic material sufficiently stiff for a connector positioned partly in contact with an underside of a modular tile to project beyond the edge of the modular tile in roughly the same plane as the underside of the modular tile.

32. The system of claim 31 wherein the plastic material of each connector comprises a polyolefin, a polyamide, or a polyester.

33. The system of claim 18 wherein the film of each connector exhibits a tensile strength between 160 and 270 MPa, inclusive, in at least one direction.

34. The system of claim 18 wherein the film of each connector has a thickness between approximately 0.0005 and 0.015 inches, inclusive.

35. The system of claim 18 wherein the film of each connector has a thickness between approximately 0.003 and 0.01 inches, inclusive.

36. The system of claim 18 wherein the layer of adhesive comprises a releasable adhesive.

37. The system of claim 18 wherein the film of each connector comprises a dimension and wherein the film is capable of being stretched at least 120% of the dimension before breaking.

38. The system of claim 18 wherein each connector is adapted to connect adjacent modular tiles together without adhering the adjacent modular tiles to the surface on which the adjacent modular tiles are positioned.

39. The system of claim 18 wherein the plurality of connectors are provided in a roll.

40. The system of claim 18 wherein the plurality of connectors are provided on release material.

41. The system of claim 18 wherein the plurality of connectors are provided on a strip of release material folded into an accordion shape.

42. The system of claim 18 wherein the plurality of connectors are provided in a stack.

43. The system of claim 18 wherein the system further identifies that, to install the modular tiles using the connectors, a first modular tile is placed on the surface;

a connector is then positioned so that only a first portion of the connector adheres to the underside of the first modular tile leaving a second portion of the connector extending from the underside of the first modular tile, and an adjacent modular tile is then positioned adjacent to the first modular tile on the surface so that the second portion of the connector adheres to the adjacent tile.

44. A floorcovering system for installation on a surface, the floorcovering system comprising:

a plurality of modular tiles, wherein each modular tile comprises an underside and a modular tile surface area; and

a plurality of modular tile connectors for connecting the plurality of modular tiles without extending along entire adjacent edges of adjacent modular tiles, wherein each of the plurality of modular tile connectors is sized to extend along less than entire adjacent edges between adjacent modular tiles, each modular tile connector comprising;

a film having two sides, each side having a connector surface area approximately 9 square inches to allow each modular tile connector to adhere to adjacent modular tiles without extending along the entire adjacent edges between the adjacent modular tiles; and

a layer of adhesive on a side of the film, wherein a thickness of the layer of adhesive is less than 0.010 inches, wherein the layer of adhesive is capable of forming a bond between the film and the undersides of adjacent modular tiles.

45. The system of claim 44 wherein the modular tiles are carpet tiles.

46. The system of claim 44 wherein the modular tile surface area is 18 inches by 18 inches.

47. The system of claim 44 wherein the modular tile surface area is 50 centimeters by 50 centimeters.

48. The system of claim 44 wherein each connector is no larger than approximately 3 inches by 3 inches.

49. The system of claim 44 wherein the layer of adhesive is sufficiently thin to be incapable of migrating beyond a connector edge and into contact with the surface.

50. The system of claim 44 wherein the layer of adhesive is sufficiently viscous to be incapable of migrating beyond a connector edge and into contact with the surface.

51. The system of claim 44 wherein the layer of adhesive is more than 0.0005 inches thick.

52. The system of claim 44 wherein the layer of adhesive is about 0.002-0.008 inches thick.

53. The system of claim 44 wherein each of the plurality of modular tiles has a textile backing surface on the underside, and wherein the layer of adhesive is about 0.005-0.008 inches thick.

54. The system of claim 44 wherein each of the plurality of modular tiles has a relatively flat backing surface, and wherein the layer of adhesive is about 0.002-0.003 inches thick.

55. The system of claim 44 wherein each of the plurality of modular tiles has a shallow embossed backing surface on the underside, and wherein the thickness of the layer of adhesive of each connector is about 0.002-0.003 inches.

56. The system of claim 44 wherein each of the plurality of modular tiles is a hard back tile, and wherein the thickness of the layer of adhesive of each connector is about 0.002-0.003 inches.

57. The system of claim 44 wherein the layer of adhesive of each connector comprises a sufficient shear strength so that, when a connector spans adjacent edges of the adjacent modular tiles so that the layer of adhesive contacts the undersides of the adjacent modular tiles, the connector prevents adjacent tiles from moving relative to the connector or each other thereby creating gaps between the adjacent tiles after installation.

58. The system of claim 44 wherein the film of each connector comprises a plastic material sufficiently stiff for a connector positioned partly in contact with an underside of a modular tile to project beyond the edge of the modular tile in roughly the same plane as the underside of the modular tile.

59. The system of claim 58 wherein the plastic material of each connector comprises a polyolefin, a polyamide, or a polyester.

60. The system of claim 44 wherein the film of each connector exhibits a tensile strength between 160 and 270 MPa, inclusive, in at least one direction.

61. The system of claim 44 wherein the film of each connector has a thickness between approximately 0.0005 and 0.015 inches, inclusive.

62. The system of claim 44 wherein the film of each connector has a thickness between approximately 0.003 and 0.01 inches, inclusive.

63. The system of claim 44 wherein the layer of adhesive comprises a releasable adhesive.

64. The system of claim 44 wherein the film of each connector comprises a dimension and wherein the film is capable of being stretched at least 120% of the dimension before breaking.

65. The system of claim 44 wherein each connector is adapted to connect adjacent modular tiles together without adhering the adjacent modular tiles to the surface on which the adjacent modular tiles are positioned.

66. The system of claim 44 wherein the plurality of connectors are provided in a roll.

67. The system of claim 44 wherein the plurality of connectors are provided on release material.

68. The system of claim 44 wherein the plurality of connectors are provided on a strip of release material folded into an accordion shape.

69. The system of claim 44 wherein the plurality of connectors are provided in a stack.

70. The system of claim 44 wherein the system further identifies that, to install the modular tiles using the connectors, a first modular tile is placed on the surface;

a connector is then positioned so that only a first portion of the connector adheres to the underside of the first modular tile leaving a second portion of the connector extending from the underside of the first modular tile, and an adjacent modular tile is then positioned adjacent to the first modular tile on the surface so that the second portion of the connector adheres to the adjacent tile.

71. A floorcovering system for installation on an underlying surface, the floorcovering system comprising:

(a) a plurality of modular tiles, wherein each modular tile comprises an underside; and

(b) a plurality of connectors for connecting the plurality of modular tiles without extending along entire adjacent edges of adjacent modular tiles, each connector comprising;

(i) a film having two sides; and

(ii) a layer of adhesive located on a side of the film, wherein the layer of adhesive is capable of forming a bond having sufficient shear strength between the film and the undersides of adjacent modular tiles to prevent the adjacent modular tiles from moving relative to the connector or each other and thereby creating gaps between the adjacent modular tiles after installation when

(1) connectors span adjacent edges of the adjacent modular tiles and extend along less than the entire adjacent edges without abutting another connector and

(2) a total surface area of the side the film is no more than approximately 5% of a surface area of the undersides of each of the modular tiles.

72. A floorcovering system for installation on an underlying surface, the floorcovering system comprising:

(a) a plurality of modular tiles, wherein each modular tile comprises an underside; and

(b) a plurality of connectors for connecting the plurality of modular tiles without extending along entire adjacent edges of adjacent modular tiles, each connector comprising;

(i) a film having two sides; and

(ii) a layer of adhesive located on a side of the film, wherein the layer of adhesive is capable of forming a bond having sufficient shear strength between the film and the undersides of adjacent modular tiles to prevent the adjacent modular tiles from moving relative to the connector or each other and thereby creating gaps between the adjacent modular tiles after installation when

(1) connectors span adjacent edges of the adjacent modular tiles and extend along less than the entire adjacent edges without abutting another connector and

(2) a total surface area of the side of the film is no more than approximately 5% of a total surface area of the undersides of all of the modular tiles.