# US 11,339,576 B2 · Floor element for forming a floor covering and a floor covering

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- Number: US 11,339,576 B2
- Document ID: US11339576B2
- Status: Granted
- Kind: B2
- Application number: 16/573,138
- Filed: 2019-09-17
- Published: 2021-03-18
- Granted: 2022-05-24
- Earliest claimed: 2019-09-17
- Assignees: Daltile Corporation
- Applicants: Daltile Corporation
- Inventors: Claudio Caselli; Rahul Patki
- Web page: https://patentgrep.com/patent/US11339576B2

## CPC

- E04F 15/087: {The lower layer being of organic plastic with or without reinforcements or filling materials}
- B32B 3/02: characterised by features of form at particular places, e.g. in edge regions {(non-uniform thickness B32B3/263)}
- B32B 3/06: for securing layers together; for attaching the product to another member, e.g. to a support {, or to another product, e.g. groove/tongue, interlocking}
- B32B 3/08: characterised by added members at particular parts {(layer formed of separate pieces of material which are juxtaposed side-by-side B32B3/14, B32B3/18)}
- B32B 3/30: characterised by a layer formed with recesses or projections, e.g. {hollows, grooves, protuberances, ribs (apertured layer B32B3/266; layer with cavities or internal voids B32B3/26)}
- B32B 5/16: characterised by features of a layer formed of particles, e.g. chips, powder {or granules (layer formed of natural mineral particles B32B19/00; layer being formed of wood fibres, chips or particles B32B21/02)}
- B32B 5/18: characterised by features of a layer {of} foamed material
- B32B 5/26: another layer {next to it} also being fibrous or filamentary {(relative arrangement of fibres or filaments of different layers B32B5/12)}
- B32B 7/12: using interposed adhesives or interposed materials with bonding properties
- B32B 9/002: {comprising natural stone or artificial stone}
- B32B 9/005: {comprising one layer of ceramic material, e.g. porcelain, ceramic tile (layered products with at least two ceramic layers composed mainly of ceramic B32B18/00)}
- B32B 9/041: {of metal}
- B32B 9/045: {of synthetic resin}
- B32B 13/06: of metal
- B32B 15/082: comprising vinyl resins; comprising acrylic resins
- B32B 15/085: comprising polyolefins
- B32B 15/09: comprising polyesters
- B32B 15/092: comprising epoxy resins
- B32B 15/095: comprising polyurethanes
- B32B 15/16: next to a particulate layer
- B32B 15/18: comprising iron or steel {(B32B15/011, B32B15/012 and B32B15/013 take precedence)}
- B32B 15/20: comprising aluminium or copper {(B32B15/016 and B32B15/017 take precedence)}
- B32B 17/10: of synthetic resin
- B32B 18/00: Layered products essentially comprising ceramics, e.g. refractory products
- B32B 27/065: {of foam}
- B32B 27/20: using fillers, pigments, thixotroping agents
- B32B 27/22: using plasticisers
- B32B 27/30: comprising vinyl {(co)polymers; comprising acrylic (co)polymers}
- B32B 27/304: {comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF}
- B32B 27/308: {comprising acrylic (co)polymers}
- B32B 27/32: comprising polyolefins {(comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30)}
- B32B 27/36: comprising polyesters
- B32B 27/38: comprising epoxy resins
- B32B 27/40: comprising polyurethanes
- C04B 37/028: {by means of an interlayer consisting of an organic adhesive, e.g. phenol resin or pitch}
- E04F 15/02038: {characterised by tongue and groove connections between neighbouring flooring elements}
- E04F 15/085: {The lower layer being of fibrous or chipped material, e.g. bonded with synthetic resins}
- E04F 15/107: {composed of several layers, e.g. sandwich panels (layered products in general B32B; producing decorative panels or veneers B44C5/04)}
- B32B 2255/04: on a particulate layer
- B32B 2255/205: Metallic coating
- B32B 2264/10: Inorganic particles
- B32B 2264/102: Oxide or hydroxide
- B32B 2264/104: Oxysalt, e.g. carbonate, sulfate, phosphate or nitrate particles
- B32B 2264/107: Ceramic
- B32B 2266/0207: Materials belonging to B32B25/00
- B32B 2266/0228: Aromatic vinyl resin, e.g. styrenic (co)polymers
- B32B 2266/025: Polyolefin
- B32B 2266/0278: Polyurethane
- B32B 2307/102: Insulating
- B32B 2307/30: having particular thermal properties
- B32B 2307/308: Heat stability
- B32B 2307/402: Coloured
- B32B 2307/412: Transparent
- B32B 2307/414: Translucent
- B32B 2307/50: having particular mechanical properties
- B32B 2307/51: Elastic
- B32B 2307/536: Hardness
- B32B 2307/54: Yield strength; Tensile strength
- B32B 2307/546: Flexural strength; Flexion stiffness
- B32B 2307/554: Wear resistance
- B32B 2307/558: Impact strength, toughness
- B32B 2307/56: Damping, energy absorption
- B32B 2307/718: Weight, e.g. weight per square meter
- B32B 2307/72: Density
- B32B 2307/7244: Oxygen barrier
- B32B 2307/7265: Non-permeable
- B32B 2307/732: Dimensional properties
- B32B 2307/734: Dimensional stability
- B32B 2307/736: Shrinkable
- B32B 2419/04: Tiles for floors or walls
- B32B 2451/00: Decorative or ornamental articles
- B32B 2471/00: Floor coverings (B32B2419/04 takes precedence)
- E04F 15/02016: {with sealing elements between flooring elements (sealings of joints between building constructions in general E04B1/68)}
- E04F 2201/023: with a continuous tongue or groove
- E04F 2201/043: with tongues and grooves being formed by projecting or recessed parts of the panel layers
- E04F: FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS (windows, doors E06B)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE

## Abstract

A floor element for forming a floor covering, wherein the floor element comprises a decorative layer, a support layer, and an intermediate layer disposed between the decorative layer and the support layer, wherein the decorative layer is made of a brittle material, wherein the floor element comprises edges provided with coupling elements adapted to cooperate with coupling elements of an adjacent similar floor element in said floor covering and wherein the intermediate layer comprises at least one edge that is offset relative to a respective edge of the decorative layer.

## Claims

### Claim 1

A floor element for forming a floor covering comprising:
a decorative layer comprising a ceramic tile or slab, the ceramic tile or slab comprising a lower surface that is substantially flat and free from relief structure;
a support layer comprising rigid polyvinylchloride (PVC) and greater than 60 wt % of a filler; and
an intermediate reinforcing layer consisting of a thermosetting resin, the intermediate layer disposed between and bonding together the decorative layer and the support layer, the intermediate layer improving the impact resistance of the decorative layer,
wherein the floor element comprises edges provided with coupling elements adapted to cooperate with coupling elements of an adjacent similar floor element in the floor covering, the coupling elements configured to limit or prevent movement in the vertical direction and in the horizontal direction, and are configured such that a play between the coupling elements is established in the coupled condition,
wherein the intermediate reinforcing layer further comprises at least one edge that is offset relative to a respective edge of the decorative layer and projects inwardly with respect to the respective edge of the decorative layer,
wherein the intermediate reinforcing layer covers between 80% and 95% of the lower surface of the decorative layer,
wherein the resin permeates an open porosity of the decorative layer and is provided on a lower surface of the decorative layer in an amount greater than 100 g/sqm,
wherein the resin comprises unsaturated polyester, and
wherein the resin has a tensile strength between 50 and 90 MPa.

### Claim 2 (depends on 1)

The floor element according to claim 1, wherein the intermediate layer covers between 90% and 95% of the lower surface of the decorative layer.

### Claim 3 (depends on 1)

The floor element according to claim 1, wherein the resin has a viscosity between 10 Pas and 1000 Pas at 20° C.

### Claim 4 (depends on 1)

The floor element according to claim 1, wherein the resin has a viscosity between 1000 Pas and 2200 Pas at 20° C.

### Claim 5 (depends on 1)

The floor element according to claim 1, wherein the resin has a tensile strength between 60 and 80 MPa.

### Claim 6 (depends on 1)

The floor element according to claim 1, wherein the resin has a hardness value of at least 50 measured on a Shore D scale.

### Claim 7 (depends on 1)

The floor element according to claim 1, wherein the support layer has a thermal expansion coefficient less than 85 μm/m per ° C.

### Claim 8 (depends on 1)

The floor element according to claim 1, wherein the decorative layer is mounted on the support layer in such a way that when the floor elements are in a coupled condition, an intermediate distance is available between the edges of adjacent decorative layers.

### Claim 9

A floor covering comprising:
a plurality of adjacent floor elements comprising coupling means configured to enable a mechanical coupling with coupling elements of adjacent floor elements,
wherein each floor element comprises:
a decorative layer of ceramic material comprising a lower surface that is substantially flat and free from relief structure;
a support layer disposed below the decorative layer and comprising rigid polyvinylchloride (PVC) and greater than 60 wt % of a filler; and
an intermediate reinforcing layer consisting of a thermosetting resin, the intermediate reinforcing layer disposed between and bonding together the decorative layer and the support layer,
wherein the intermediate reinforcing layer further comprises at least one edge that is offset relative to a respective edge of the decorative layer and projects inwardly with respect to the respective edge of the decorative layer, the intermediate layer improving the impact resistance of the decorative layer,
wherein the intermediate layer covers between 80% and 95% of the lower surface of the decorative layer,
wherein the floor covering further comprises a grout filling an intermediate distance separating the decorative layers of the adjacent floor elements,
wherein the resin permeates an open porosity of the decorative layer and is provided on a lower surface of the decorative layer in an amount greater than 100 g/sqm,
wherein the resin comprises unsaturated polyester,
wherein the resin has a tensile strength between 50 and 90 Mpa, and
wherein the coupling elements are configured to limit or prevent movement in the vertical direction and in the horizontal direction, and are configured such that a play between the coupling elements is established in the coupled condition.

### Claim 10 (depends on 9)

The floor covering according to claim 9, wherein the grout at least partially fills an empty space between the decorative layer and the support layer.

### Claim 11 (depends on 9)

The floor covering according to claim 9, wherein the grout is epoxy-based, silicone-based, polyurethane-based or acrylic-based grout.

### Claim 12 (depends on 9)

The floor covering according to claim 9, wherein the grout has a compressive strength above 20 MPa and/or an hardness Shore A above 70.

### Claim 13

A floor covering comprising:
a plurality of adjacent floor elements comprising coupling means configured to enable a mechanical coupling with coupling elements of adjacent floor elements,
wherein the floor elements comprise:
a decorative layer comprising a ceramic material with a lower surface that is substantially flat and free from relief structure;
a support layer disposed below the decorative layer and comprising rigid polyvinylchloride (PVC) and greater than 60 wt % of a filler;
an intermediate layer reinforcing layer consisting of a thermosetting resin, the intermediate reinforcing layer disposed between and bonding together the decorative layer and the support layer, the intermediate layer improving the impact resistance of the decorative layer; and
an underlayer made of a compressible material,
wherein the intermediate layer further comprises at least one edge that is offset relative to a respective edge of the decorative layer and projects inwardly with respect to the respective edge of the decorative layer,
wherein the intermediate layer covers between 80% and 95% of the lower surface of the decorative layer,
wherein the resin permeates an open porosity of the decorative layer and is provided on a lower surface of the decorative layer in an amount greater than 100 g/sqm,
wherein the resin comprises unsaturated polyester,
wherein the resin has a tensile strength between 50 and 90 MPa, and
wherein the coupling elements are configured to limit or prevent movement in the vertical direction and in the horizontal direction, and are configured such that a play between the coupling elements is established in the coupled condition.