A flooring assembly

Abstract

Flooring assembly 10, comprising an underlayment 12 having a first layer 16 of a sponge or foam rubber material and comprising a first magnetic material 13, adapted to be laid directly on to a subfloo

Description

The present invention relates to a flooring assembly. In particular, the present invention relates to an assembly by which an underlayment and a floor covering may be laid on to a subfloor without the use of any adhesives or physical fixtures. Floors, whether in an indoor or outdoor space, for example in a room, lobby, corridor, outdoor walkway, footbridge, etc., typically comprise a subfloor and a covering. The subfloor is usually the structural part of the floor and functions as support for bearing weight. The covering is usually laid over the subfloor to provide protection to the subfloor and to provide an aesthetically more pleasing appearance amongst other things. For example, for indoor use, the covering may be floor tiles, carpet, or wooden panels. In certain environments, typically indoors, an underlayment is additionally provided as an intermediate layer between the subfloor and the covering. Depending on the material used, rubber for example, the underlayment may serve various purposes, including acoustic dampening and thermal insulation. To install a floor covering with an underlayment, the underlayment is usually laid over the subfloor first and affixed to the subfloor with adhesives or other suitable forms of physical fixture, such as nails. For example, the subfloor may be first treated with a coating of adhesive material and rolls of underlayment material may be unrolled on to the adhesive-treated subfloor. Once the underlayment is in place, the covering may then be laid over the underlayment and fixed in place, also with adhesives or other suitable forms of physical fixture. This arrangement provides a secure fixture of the underlayment and covering. However, fixing the underlayment to the subfloor, and the covering to the underlayment, in such a permanent or semi-permanent manner makes the task of replacing either or both the underlayment and the covering, for example to replace damaged parts or for redecorating, difficult, if not impossible. Using adhesives to install the underlayment and / or the covering is also a hazardous and timeconsuming process, and special protective measures and equipment may be needed in cases where the adhesive contains harmful chemicals. There is therefore a need for a floor covering assembly that is easy to install and easy to replace. According to the first aspect of the present invention, there is provided a flooring assembly, comprising an underlayment having a first layer of a sponge or foam rubber material and comprising a first magnetic material, adapted to be laid directly on to a subfloor; and a floor covering having a cover layer and comprising a second magnetic material, adapted to be laid on to the underlayment when laid on the subfloor. In embodiments, the underlayment is adapted to be laid on the subfloor and remain in place without an adhesive or physical fixtures. In embodiments, one of the first magnetic material and the second magnetic material is an unmagnetized magnetic material, and the other of the first magnetic material and the second magnetic material is a magnetised magnetic material. In embodiments, the first layer of the underlayment includes a first surface on one side and a second surface on an opposite side; and the first magnetic material is provided in a second layer applied to the first surface. Preferably, the second layer is a film, bonded to the first surface of the first layer. In embodiments, the first magnetic material is disposed within the first layer of the underlayment. Preferably, the first layer of the underlayment includes a first surface on one side and a second surface on an opposite side; and the first magnetic material is disposed within the first layer to a predetermined depth from the first surface. In embodiments, the floor covering includes a cover layer having a display side on one side and a contact surface on an opposite side; and the second magnetic material is provided in a contact layer applied the contact surface. Preferably, the contact layer is a film bonded to the contact surface. In embodiments, the second magnetic material is disposed within the cover layer of the floor covering. Preferably, the cover layer of the floor covering includes a display side on one side and a contact surface (46) on an opposite side; and the second magnetic material is disposed within the cover layer to a predetermined depth into the contact surface. In embodiments, the underlayment has a thickness between 1.5mm to 15mm. Preferably, the underlayment has a thickness of at least 2.5mm. In embodiments, the underlayment has a density between 100kg / m3 and 2000kg / m3. Preferably, the underlayment has a density between 500kg / m3 and 1600kg / m3. More preferably, the underlayment has a density of at least 960kg / m3. Embodiments of the present invention will hereinafter be described by way of examples, with references to the accompanying drawings, in which: Figure 1 is a perspective view of an embodiment of a flooring assembly; Figure 2 is a cross-sectional view of an underlayment of an embodiment of a flooring assembly; Figure 3 is a cross-sectional view of floor covering of an embodiment of a flooring assembly; Figure 4 is a cross-sectional view of an embodiment of a flooring assembly; Figure 5 is a cross-sectional view of another embodiment of a flooring assembly; Figure 6 is a cross-sectional view of an underlayment of another embodiment of a flooring assembly; and Figure 7 is a cross-sectional view of floor covering of another embodiment of a flooring assembly. The flooring assembly of the present invention generally comprises an underlayment and a floor covering. The underlayment is generally configured so that it can be laid on to a subfloor and remain in place during use without the use of an adhesive or any other forms of physical fixtures. The underlayment and the floor covering are generally configured to have magnetic contact to enable the floor covering to be laid on to and remain sufficiently secured to the underlayment without the use of an adhesive or any other forms of physical fixtures. The magnetic contact between the underlayment and the floor covering also enables one floor covering to be removed and replaced with a different floor covering without the use of any tools. To facilitate this magnetic contact, the underlayment has incorporated therewith a first magnetic material and the floor covering has incorporated therewith a second magnetic material. The first magnetic material and the second magnetic material are arranged in a way such that a display side of the floor covering, which may have a form similar to a floor tile, carpet, wooden floor board, or other common forms of flooring, is oriented at the top when the flooring assembly is laid. As will be explained in more detail herein, the first magnetic material, the second magnetic material, or both, may be an unmagnetized magnetic material (i.e. a material that displays an induced magnetic attraction towards an external magnetic field) or a magnetised magnetic material (i.e. a material that displays a magnetic field without external influence). Referring to figure 1, a flooring assembly 10 in accordance with various embodiments of the present invention is shown. The flooring assembly 10 comprises an underlayment 12 that is adapted to be laid directly on to a subfloor 100 without the use any adhesive or physical fixture to attach the underlayment 12 to the subfloor. The flooring assembly 10 also comprises a floor covering 14 that is adapted to be laid on to the underlayment 12 without the use any adhesive or physical fixture to attach the floor covering 14 to the underlayment 12. In various embodiments, the underlayment 12 is generally in the form of a flat sheet and includes a sponge or foam rubber material provided in a first layer 16. Using a sponge or foam rubber material, also known as cellular rubber or expanded rubber, provides acoustic and vibration dampening qualities to the underlayment 12, which may be particular desirable in places such as supermarkets, hotels, or hospitals, where there may be heavy footfall with a need to keep noise generated by footsteps to a minimum. Using a sponge or foam rubber material also provides thermal insulation properties, which may be desirable in a domestic environment for example. Typically, sponge or foam rubber is produced by using a foaming agent to create pockets of air within a natural or synthetic rubber material. When laid on to a subfloor 100, the sponge or foam rubber in the underlayment 12 also has the ability to deform around small imperfections on the surface of the subfloor 100, effectively smoothing off the surface. Using a sponge or foam rubber material has further advantages. For example, sponge and foam rubber have excellent impact and airborne noise reduction properties. When combined with other layers of the flooring assembly 10, the additional weight of those layers further augment these properties. Sponge rubber in particular also has low tog rating, making it particularly ideal for use in conjunction with underfloor heating systems. In various embodiments, the first layer 16 of the underlayment 12 has a generally uniform thickness ranging from 1.5mm to 15mm. In some embodiments, the first layer 16 of the underlayment 12 has a thickness ranging from 4mm to 12mm. In various embodiments, the first layer 16 of the underlayment 12 has a density ranging from 100kg / m3 to 2000kg / m3. In particular embodiments, the first layer 16 of the underlayment 12 has a density between 500kg / m3 and 1600kg / m3. Generally, the thickness and density of the sponge or foam rubber of the first layer 16 are selected so as to provide sufficient acoustic and vibration dampening whilst providing a suitably stable and comfortable platform on which to stand and / or walk. The density of the first layer 16 is also selected to give the underlayment 12 a sufficient flop-weight such that it can be laid on to the subfloor 100 and remain in place under its own weight whilst in use without the use of any adhesive or physical fixtures to secure the underlayment 12 to the subfloor 100. In particular embodiments, the first layer 16 has a thickness of 2.5mm. In particular embodiments, the first layer 16 has a density of at least 960kg / m3. This thickness and density of the first layer 16 results in an underlayment 12 that has the desirable level of acoustic and vibration dampening whilst being suitably firm. In some embodiments, the first layer 16 is formed from a natural rubber material such as latex. In some other embodiments, the first layer 16 is formed from a synthetic rubber material such as neoprene or polyurethane. Referring still to figure 1, the underlayment 12 generally has incorporated therewith a first magnetic material 13, which can be an unmagnetized magnetic material or a magnetised magnetic material. In the particular embodiment shown in figure 1, the first magnetic material 13 is incorporated as a second layer 18 applied on to the first layer 16. Shown in more detail in figure 2, the first layer 16 is in a generally sheet form, with a first surface 24 on one side of the sheet and a second surface 26 on an opposite side of the sheet. The second layer 18 is disposed on the first surface 24 either as a coating applied thereto or as a film bonded thereto. For example, in some embodiments, the first magnetic material 13 comprises iron filings disposed in a liquid resin matrix that is applied to the first surface 24, which is then allowed to dry and set into a solid. In some embodiments, the first magnetic material 13 comprises iron filings set into a flexible substrate, such as soft flexible polymer material, which is then bonded to the first surface 24 with a pressure sensitive adhesive film. In some other embodiments, the second layer 18 may be a magnetised layer similar to those found in flexible fridge magnets. In various embodiments, the second surface 26 of the underlayment 12 is generally a flat surface. In some other embodiments, the second surface 26 may be textured with surface features such as corrugations or other patterns. It will also be appreciated by the skilled person that the first surface 24 may be flat or may be similarly textured with surface features. Referring back to figure 1, the floor covering 14 of the particular embodiment of the flooring assembly 10 includes a cover layer 20 and a contact layer 22. The cover layer 20 is generally the portion of the floor covering 14 that is on top when the flooring assembly 10 is laid on to a subfloor 100 and the contact layer 22 is the portion of the floor covering 14 that includes a second magnetic material 15 to facilitate the magnetic contact with the underlayment 12. For example, the cover layer 20 may have a similar form to a floor tile, carpet panel, wooden flooring panel, or any other suitable form of covering for a floor known to the skilled person. In various embodiments, a particular one of which is shown in more detail in figure 3, the cover layer 20 has a display side 28 on one side, which is generally the side that is visible when the flooring assembly 10 is laid on to a subfloor 100, and a contact surface 30 on an opposite side, which is the side that is not visible when the flooring assembly 10 is laid on to a subfloor 100. In the particular embodiment shown in figure 3, the contact layer 22 is disposed on the contact surface 30 of the cover layer 20 either as a coating applied thereto or as a film bonded thereto. In various embodiments, the second magnetic material 15 of the contact layer 22 may similarly comprise iron filings disposed in a resin matrix, iron filings set into a flexible substrate, or a magnetised layer similar to those found in flexible fridge magnets. In various embodiments, when laid on to a subfloor 100, the flooring assembly 10 resembles a stratified arrangement, with the first layer 16 of the underlayment 12 being at the bottom and directly on top of the subfloor 100, the second layer 18 of the underlayment 12 being on top of the first layer 16, the contact layer 22 of the floor covering 14 being above and in magnetic contact with the second layer 18 of the underlayment 12, and the cover layer 20 of the floor covering 14 being at the top of the stratified arrangement. To facilitate this, the first magnetic material 13 and the second magnetic material 15 may be arranged in several different ways. Referring to figure 4, the embodiment of the flooring assembly 10 of figure 1 is shown in a cross-sectional view with the floor covering 14 in magnetic contact with the underlayment 12. As shown, the first magnetic material 13 in the second layer 18 of the underlayment 12 and the second magnetic material 15 in the contact layer 22 of the - 7 - floor covering 14 are both magnetised magnetic material such as those given as examples hereinabove, with magnetic poles arranged in a direction perpendicular to the strata of the flooring assembly 10. In the particular embodiment shown, the north and south poles of the first magnetic material 13 are arranged with the south pole at the exposed side, i.e. the side of the second layer 18 that makes physical contact with the floor covering 14, and the north and south poles of the second magnetic material 15 are arranged with the north pole on the exposed side, i.e. the side of the contact layer 22 that makes physical contact with the underlayment 12. In another embodiment, which is not shown, the magnetic poles may be arranged in the opposite orientation. In another embodiment, shown in figure 5, the first magnetic material 13 in the second layer 18 of the underlayment 12 is a non-magnetised magnetic material such as those given as examples hereinabove, whilst the second magnetic material 15 in the contact layer 22 of the floor covering 14 is a magnetised magnetic material. As shown, the north and south poles of the second magnetic material 15 are arranged with the north pole on the exposed side, i.e. the side of the contact layer 22 that makes physical contact with the underlayment 12, although it will be appreciated by the skilled person that the opposite arrangement of the poles is equally suitable when the first magnetic material 13 is a non-magnetised magnetic material. It will also be appreciated by the skilled person that the first magnetic material 13 may instead be the magnetised magnetic material and the second magnetic material 15 may instead be the nonmagnetised magnetic material. In some embodiments, an alternative underlayment 32 as shown in figure 6 is provided instead of the underlayment 12 shown in figures 1 and 2. As shown in figure 6, the alternative underlayment 32 comprises a first layer 34 of sponge or foam rubber material such as those given as examples above, similar to the first layer 16 of the underlayment 12 shown in figures 1 and 2. The alternative underlayment 32 also similarly has a first surface 36 on one side of the sheet and a second surface 38 on an opposite side of the sheet. Similar to the underlayment 12 shown in figures 1 and 2, the first layer 34 of the alternative underlayment 32 has a generally uniform thickness ranging from 1.5mm to 15mm. In some embodiments, the first layer 34 of the alternative underlayment 32 has a thickness ranging from 4mm to 12mm. In various embodiments, the first layer 34 of the alternative underlayment 32 has and a density ranging from 100kg / m3 to 2000kg / m3. In particular embodiments, the first layer 34 of the alternative underlayment 32 has a density between 500kg / m3 and 1600kg / m3. In particular embodiments, the first layer 34 has a thickness of 2.5mm. In particular embodiments, the first layer 34 has a density of 960kg / m3. The alternative underlayment 32 differs from the underlayment 12 shown in figures 1 and 2 in that instead of a separate layer, the first magnetic material 13 is disposed within the first layer 34 itself. In particular embodiments, such as that shown in figure 6, the first magnetic material 13 is disposed within the first layer 34 in a region close to the first surface 36. The first magnetic material 13 is disposed within a predetermined depth, which has the effect of concentrating the first magnetic material 13 to the surface (i.e. the first surface 36) that contacts the floor covering 14 (or the alternative floor covering 40 of figure 7) when the flooring assembly 10 is laid. In other embodiments, the first magnetic material 13 of the alternative underlayment 32 may be simply distributed within the first layer 34. In various embodiments, the second surface 38 of the alternative underlayment 32 is generally a flat surface. In some other embodiments, the second surface 38 may be textured with surface features such as corrugations or other patterns. It will also be appreciated by the skilled person that the first surface 36 may be flat or may be similarly textured with surface features. In some embodiments, an alternative floor covering 40 as shown in figure 7 is provided instead of the floor covering 14 shown in figures 1 and 3. As shown in figure 7, the alternative floor covering 40 comprises a cover layer 42 similar to the cover layer 20 shown in figures 1 and 3. The alternative floor covering 40 also similarly has a display side 44 on one side and a contact surface 46 on an opposite side. The alternative floor covering 40 differs from the floor covering 14 shown in figures 1 and 3 in that instead of a separate layer, the second magnetic material 15 is disposed with in the cover layer 42 itself. In particular embodiments, such as that shown in figure 7, the second magnetic material 15 is disposed within the cover layer 42 in a region close to the contact surface 46. The second magnetic material 15 is disposed within a predetermined depth, which has the effect of concentrating the second magnetic material 15 to the surface (i.e. the contact surface 46) that contacts the underlayment 12 (or the alternative underlayment 32 of figure 6) when the flooring assembly 10 is laid. In other embodiments, the second magnetic material 15 of the alternative floor covering 40 may be simply distributed within the cover layer 42. In the embodiments hereinabove, the contact layer 22 of the floor covering 14 is provided as covering the whole of the contact surface 30 of the cover layer 20. However, as will be appreciated by the skilled person, that is not strictly necessary. In that respect, in some embodiments, which are not shown, the contact layer 22 may be patches or strips of any suitable shape or size. For example, the floor covering 14 may have a cover layer 20 in the shape of a square panel and the contact layer 22 may be patches bonded near to the corners of the square. In the embodiments described hereinabove, the underlayment 12, and similarly the alternative underlayment 32, may be in the form of a large sheet and may be additionally supplied in a roll. The floor covering 14, and similarly the alternative floor covering 40, may also be in the form of a large sheet may be additionally supplied in a roll supplied in a roll, or it may be in the form of rigid or flexible tiles or panels. To install the flooring assembly 10, the underlayment 12 may be unrolled first if necessary and laid directly on to a subfloor 100. Once the underlayment 12 is in place, the floor covering 14 may be unrolled first if necessary and laid over the underlayment 12. With the magnetic contact between the underlayment 12 and the floor covering 14, if the floor covering 14 requires replacing due to damage or any other reason, it can be simply detached from the underlayment 12 without the need for any tools and simply replaced with a new floor covering 14. In the embodiments described hereinabove, the first layer 16 of the underlayment 12 and the first layer 32 of the alternative underlayment 34 may be manufactured by first blending a synthetic rubber, such as styrene-butadiene, with oils, blowing agents, and fillers, to create a mixture for the above-mentioned performance characteristics (i.e. density, thermal insulation, acoustic insulation, etc.). This is followed by a calendarizing process in which the mixture is converted into a smooth and consistent paste. The paste is then rolled into a wide, thin sheet, which in turn is rolled onto a chain to produce a desired flat or textured profile. The sheet is then heated at temperatures up to 250°C and blown, cured, and allowed to cool. Finally, it is trimmed, cut, rolled, and wrapped in packaging. In an alternative method, the first layer 16 of the underlayment 12 and the first layer 32 of the alternative underlayment 34 may be manufactured from offcuts or trimmings of polyurethane foam from other processes, or recycled polyurethane foam. The polyurethane form is shredded and then granulated into smaller pieces, then mixed and coated with a binding agent before moulding into a large “log” of a pre-defined density. The log is subjected to steam under high pressure to cure the binding agent and bond the material together. The log is then dried to remove residual moisture and peeled to a pre-defined product thickness. In a lamination process, backing and films are applied, and the underlayment is finished, trimmed, cut, rolled, and wrapped in packaging. The floor covering 14 and alternative floor covering 40 may be manufactured in different ways depending on the materials used for the cover layer 20 or cover layer 42. For example, in embodiments where the cover layer 20 or cover layer 42 is in the form of a floor tile, the cover layer 20 or cover layer 42, and the contact layer 22 or contact layer 42, may be extruded as sheets into desired thicknesses from various suitable materials, such as vinyl compounds, additives, and magnetic materials. The sheet for the cover layer 20 or cover layer 42 is coated and treated in various suitable ways, and a heat and pressure activated adhesive is then applied. The sheets are then heated and pressed to bond them together. As disclosed hereinabove, embodiments of the flooring assembly 10 in accordance with the present invention may be laid on to a subfloor 100 without the use of adhesives or other physical fixtures. It will however be appreciated by the skilled person that this does not limit or preclude the use of adhesives or other physical fixtures. For example, temporary means of fixture such as adhesive tape or pressuresensitive adhesive putty may be used where and when appropriate. Embodiments of the present invention have been described with particular reference to the examples illustrated. However, it will be appreciated that variations and modifications may be made to the examples described within the scope of the appending claims.

Claims

:

1. A flooring assembly (10), comprising:an underlayment (12, 32) having a first layer (16, 34) of a sponge rubber5 material and comprising a first magnetic material (13), adapted to be laid directly on to a subfloor (100); anda floor covering (14, 40) having a cover layer (20, 42) and comprising a second magnetic material (15), adapted to be laid on to the underlayment (12, 32) when laid on the subfloor (100);10 wherein one of the first magnetic material and the second magnetic material isan unmagnetized magnetic material, and the other of the first magnetic material and the second magnetic material is a magnetised magnetic material.

2. The flooring assembly of claim 1, wherein the underlayment (12, 32) is adapted15 to be laid on the subfloor (100) and remain in place without an adhesive or physical fixtures.

3. The flooring assembly of any preceding claim, wherein:the first layer (16) of the underlayment includes a first surface (24) on one side2 0 and a second surface (26) on an opposite side; andthe first magnetic material is provided in a second layer (18) applied to the first surface (24).

4. The flooring assembly of claim 3, wherein the second layer is a film, bonded to2 5 the first surface of the first layer.

5. The flooring assembly of claim 1 or 2, wherein the first magnetic material is disposed within the first layer (34) of the underlayment (32).3 0 6. The flooring assembly of claim 5, wherein:the first layer of the underlayment includes a first surface (36) on one side and a second surface (38) on an opposite side; andthe first magnetic material is disposed within the first layer to a predetermined depth from the first surface (36).

357. The flooring assembly of any preceding claim, wherein:05 06 24the cover layer (20) has a display side (28) on one side and a contact surface(30) on an opposite side; andthe second magnetic material is provided in a contact layer (22) applied the contact surface (30).

58. The flooring assembly of claim 7, wherein the contact layer is a film bonded to the contact surface.

9. The flooring assembly of any one of claims 1 to 6, wherein the second magnetic 10 material is disposed within the cover layer (42) of the floor covering (40).

10. The flooring assembly of claim 9, wherein:the cover layer (42) of the floor covering (40) includes a display side (44) on one side and a contact surface (46) on an opposite side; and15 the second magnetic material is disposed within the cover layer (42) to apredetermined depth into the contact surface (46).

11. The flooring assembly of any preceding claim, wherein the underlayment has a thickness between 1.5mm to 15mm.2012. The flooring assembly of claim 11, wherein the underlayment has a thickness of at least 2.5mm.

13. The flooring assembly of any preceding claim, wherein the underlayment has a2 5 density between 100kg / m3 and 2000kg / m3.

14. The flooring assembly of claim 13, wherein the underlayment has a density between 500kg / m3 and 1600kg / m3.3 0 15. The flooring assembly of claim 14, wherein the underlayment has a density of atleast 960kg / m3.

Images