Flooring tiles for use on stairs and methods of manufacturing the same

Abstract

The present invention relates to flooring tiles 100, in particular luxury vinyl flooring tiles (LVTs) that can easily be laid on stairs101 or staircases, even with bullnoses 107. The tile has body sec

Description

Technical Field The present invention relates to flooring tiles, in particular luxury vinyl flooring tiles (LVTs) that can easily be laid on stairs or staircases, even those with bullnoses or other decorative corners. The tile has body section where there is a wear layer, an image layer and a backing layer, and also one or more flexible sections, in the form of strips with less or no backing layer than the body section. As the flexible sections are less rigid and more pliable than the body section, the flexibles sections are able to wrap around the edge or bullnose of a stair, whilst the body sections retain the ease of laying of a standard tile. The backing layer is also preferably an acoustic layer reducing impact sound. Background Luxury Vinyl Tile (LVT) flooring has become increasingly popular in both residential and commercial settings due to its durability, aesthetic appeal, and ease of installation. LVT is a type of resilient flooring that mimics the appearance of natural materials such as wood, stone, or ceramic tile, while offering superior performance characteristics. It is composed of multiple layers, including a clear wear layer, a printed design or image layer, and a backing layer, which together provide a robust and flexible flooring solution. In some cases an additional core layer is incorporated. A luxury vinyl floor tile typically comprises multiple layers, each serving a specific purpose. The layers may include: • Backing Layer: Typically, the bottommost layer that provides stability, rigidity and dimensional support. • Core Layer: An optional central layer that offers additional rigidity and dimensional stability. • Image Layer: A decorative layer that gives the tile its appearance. • Wear Layer: The topmost layer that protects against wear and tear. Benefits of Laying LVT Tile and Boards LVT flooring offers numerous advantages over traditional flooring materials. One of its primary benefits is its exceptional durability; the wear layer protects against scratches, dents, and stains, making it ideal for high-traffic areas. Additionally, LVT is water-resistant, making it suitable for installation in moisture-prone areas such as kitchensand bathrooms. Its ease of maintenance is another significant advantage; routine cleaning typically requires only sweeping and occasional mopping. Aesthetically, LVT provides a versatile range of design options, allowing consumers to achieve the look of natural wood or stone without the associated cost and maintenance requirements. LVT is also relatively easy to install, with options for glue-down, click-lock, or loose-lay methods, making it accessible for both professional installers and DIY enthusiasts. Furthermore, LVT flooring is often more comfortable underfoot compared to harder surfaces, and it can provide sound insulation, contributing to a quieter environment. Problems with laying LVT on Stairs and Staircases Despite its many benefits, installing LVTflooring on stairs and staircases presents several challenges. The primary issue is the difficulty in achieving a secure and aesthetically pleasing fit around the edges and nosing of each step. Traditional LVT tiles and boards are typically designed for flat surfaces, and their relative lack of flexibility can make it challenging to wrap them neatly around the contours of a staircase without gaps or lifting. Another problem is ensuring the durability of the flooring on stairs, which experience concentrated foot traffic and impact. The edges of LVT tiles and boards can be prone to wear and damage when subjected to the repeated pressure of footfalls, especially at the nosing of stairs. Additionally, achieving a consistent look and feel across both the treads and risers of the staircase can be difficult, as the dimensional requirements differ from those of flat flooring surfaces. Further, the installation process for LVT on stairs can be more labour-intensive and timeconsuming compared to flat surfaces. Precision cutting and fitting are required to ensure each piece conforms to the shape of the stairs, and additional adhesives or fasteners may be necessary to secure the flooring in place, further complicating the installation process. Separate pre-shaped nosing pieces are often required, adding to the cost and time taken for installation. In summary, while LVT flooring offers numerous benefits for flat surfaces, its application on stairs and staircases poses unique challenges. It would be beneficial to provide a flooring tile, particularly a luxury vinyl flooring tile, which obviates or mitigates one or more of the problems associated with the prior art. Summary of Invention According to the present invention there is provided a tile for use on stairs and staircases which comprises: a wear layer; a backing layer; and an image layer disposed between the wear layer and the backing layer, characterised in that the tile has a body section where the backing layer is provided at a first thickness, and at least one flexible section where the backing layer is either provided at a significantly reduced thickness compared to the first thickness or the backing layer is not present. Preferably the tile is a flooring tile. Most preferably the tile is a Luxury Vinyl Tile (LVT). Advantageously, the body section can be laid easily on the tread of a stair, however by providing at least one flexible section of the tile where the backing layer is not present or only present at a reduced thickness the flexible section has more flexibility that the body section and can be wrapped around the edge or a bullnose of a stair providing a seamless and secure fit. In other words, the body section has sufficient backing layer to provide structural rigidity such that it retains a substantially planar conformation during the laying process (it retains the ability to resist moderate bending) andean easily be placed on a stair tread; and the flexible section, with less or no backing layer, is less rigid and more pliable than the body section which allows the flexible section to wrap around the edge or bullnose of a stair. The flexible section of the tile is designed to have more flexibility compared to the body sections which contain more backing material and are therefore more rigid than the flexible sections. The one or more flexible sections allows the tile to conform to the shape of an edge, such as a bullnose on a stair, while the body of the tile remains structurally robust, which the body section retains the more rigid planar structural integrity of a traditional tile which is easy to lay. This design ensures that the tile can adapt to various shapes and surfaces without compromising its overall strength and durability. The flexible section enhances the tile's versatility and practicality making it easier to apply to a staircase without requiring elevated levels of skill and physical adaptation of the tile. In summary the body section of the tile has more backing material and is both more rigid / stiff (i.e. able to resist bending forces) and harder (able to resist surface deformation) than the flexible section which bends more easily and will deform more easily. The layers are arranged such that the image layer is disposed between the wear layer and the backing layer. Preferably the wear layer is provided directly on top of the image layer. Preferably the wear lay is the uppermost layer in use. Optionally the wear layer can itself comprise multiple layers. Optionally the depth of the wear layerisO.1 mm to 1.5mm thick. More preferably the wear layer is 0.3mm or greater in thickness. More preferably the wear layer is 0.3mm-1mm thick. Yet more preferably, the wear layer is 0.3mm to 0.7mm thick. Most preferably, the wear layer is 0.5mm to 0.7mm thick. In a preferred embodimentthe wear layer is 0.55mm thick. The appropriate thickness of a wear layer typically correlates to intended usage. Optionally the backing layer can itself comprise multiple layers. Optionally the tile may include a core layer either as part of the backing layer or between the image layer and the backing layer. Preferably, the at least one flexible section is provided as a longitudinal strip spanningthe length (L) of the tile. As the flexible section spans the length of a tile from edge to edge this forms a fold axis and means that the tile itself can bend or conform easily along that length. Most preferably the at least one flexible section is provided as a longitudinal strip spanning the length (L) of the tile and positioned at the edge of the tile. Most preferably the at least one flexible section is provided as a longitudinal strip spanning the length (L) of the tile and positioned at the front edge of the tile. Advantageously as the flexible section is at the longitudinal edge of the tile, effectively the front edge, the tile can be placed on a stair tread and the flexible section easily aligned with the leading edge of a stair. The flexible section can then wrap around the leading edge (which may be a bullnose such that the flexible section simply wraps round and conforms to the shape of the bullnose. Optionally, there is at least one flexible section provided as a lateral strip spanningthe width (W) of the tile. As the flexible section spans the width of a tile from (front) edge to (rear) edge this forms a fold axis and means that the tile itself can bend or conform easily alongthat width. Optionally, a plurality of flexible sections are provided. These may be a combination of one or more longitudinal strips spanning the length (L) of the tile and one or more lateral strips spanningthe width (W) of the tile. In an embodiment that is useful for staircases with one open side, a first flexible section is provided as a longitudinal strip spanning the length (L) of the tile and positioned at the front edge of the tile, and a second flexible section is provided as a lateral strip spanning the width (W) of the tile and positioned at a side edge of the tile. Optionally, and particularly for use for staircases which are open on both sides, a third flexible section is provided as a lateral strip spanning the width (W) of the tile and positioned at the opposite side edge of the tile to the second flexible section. Optionally, when there are a plurality of flexible sections one or more of said flexible sections may join together. Optionally, the flexible section may contain some non-continuous backing material. The flexible sections are strategically placed to ensure ease of installation without compromisingthe tile's overall stability and performance. Optionally, the at least one flexible section is provided as a longitudinal strip spanning the length (L) of the tile and positioned away from the edge of the tile, such that there are two body sections separated by a flexible section. Advantageously, providing two body sections allows the first body section to be fitted to the tread of a stair, the flexible section wraps around the edge or bullnose of the stair, and the second body section can be fitted to the riser below the tread. Preferably the lower surface of the flexible section is provided with an adhesive layer. The adhesive layer may be a continuous adhesive layer or a semi-continuous adhesive layer. Preferably the adhesive layer is covered by a removable protective layer. Advantageously, the protective layer can be peeled away when the tile is ready to be installed. This easy peel feature simplifies the installation process, ensuring that the adhesive remains uncontaminated and effective until the moment of installation. The removable protective layer is engineered to be easily detachable, requiring minimal effort to remove, yet it is robust enough to protect the adhesive layer during transport and handling. Once the protective layer is removed, the adhesive beneath is exposed and ready to firmly adhere to standard floor surfaces, providing a strong and lasting bond. Such adhesives and ‘easy-peel’ protective layers are well-known in the art. Optionally, the body section is provided with an adhesive layer. Again, the adhesive layer may be a continuous adhesive layer or a semi-continuous adhesive layer and preferably is covered by a removable protective layer. Optionally at the boundary between the body section and the flexible section, the backing layer reduces in thickness with a tapered angle. At the boundary between the body section and the flexible section, the backing layer may thin out with a tapered angle effective giving a tapering thickness with an angled reduction. Advantageously this allows for easy wrapping and reduces wear at the boundary between the body section and the flexible section. Optionally, the tapering of the backing layer is provided as a tapering reduction in thickness of the backing layer from the edge of the boundary closest to the body section to the edge of the boundary closest to the flexible section. Alternatively, it could be provided as an undercut where the backing layer is undercut at the boundary. Optionally the backing layer is an acoustic layer. Alternatively, an acoustic layer is provided between the image layer and the backing layer. Alternatively, an acoustic layer is provided on the opposite side of the backing layer to the image layer. Optionally a flexible section may be easily removable such that a user can opt to remove it when laying. Pre-scored areas can be included at the boundary between the body section and the flexible section to allow for easier removal of a flexible section. According to another aspect of the present invention there is provided a method of manufacturing a tile according to the first aspect of the invention comprising obtaining a sheet of tiling material, said tiling material comprising: a wear layer; a backing layer; and an image layer disposed between the wear layer and the backing layer, and removing all or a significant portion of the backing layer from a section of the tiling material to form a flexible section where the backing layer is either provided at a significantly reduced thickness compared to the first thickness or the backing layer is not present. Optionally, after removing all or a significant portion of the backing layer from a section of the tiling material, the tiling material is cut to form a tile shape which comprises a body section where the backing layer is provided at a first thickness, and at least one flexible section where the backing layer is either provided at a significantly reduced thickness compared to the first thickness or the backing layer is not present. Alternatively, prior to removing all or a significant portion of the backing layer from a section of the tiling material, the tiling material is cut to form a tile shape. According to another aspect of the present invention there is provided a method of manufacturing a tile according to the first aspect of the invention comprising: producing a sheet of tiling material by selectively laminating a backing layer only to portions of an upper section of a tile, said upper section comprising an image layer and a wear layer. The resulting tile comprises at least one body section where the backing layer is present at a first thickness, and a flexible section where the backing layer is either provided at a significantly reduced thickness compared to the first thickness or the backing layer is not present. Throughout this application a tile can be any shape of slab or section, such as planks, square tiles, rectangular tiles, or any suitably shaped slab for installation. A tile can be a single unit that gives the visual impression of being multiple units e.g. multiple planks or tiles. Various further features and aspects of the invention are defined in the claims. Unless defined otherwise, all technical and scientific terms used herein have the meaning commonly understood by a person skilled in the art to which this invention belongs. The term ‘stair’ or‘step’ refers to portion of staircase or stairway which permits ascending or descending from one floor to another. It is composed of a tread and a riser. A staircase or stairway is composed of a set of steps. A‘tread’ is the upper, substantially horizontal, portion of a step upon which the foot is placed while ascending or descending a stairway. A ‘riser’ is the vertical portion of a step providing a support to the tread. The term ‘rise’ refers to the vertical distance between two successive tread faces. The term ‘nosing’ is the outer projecting edge of a tread. There are different shapes of nosing including nosing with no overhang where the nosing is substantially flush with the riser, square edge nosing which extends out visibly from the plane of the riser and has a squared off appearance, bullnose or half round nosingwhich extends out visibly from the plane of the riser and has a more round edged appearance. Detailed description To provide a better understanding of the present invention, embodiments will now be described by way of example only and with reference to the following figures in which: Figure 1a is a perspective view from the underside of a tile according to the present invention which is particularly useful on a closed staircase; Figure 1 b is a view of the bottom or underside of the tile of 1 a; Figure 2a is a perspective view from the underside of a tile according to the present invention which is particularly useful on an open staircase; Figure 2b is a view of the bottom or underside of the tile of 2a; Figure 2c is a front side view of the tile of 2a; Figure 3a is a perspective viewfrom the underside of anothertile accordingto the present invention which is particularly useful on the riser of an open staircase; Figure 3b is a view of the bottom or underside of the tile of 3a; Figure 3c is a front side view of the tile of 3a; Figure 4a is a perspective viewfrom the underside of anothertile accordingto the present invention which is particularly useful for the tread and the riser of an open staircase; Figure 4b is a view of the bottom or underside of the tile of 4a; Figure 5a is a perspective viewfrom the underside of anothertile accordingto the present invention which is particularly useful for the tread and the riser of an open staircase; Figure 5b is a view of the bottom or underside of the tile of 5a; A vinyl floor tile 100 accordingto a first embodiment of the present invention is generally depicted in Figures 1 a, 1 b and 1 c. The depicted vinyl floor tile 100 is particularly useful for easy fitting to the tread 102 of a stair 101 of a closed staircase, i.e. a staircase where both sides of each stair 101 are enclosed or boxed in. The upper surface 103 of the vinyl floor tile 100 is designed to be both aesthetically pleasing and functional. It is composed of a wear layer 104 and an image layer 105. In use, the wear layer 104 is the topmost protective layer of the vinyl floor tile 100. It is typically made from a clear, durable material such as polyurethane. The wear layer 104 is responsible for resisting scratches, stains, and general wear, ensuring the vinyl floor tile 100 maintains its appearance over time. The thickness of the wear layer 104 varies depending on the intended use of the tile, with thicker layers offering greater durability for high-traffic areas. The wear layer 104 may be embossed to give a desired surface decoration e.g. to mimic natural woodgrain or the uneven surface of a stone tile. In the depicted embodiment the wear layer is 0.55mm thick and is formed from pure transparent PVC. It would be generally understood that whilst 0.55mm thickness is a preferred thickness the wear layer could be other thicknesses. For example, it is preferred that the wear layer 104 is greater than 0.3mm deep to provide an appropriate level of protection for most flooring uses, and more preferably the wear layer is 0.3mm-1.0mm thick to give a balance between durability and flexibility. Preferably, the wear layer is 0.3mm to 1.0mm thick. More preferably, the wear layer is 0.5mm to 1.0mm thick. Yet more preferably, the wear layer is 0.5mm to 0.7mm thick. The wear layer may incorporate an upper coating as a sub-layer. Beneath the wear layer 104 lies the image layer 105, which provides the visual appeal of the vinyl floor tile 100. The image layer 105 is a high-resolution printed film that replicates the look of a natural material such as wood, stone, or ceramic. The quality and detail of the image layer 105 are important in achieving a realistic appearance. Typically, the wear layer 104 is present as a continuous layer across the full surface area of the image layer 105, and of the vinyl floor tile 100. In the depicted embodiment the image layer is 0.07mm thick and is formed from PVC film. This is a preferred thickness for this layer. The lower surface of vinyl floor tile 100 comprises the backing layer 106. Here the backing layer 106 is positioned on the opposite side of the image layer 105 than the wear layer 104. In this embodiment the backing layer 106 is made from PVC, however it will be understood that the backing layer 106 may be made from other materials such as fiberglass, a combination of PVC and fibreglass, filler (stone powder), plasticisers or optionally another composite. The backing layer 106 may itself consist of multiple sublayers for added functionality. The backing layer 106 can act to provide stability and support to vinyl floor tile 100 and increases the rigidity of the vinyl floor tile 100 where it is present. The backing layer 106 also assists in keeping the vinyl floor tile 100 remains flat and secure once installed. In some cases, the backing layer may include additional sub-layers, such as an acoustic layer to reduce sound transmission or a moisture barrier to prevent water damage. The backing layer is typically 2-4.5mm in thickness on the body section. It is also preferred that the backing layer will is an an acoustic backing with a range of optional properties. In this embodiment the backing layer reduces impact noise by 16db. Preferably the backing layer is recyclable. Preferably the backing layer is formed from recycled materials. Preferably the tile is recyclable. Preferably the tile is formed from recycled materials. The body section of the vinyl floor tile 100 has the image layer 105 between the wear layer 104 and a backing layer 106, the backing layer 106 being of a first depth that is substantially the same of greater across the entire body section of the vinyl floor tile 100). Importantly, the backing layer 106 is absent from a section of the vinyl floor tile 100. The backing layer 106 is absent from a longitudinal strip that extends from edge to edge and along the entire front length (L) of the vinyl floor tile 100. This longitudinal strip or section forms a flexible area where only the upper surface 103 is present (i.e. the flexible section has only the wear layer 104 and image layer 105) making it more flexible and pliable than the body section of the vinyl floor tile 100 where the wear layer 104, the image layer 105 and the backing layer 106 are all present). As can be seen more clearly in figure 6, in use, the vinyl floor tile 100 is positioned such that the body section of the vinyl floor tile 100 is laid on the tread 102 of a stair 101. As it is more pliable and flexible than the body section, the flexible section of the vinyl floor tile 100 can then be wrapped around the nose 107 of the stair 101. In this embodiment, the underside of the vinyl floor tile 100 is provided with an adhesive layer. This could be in the form of a tape adhesive layer, a contact spray adhesive or any other appropriate adhesive layer known in the art. To ensure easy installation, the underside of the vinyl floor tile 100 is equipped with a strong adhesive layer. This adhesive layer is formulated to provide a secure bond, ensuring that the tile remains firmly in place once applied as a floor covering. For added convenience during transportation and handling, a removable barrier layer covers the adhesive. This barrier layer can be effortlessly peeled off just before fitting the tile, thereby exposing the adhesive and allowing for precise placement. The adhesive's strength and the ease of removing the barrier layer make this vinyl floor tile an ideal choice for both professional installers and DIY enthusiasts. Whilst the above embodiment describes a vinyl floor tile 100 where the backing layer 106 is absent from a section of the vinyl floor tile 100 that forms the flexible layer, an alternative embodiment is envisaged where the backing layer is present but is provided at a significantly reduced depth when compared to the body section. Typically, the backing layer 106 is at least 50% less thick in the flexible section than in the body section and preferably the backing layer 106 is at least 75% less thick in the flexible section than in the body section. As such the body section remains more structurally rigid than the flexible layer. For example, the backing layer on the body section is typically, up to 45.mm, more typically 2.0mm-4.5mm, in thickness, and would by 50% or less of that thickness on the flexible section if present at all. Another embodiment of a vinyl floor tile 200 is depicted in figure 2a, 2b and 2c. The depicted vinyl floor tile 200 is particularly useful for easy fitting to the tread 102 of a stair 101 of an open staircase, i.e. a staircase where both sides of each stair 101 are open and on view. The upper surface 103 is formed in substantially the same way as in the embodiment described above. Again, body section of the vinyl floor tile 200 has the image layer 105 between the wear layer 104 and a backing layer 106, the backing layer 106 being of a first depth that is substantially the same of greater across the entire body section of the vinyl floor tile 200). The backing layer 106 is again absent from a section of the vinyl floor tile 200. In this embodiment the backing layer 106 is again absent from a longitudinal strip that extends from edge to edge and along the entire front length (L) of the vinyl floor tile 200. However, the backing layer 106 is also absent from two lateral strips that extend from edge to edge and along the left side width (W) and along said right side width of the vinyl floor tile 200. These sections where the backing is not present form flexible areas where only the upper surface 103 is present (i.e. the flexible sections have only the wear layer 104 and image layer 105) making them more flexible and pliable than the body section of the vinyl floor tile 100 where the wear layer 104, the image layer 105 and the backing layer 106 are all present). In use, the vinyl floor tile 200 is positioned such that the body section of the vinyl floor tile 200 is laid on the tread 102 of a stair 101. As it is more pliable and flexible than the body section, the front longitudinal flexible section of the vinyl floor tile 200 can then be wrapped around the nose 107 of the stair 101, and the lateral side sections can similarly be wrapped around the sides of the stair which may also have bullnose type protruding edges. In this embodiment, the underside of the flexible section of vinyl floor tile 200 is provided with an adhesive layer (the adhesive could be applied to the underside of the body also). A removable barrier layer covers the adhesive. This barrier layer can be effortlessly peeled off just before fitting the tile. Alternatively, contact spray adhesive can be used Another embodiment of a vinyl floor tile 300 is depicted in figure 3a, 3b and 3c. The depicted vinyl floor tile 300 is particularly useful for easy fitting to the riser 109 of a stair 101 of an open staircase, i.e. a staircase where both sides of each stair 101 are open and on view. The upper surface 103 is formed in substantially the same way as in the embodiment described above. Again, body section of the vinyl floor tile 300 has the image layer 105 between the wear layer 104 and a backing layer 106, the backing layer 106 being of a first depth that is substantially the same of greater across the entire body section of the vinyl floor tile 300). The backing layer 106 is again absent from a section of the vinyl floor tile 300. In this embodiment the backing layer 106 is absent from two lateral strips that extend from edge to edge and along the left side width (W) and along said right side width (W) of the vinyl floor tile 300. These sections where the backing is not present form flexible areas where only the upper surface 103 is present (i.e. the flexible sections have only the wear layer 104 and image layer 105) making them more flexible and pliable than the body section of the vinyl floor tile 300 where the wear layer 104, the image layer 105 and the backing layer 106 are all present). In use, the vinyl floor tile 300 is positioned such that the body section of the vinyl floor tile 300 is applied to the riser 109 of a stair 101. As they are more pliable and flexible than the body section, the lateral flexible sections of the vinyl floor tile 300 can then be wrapped around the sides of the stair 101, which may also have bullnose type protruding edge profiles. Another embodiment of a vinyl floor tile 400 is depicted in figure 4a and 4b. The depicted vinyl floor tile 400 is particularly useful for easy fitting to the tread 102 and riser 109 of a stair 101 of an open staircase, i.e. a staircase where both sides of each stair 101 are open and on view. The upper surface 103 is formed in substantially the same way as in the embodiments described above. Again, body section of the vinyl floor tile 400 has the image layer 105 between the wear layer 104 and a backing layer 106, the backing layer 106 being of a first depth that is substantially the same of greater across the entire body section of the vinyl floor tile 400). The backing layer 106 is again absent from a section of the vinyl floor tile 400. In this embodiment the backing layer 106 is absent from two lateral strips that extend from edge to edge and along the left side width (W) and along said right side width (W) of the vinyl floor tile 400 as well as a large front section in the form of a broad longitudinal strip sized to cover the surface area of a riser 109. These sections where the backing is not present form flexible areas where only the upper surface 103 is present (i.e. the flexible sections have only the wear layer 104 and image layer 105) making them more flexible and pliable than the body section of the vinyl floor tile 400 where the wear layer 104, the image layer 105 and the backing layer 106 are all present). In use, the vinyl floor tile 400 is positioned such that the body section of the vinyl floor tile 400 is applied to the tread 102 of a stair 101. As they are more pliable and flexible than the body section, the lateral flexible sections of the vinyl floor tile 400 can then be wrapped around the sides of the stair 101, which may also have bullnose type protruding edge profiles. The large front longitudinal flexible section of the vinyl floor tile 400 can then be wrapped around the nose 107 of the stair 101 and extend down and cover the surface of the riser 109 of the stair 101. It would be appreciated that the tile 400 can easily be converted for use on a closed staircase by removing (or manufacturing without) the lateral flexible sections of the vinyl floor tile 400. Another embodiment of a vinyl floor tile 500 is depicted in figure 5a and 5b. The depicted vinyl floor tile 500 is particularly useful for easy fitting to the tread 102 and riser 109 of a stair 101 of an open staircase, i.e. a staircase where both sides of each stair 101 are open and on view. The upper surface 103 is formed in substantially the same way as in the embodiments described above. Again, body sections of the vinyl floor tile 500 has the image layer 105 between the wear layer 104 and a backing layer 106, the backing layer 106 being of a first depth that is substantially the same of greater across the entire body section of the vinyl floor tile 500). The backing layer 106 is again absent from a section of the vinyl floor tile 500. In this embodiment the backing layer 106 is absent from two lateral strips that extend from edge to edge and along the left side width (W) and along said right side width (W) of the vinyl floor tile 500 as well as from more centrally located longitudinal strip 103a. This effectively forms two body sections with a longitudinal flexible section in the form of more centrally located longitudinal strip 103a therebetween. These sections where the backing is not present form flexible areas where only the upper surface 103 is present (i.e. the flexible sections have only the wear layer 104 and image layer 105) making them more flexible and pliable than the body section of the vinyl floor tile 500 where the wear layer 104, the image layer 105 and the backing layer 106 are all present). In use, the vinyl floor tile 500 is positioned such that a first body section of the vinyl floor tile 500 is applied to the tread 102 of a stair 101 and a second body section of the vinyl floor tile 500 is applied to the riser 109 of a stair 101. The more centrally located longitudinal strip 103a of the vinyl floor tile 500 allows the tile to bend around the nose of the stair and easily conforms to the shape of a bullnose if it is present. In this embodiment there is also an optional additional front flexible strip (shown in fig 5a in dashed lines). This front strip can be easily removed if not required when laying the tile 500. To assist with removal, the boundary between the body section and the front strip can be pre-scored with either a fold or, more preferably, a line of perforations. In the above embodiments the underside of the vinyl floor tile 100, 200, 300, 400, 500 is the underside of the vinyl floor tile 100, 200, 300, 400, 500 is provided with an adhesive layer. This adhesive layer is formulated to provide a secure bond, ensuring that the tile remains firmly in place once applied as a floor covering. For added convenience during transportation and handling, a removable barrier layer covers the adhesive. This barrier layer can be effortlessly peeled off just before fitting the tile, thereby exposing the adhesive and allowing for precise placement. It would however be understood that the adhesive layer may not be present or may be present only on portions of the underside of the vinyl floor tile 100,200,300,400,500, for example only on the underside of the flexible sections. In addition, whilst the above embodiments describe a vinyl floor tile 100, 200, 300,400, 500 where the backing layer 106 is absent from a section to form the flexible layer, alternative embodiments of each of the above are envisaged where the backing layer is present on the flexible sections but is provided at a significantly reduced depth when compared to the body section. Typically, the backing layer 106 is at least 50% less thick in the flexible section than in the body section and preferably the backing layer 106 is at least 75% less thick in the flexible section than in the body section. As such the body section remains more structurally rigid than the flexible layer. In any of the above embodiments additional layers such as core layers may be included. Such additional layers include core layers that are provided between the backing layer and the image layer. A core layer, if present on the tile, may be omitted from the flexible section to leave only the upper layer (wear layer and image layer) or it may be present on the flexible section providing that it allows for appropriate flexibility of the flexible section compared to the body section. The edges of a floor tile in any of the above embodiments can be designed to facilitate easy installation and alignment. Some tiles feature bevelled or micro-bevelled edges, which create a subtle groove between tiles, enhancing the overall appearance and reducing the likelihood of chipping. In particular the edges of a tile which are formed from body section can be engineered to provide bevelled or other shaped edges. In any of the above embodiments, at the boundary between a body section and a flexible section the depth of the backing layer can be tapered such that it reduces from a first larger depth in the body section to a second smaller (or often zero) depth on the flexible section. Methods of manufacture Luxury Vinyl Tile (LVT) is often manufactured using continuous lamination equipment, such as a rotary cutting press machine. This approach involves producing the material in long continuous runs, which are then cut into smaller sections called slabs, and subsequently trimmed into the final product formats like tiles or planks. The continuous method allows for precise control over temperature and pressure. Another widely used manufacturing method involves large presses for laminating the layers, such as a static press. The press method provides greater flexibility compared to continuous lamination but is typically more labour-intensive. The process requires assembling, often manually, slab pieces using pre-cut individual layers and emboss plates before loading them into the press with multiple layers stacked atop one another. Pressure is applied both at the top and bottom of the press, and the material undergoes heating and cooling within one chamberto achieve lamination. Other LVT constructions include Rigid Core variants such as Expanded Polymer Core or Solid Polymer Core (SPC), and Waterproof Core (WPC). These constructions typically feature a core layer along with the wear layer, print, and backing layers. The tiles of the present invention may be produced using any of these methods. In one example, to manufacture a vinyl tile, a continuous sheet of tiling material is acquired, the continuous sheet including a wear layer, an image layer, and backing layer. The sheet is produced using continuous lamination equipment such as a rotary cutting press machine, allowing precise control over temperature and pressure. The continuous sheet is then cut into smaller sections called slabs, which are subsequently trimmed into the final product formats such as tiles or planks. To form a flexible section, all or a significant portion of the backing layer is removed from a designated section of the tiling material. This can be accomplished by either removing the backing layer entirely from the flexible section or by providing the backing layer at a significantly reduced thickness compared to the first thickness. Typically, the backing layer is at least 50% less thick in the flexible section than in the body section, and preferably at least 75% less thick. It would be understood that the continuous sheet of tiling material could have been obtained by any appropriate means. It would also be understood that all or a significant portion of the backing layer could be removed from designated sections before the continuous sheet is cut into slabs In another example, the flexible sections in the tiling material are formed by selectively laminating a backing layer only to designated portions of the upper section of a tile. This upper section includes an image layer and a wear layer. The selectively laminated portions become the body section of the tile, while the areas where the backing layer is not applied become the flexible sections. To manufacture such a tile, a continuous sheet of tiling material is first produced, comprising the wear layer and image layer. Using machinery, such as a rotary cutting press, the continuous sheet is processed to ensure uniformity and consistency in the upper layers. The next step involves selectively applying the backing layer to specific sections of the continuous sheet. This selective lamination can be achieved using lamination equipment that allows for precise control over the application of the backing layer, ensuring that it adheres only to the designated portions. Once the backing layer is selectively laminated, the continuous sheet is cut into smaller sections, referred to as slabs, which are then further trimmed into the final product formats like tiles or planks. This method allows for the production of tiles with flexible sections without the need for additional steps to remove the backing layer, thereby streamlining the manufacturing process and reducing production costs. All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and / or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and / or steps are mutually exclusive. Each feature disclosed in this specification (including any accompanying claims, abstract and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features. The invention is not restricted to the details of the foregoing embodiment(s). The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed. With respect to the use of substantially any plural and / or singular terms herein, those having skill in the art can translate from the plural to the singular and / or from the singular to the plural as is appropriate to the context and / or application. The various singular / plural permutations may be expressly set forth herein for sake of clarity. It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims are generally intended as “open” terms (e.g., the term “including” or “comprising” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases "at least one" and "one or more" to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles "a" or "an" limits any particular claim containing such introduced claim recitation to embodiments containing only one such recitation, even when the same claim includes the introductory phrases "one or more" or "at least one" and indefinite articles such as "a" or "an" (e.g., “a” and / or “an” should be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should be interpreted to mean at least the recited number (e.g., the bare recitation of "two recitations," without other modifiers, means at least two recitations, or two or more recitations). It will be appreciated that various embodiments of the present disclosure have been described herein for purposes of illustration, and that various modifications may be made without departing from the scope of the present disclosure. Accordingly, the various embodiments disclosed herein are not intended to be limiting, with the true scope being indicated by the following claims.

Claims

1. A tile for use on stairs and staircases which comprises:a wear layer;a backing layer; andan image layer disposed between the wear layer and the backing layer, characterised in that the tile has a body section where the backing layer is provided at a first thickness, and at least one flexible section where the backing layer is either provided at a reduced thickness compared to the first thickness or the backing layer is not present and wherein at least one flexible section is adapted and sized to be wrapped around the nose of a stair and conform to the shape of a bullnose.

2. A tile as in Claim 1 which is a flooring tile.

3. A tile as in any of claims 1 or 2 wherein the image layer is disposed between the wear layer and the backing layer.

4. A tile as in any of the previous claims wherein the wear layer is provided directly on top of the image layer and is the uppermost layer in use.

5. A tile as in any of the previous claims wherein the wear layer itself comprises multiple sub-layers.

6. A tile as in any of the previous claims wherein the depth of the wear layer is 0.3mm-1 mm thick, and preferably the wear layer is 0.55mm thick.

7. A tile as in any of the previous claims wherein the backing layer itself comprises multiple sub-layers.

8. A tile as in any of the previous claims wherein the tile includes a core layer either as part of the backing layer or between the image layer and the backing layer.27 06 259. A tile as in any of the previous claims wherein the at least one flexible section is provided as a longitudinal strip spanning the length (L) of the tile.W.Atile as in any of the previous claims wherein the at least one flexible section is provided as a longitudinal strip spanning the length (L) of the tile and positioned at the edge of the tile.

11. A tile as in any of the previous claims wherein at least one flexible section is provided as a lateral strip spanning the width (W) of the tile.

12. A tile as in any of the previous claims wherein a plurality of flexible sections are provided.

13. A tile as in any of the previous claims wherein a first flexible section is provided as a longitudinal strip spanning the length (L) of the tile and positioned at the front edge of the tile, and a second flexible section is provided as a lateral strip spanning the width (W) of the tile and positioned at a side edge of the tile.

14. A tile as in any of the previous claims wherein when there are a plurality of flexible sections one or more are conjoined.

15. A tile as in any of the previous claims wherein the at least one flexible section is provided as a longitudinal strip spanning the length (L) of the tile and positioned away from the edge of the tile, such that there are two body sections separated by a flexible section.

16. A tile as in any of the previous claims wherein the lower surface of the flexible section is provided with an adhesive layer.

17. A tile as in any of the previous claims wherein the lower surface of the body section is provided with an adhesive layer.27 06 2518. A tile as in claims 16 or 17 wherein the adhesive layer is covered by a removable protective layer.

19. A tile as in any of the previous claims wherein at the boundary between the body section and the flexible section, the backing layer reduces in thickness with a tapered angle.

20. A tile as in any of the previous claims which contains an acoustic layer.21 .A method of manufacturing a tile according to any of claims 1 to 20 comprising obtaining a sheet of tiling material, said tiling material comprising:a wear layer;a backing layer; andan image layer disposed between the wear layer and the backing layer, and removing all or a significant portion of the backing layer from a section of the tiling material to form a flexible section where the backing layer is either provided at a significantly reduced thickness compared to the first thickness or the backing layer is not present and where the flexible section is adapted and sized to be wrapped around the nose of the stair and conform to the shape of a bullnose.

22. A method of manufacturing a tile as in Claim 21 wherein, after removing all or a significant portion of the backing layer from a section of the tiling material, the tiling material is cut to form a tile shape which comprises a body section where the backing layer is provided at a first thickness, and at least one flexible section where the backing layer is either provided at a significantly reduced thickness compared to the first thickness or the backing layer is not present.

23. A method of manufacturing a tile as in Claim 21 wherein, prior to removing all or a significant portion of the backing layer from a section of the tiling material, the tiling material is cut to form a tile shape.

24. A method of manufacturing a tile accordingto Claims 1 to 20 comprising: producing a sheet of tiling material by selectively laminating a backing layer only to portions of an upper section of a tile, said upper section comprising an image layer and a wear layer.27 06 25

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