Flooring system

Abstract

A flooring system 2 comprising: a plurality of tile members 8, with a lower layer 4 including polymer and / or rubber layer and a magnetic material. The lower layer may include a polymer or a polymeric

Description

The present invention relates to a system, including apparatus and method of use of the same, for constructing a floor or similar surface on which items are placed or moved. Although the following description refers to interior floor surfaces comprising tiles formed primarily from porcelain or ceramics, the skilled person will appreciate that the present system can be used for other types of tiles and is not limited to porcelain or ceramic tiles. Tiled floors, whether the tiles are formed of ceramic, porcelain, natural stone, or reconstituted compositions, are a popular choice in homes and commercial spaces. The advantages of tiles are: Durability — with a high resistance to wear and tear tiles, especially porcelain and natural stone, are highly durable and can withstand heavy foot traffic, making them ideal for high-use areas like kitchens, bathrooms, and hallways. Many tiles are resistant to scratches and stains, keeping them looking new for longer. Porcelain tiles are especially good for this. Low Maintenance - Tiles can be easily cleaned with a mop, broom, or vacuum. They don't hold onto dirt, dust, or pet hair, making them a good option for those with allergies. Tiles, especially porcelain and ceramic, are highly resistant to water and moisture, making them perfect for bathrooms, kitchens, and other moisture-prone areas. Aesthetic Variety —Tiles come in a vast array of colours, designs, textures, and finishes. They can mimic natural materials like wood or stone, giving homeowners a wide variety of design options. Tiles can also be arranged in various patterns, including mosaics, herringbone, and other unique layouts to achieve a customized look. Hypoallergenic - Tiles do not harbour dust mites, pollen, or other allergens like carpets do, making them a good option for people with allergies. Energy Efficiency - Tiles, especially stone, have thermal mass, meaning they absorb and store heat during the day and release it at night. This helps regulate indoor temperatures and can reduce heating costs in colder climates. Also tiles conduct heat well, making them ideal for use with underfloor heating systems. However, the main disadvantages of floors formed from tiles are that they are noisy and cold as a result of the relatively hard surface. Tiles, particularly ceramic and stone, can feel cold underfoot, especially in winter. Without underfloor heating, this can make tiled areas uncomfortable in colder climates. Furthermore, whilst durable, the tiles are very hard, with no cushioning effect and which can lead to the same being uncomfortable for standing on over longer periods of time and can cause injury if something is dropped or if someone falls onto the tiled surface. Also, the formation of the tiled floors involves a relatively labour intensive installation process as tile installation requires specialized tools and expertise, especially for cutting, levelling, and grouting. This can increase the cost of installation, particularly if the subfloor beneath the tiles needs levelling, insulating or repairs. In addition, installing tiles takes time, including preparation, setting the tiles, and allowing time for adhesive and grout to dry. The lines of grout which are present between adjacent tiles can also be prone to staining, cracking, or discoloration over time, requiring periodic cleaning or resealing to maintain their appearance. Unsealed grout can also absorb moisture, leading to mould growth. Also, repairs can be expensive and, while tiles are durable, if they do crack or chip, repairs and / or replacement can be difficult and / or can be difficult to achieve in a visually effective manner. Alternatively if no grout or tile adhesive is used conventionally, the use of tiles alone can mean that the weight of the tile itself is not enough to hold it down in position and there can be serious potential issues with this such as the tiles could be lifted by a person or persons which means they can be vandalised, stolen, or in extreme circumstances, used as weapons. It is therefore an aim of the present invention to provide a tile flooring system that addresses the abovementioned problems. In a first aspect of the invention there is provided A flooring system comprising a plurality of tile members, a lower layer including a polymer and / or rubber layer and a magnetic material. In one embodiment the magnetic foil is a flexible metallic foil. Preferably the lower layer comprises a polymer or polymeric layer. Typically the polymeric layer includes polyurethane. Further typically the polyurethane is foamed and / or is a cellular polyurethane. In one embodiment the polymeric layer includes a further polymer bound in polyurethane. In one embodiment the further polymer is rubber. In one embodiment the lower layer includes Regupol™. Typically the Regupol™ is a polyurethane based polymer. Further typically the lower layer includes cork granules. Typically the lower layer is constructed from recycled materials. Further typically the lower layer includes recycled polyurethane and cork granules. In one embodiment the lower layer includes recycled tyre crumb. In one embodiment the lower layer comprises ethylene propylene diene terpolymer (EPDM). In one embodiment the lower layer comprises recycled EPDM. Typically the EPDM is charged with mineral fibres. In one embodiment the lower layer has a specific gravity of around 2,000 kg / m3. Typically the lower layer is at or around 2-5 mm in thickness. Further typically the lower layer is at least 3mm thick. In one embodiment the magnetic foil comprises plastoferrite. Typically the plastoferrite is at or around 0.5 mm in thickness. In one embodiment the lower layer comprising the polymer and magnetic foil is at or around 2.5 mm in thickness. In one embodiment the magnetic foil is bonded or applied to the back or inward facing surface of one or more tiles when in position in the flooring system. As such, if the flooring system is used in conjunction with a magnetic subfloor such as a steel or ferrous subfloor, the tiles are magnetically bonded in place. In one embodiment the system includes at least one edge member or trim. Typically the edge or trim member includes plastics or polymer material. Further typically the edge or trim member includes an ABS polymer. Typically the tiles are formed of any or any combination of ceramic, natural stone, or reconstituted stone. Further typically the tiles have a thickness of 5mm to 20mm. Typically the tiles are at least 8mm in thickness. In one embodiment the tile edges include polymer banding. Typically the polymer banding simulates a grout line. Further typically the polymer banding comprises acrylonitrile, butadiene, and styrene (ABS). In one embodiment the banding can be coloured or colour coded as desired. In a second aspect of the invention there is provided a tile with a backing including a metal layer and a backing covering comprising at least one polymeric or rubber layer. Typically the metal layer is provided as a metallic foil. In a third aspect of the invention there is provided a flooring system comprising a plurality of tile members laid upon at least a first lower layer, said lower layer including a polymeric and / or cork layer. Preferably the system includes a lower metallic and / or magnetic layer. In a further aspect of the invention there is provided a method of laying a flooring system comprising a plurality of tile members, at least a first lower layer, said lower layer including a polymer and / or rubber and / or cork layer and a magnetic material. Preferably the magnetic foil is more flexible and / or less rigid than the tile and / or polymer and / or cork of the lower layer. Preferably the system is laid upon a subfloor such as a raised floor. Typically the system is laid upon raised metal access floors. Typically the said lower layer is positioned intermediate the tiles and the sub floor. Specific embodiments of the invention are now described with reference to the following figures wherein: Figure 1 shows a view of a floor system in accordance with one embodiment of the invention. The present invention provides a solution to allow for the creation for a flooring system in an effective manner and is of particular use in the dry laying of porcelain tile flooring on raised metal access floors as will now be described. Raised access floors formed of metal are known and the current invention allows full future accessibility to the void space under the floor even when the tiles are in position. In accordance with the invention a magnetic backing material is typically applied to the underside of the tiles which hare to be laid and typically an ABS banding of a selected colouring is applied to the tile edges. The particular colouring can be selected to match the visual effect desired by the end customer and / or installer and the banding is provided so as to simulate the lines of grout which would conventionally be visibly apparent in a conventional tiling system. However in accordance with the invention. The provision of the magnetic backing material and strong magnetic adhesion with the metal formed access floor or subfloor onto which the tiles are applied ensure that the retention of the tiles in position achieves the same or similar performance as would traditional “wet” laid floor using tile adhesive and grout. The system and process of the present invention can be applied to any tile, and in particular a rectangular or square shaped and also including tiles with visual effects thereon, such as porcelain tiles including wooden plank effects. In accordance with the invention the system can be laid without any adhesive or grout and is thus a cleaner process than conventional systems, thus reducing installation times by around 80% with the added benefit that the floor is immediately usable. A further benefit is the ability to easily replace damaged tiles or to remove the floor completely for reuse elsewhere as the tiles can be removed from the floor or sub floor by overcoming the magnetic attraction strength between the magnetic material on the tile and the floor or sub floor onto which the tiles are placed. However, while the use of the magnetically attractive material alone can be effective, in certain cases and depending on certain tile types, a magnetically attractive material alone cannot be used as, particularly porcelain tiles, are normally manufactured with a bow on them of perhaps 2-3mm on some types and sizes due to the high temperature kiln firing process which is used. To avoid this problem in the current invention the flooring system includes a composite surface including first lower layer which, in this embodiment is a soft rubber compound of a depth which is selected so as to compensate at the contact face of the said lower layer onto the floor or sub-floor for any of the bowing of the tile surface on the opposing side of the said lower layer. The depth of the lower layer will therefore depend on the thickness and bow of tile which is typically already known for the specific type of tile which is to be used and so compensates for the bowing. This therefore avoids the likelihood of the tiles becoming damaged by stress cracking in most circumstances. Turning to figure 1 there is illustrated a cross section through a flooring system 2 in accordance with one embodiment of the invention. In this embodiment the flooring system 2 includes tiles 8 provided with a lower or backing 4 layer of 2mm thick rubber charged by mineral fibres to grant it a relatively high specific gravity —2.000 kg / m3. The flooring system is essentially silent in terms of the noise created by a person walking over the same or article being moved across the same in comparison to convention flooring systems including tiles due to the provision of the lower or backing layer. This provides very high soundproofing, and grip effect to the laying level; non-toxic, odourless. Temperature between -30°C and + 70°C. An additional flexible magnetic foil 6 is provided which may in one embodiment be of a thickness of 60.5 mm thick and in one embodiment is made of plastoferrite, composed of a mixture of rubber and ferrite, with 430 gauss readings in contact, and a force of 0.18 G x cm2 on the ground, total thickness 2.5 mm. Edging components 10 may also be provided to further enhance the appearance and / or effectiveness of the tiling system. In a further embodiment of the invention the flooring system includes the backing layer 4 for the tiles and which allows the tiles to be laid on non-metallic floors or subfloors such as those formed by concrete for example. This variant requires a surface substantially free of protrusions and to be relatively smooth to be prepared, such as can be achieved using a free flow Anhydrite screed. It also offers the same benefits as the first embodiment in terms of speed of laying the tiles and the ease of removal and reuse of the tiles and reduced noise of the flooring system when in position, thus making this an attractive solution for numerous applications.

Claims

1. A flooring system comprising a plurality of tile members, a lower layer including a polymer and / or rubber layer and a magnetic material.

2. A system according to claim 1 wherein the lower layer includes a polymer or polymeric layer.

3. A system according to claim 2 wherein the polymeric layer includes polyurethane.

4. A system according to claim 3 wherein the polyurethane is foamed and / or cellular polyurethane.

5. A system according to claim 2 wherein the lower layer includes a further polymer bound in polyurethane.

6. A system according to any of the preceding claims wherein the lower layer includes Regupol ™.

7. A system according to any of the preceding claims wherein the lower layer includes cork granules.

8. Apparatus according to any of the preceding claims wherein the lower layer is constructed from materials whereby at least some of which are recycled.

9. A system according to claim 9 wherein the lower layer includes recycled polyurethane and cork pieces or granules.

10. A system according to claim 8 or 9 wherein the lower layer includes recycled tyre crumb.

11. A system according to any of the preceding claims wherein the lower layer comprises ethylene propylene diene terpolymer (EPDM).

12. A system according to claim 11 wherein the lower layer EPDM is recycled.

13. A system according to any of claims 11 and 12 wherein the EPDM is charged with mineral fibers.

14. A system according to any of the preceding claims wherein the lower layer has a specific gravity of around 2000kg per m215. A system according to any of the preceding claims wherein the lower layer is between 2-5mm in thickness.

16. A system according to any of the preceding claims wherein the magnetic material is a foil.

17. A system according to any of the preceding claims wherein the magnetic foil is bonded or applied to the back or inward facing surface of one or more of said tiles.

18. A system according to any of the preceding claims wherein, when laid on a steel or ferrous subfloor, the tiles are magnetically bonded in place by the magnetic attraction between the said subfloor and magnetic foil.

19. A system according to any of the preceding claims wherein the system includes at least one edge member or trim.

20. A system according to any of the preceding claims wherein the tiles are formed of ceramic material, porcelain,natural stone or reconstituted stone and of a thickness of between 5-20mm.

21. A tile with a lower or backing layer comprising a magnetic material and at least one polymeric or rubber layer.

22. A flooring system comprising a plurality of tile members laid upon at least a first lower layer, said lower layer including a polymeric and / or cork layer.

23. A system according to claim 22 wherein the lower layer includes a magnetic material.

24. A system according to any of claims 22 and 23 wherein the tile members includes edge trims or members.

25. A system according to any of claims 22-24 wherein the system includes a raised metal access floors onto which the tiles are laid and retained.

26. A method of laying a flooring system comprising a plurality of tile members, at least a first lower layer, said lower layer including a polymer and / or rubber and / or cork layer and a magnetic material.

27. A method according to claim 26 wherein the magnetic foil is flexible and less rigid than the tile and / or polymer and / or cork of the lower layer.

28. A method according to any of claims 26-27 wherein the method includes the laying of the flooring system on a floor or subfloor formed of a magnetically attractive material so that the magnetic attraction with the foil bonds the tiles in position.A

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