Multicomponent tiles and a method for manufacturing multicomponent tiles

Abstract

A plastics floor covering ( 1 ) included a plurality of discrete plastics components ( 2, 3, 4 ) each having an upper surface and a lower surface (lower surface shown). The discrete components ( 2, 3, 4 ) are assembled together to form a predetermined design and are held in the assembled position to form a unitary floor covering ( 1 ) by at least one portion of a joining film ( 14 ) secured to the lower surface of each discrete component ( 2, 3, 4 ). The joining film ( 14 ) spans at least the edges of neighboring discrete components ( 2, 3, 4 ) and is coated with a thermally labile polymeric coupling agent. The joining film ( 14 ) is perforated in a preferred embodiment of the invention.

We claim:  
     
         1 . A method of manufacturing a plastics floor tile, the method comprising the steps of cutting a plurality of discrete plastics components, each said component comprising a wear layer having an upper surface and at least one backing layer having a lower surface, from one or more sheets of a plastics material, assembling said components together to form at least a portion of a floor tile of the desired shape and design, securing said components together relative to one another by the application of at least one portion of a joining film to said lower surface of the assembled said components so that said joining film spans at least the neighboring edges of adjacent said components.  
     
     
         2 . The method of  claim 1  wherein said joining film is coated with a thermally labile polymeric coupling agent.  
     
     
         3 . The method of  claim 1  further comprising the application of heat and pressure for a period of about 7-15 seconds to cause said coupling agent to react with said joining film and said lower surface.  
     
     
         4 . The method of  claim 3  wherein the temperature used is about 130-170° C. and the pressure used is about 4-6 Mpa.  
     
     
         5 . The method of  claim 3  wherein while applying heat and pressure to said lower surface of at least a portion of assembled said components, said upper surface of said portion is cooled to ambient temperature (about 20-25° C. ).  
     
     
         6 . The method of  claim 5  wherein the cooling is carried out by use of cold water.  
     
     
         7 . The method of  claim 3  wherein pressure is applied by means of a rubber press.  
     
     
         8 . The method of  claim 2 , characterized in that said joining film is provided with perforations.  
     
     
         9 . The method of  claim 1  further comprising the application of heat and pressure for a period of about 10 seconds to cause said coupling agent to react with said joining film and said lower surface.  
     
     
         10 . The method of  claim 3  wherein the temperature used is about 150° C. and the pressure used is about 5 Mpa.  
     
     
         11 . The method of  claim 1  further comprising the step of chamfering abutting edges of said upper surface of said components  
     
     
         12 . A plastics floor tile comprising a plurality of discrete plastics components, each said component comprising a wear layer having an upper surface and at least one backing layer having a lower surface, said components secured together relative to one another via at least one portion of a joining film applied to the lower surface of said components formed by the process of cutting said components from one or more sheets of a plastics material, assembling said components together to form at least a portion of a floor tile of the desired shape and design, applying said at least one portion of a joining film to said lower surface of said components so that said joining film spans at least the neighboring edges of adjacent said components.  
     
     
         13 . The plastics tile of  claim 12  wherein said joining film is of the same plastics material as said lower surface.  
     
     
         14 . The plastics floor tile of  claim 12  wherein said joining film is made of a plastics material having physical properties compatible with those of said lower surface.  
     
     
         15 . The plastics floor tile of  claim 12  wherein said joining film is about 60 to 85 microns thick.  
     
     
         16 . The plastics floor tile of  claim 12  wherein said joining film is about 75 microns thick.  
     
     
         17 . The plastics floor tile of  claim 12  wherein said joining film is coated with a thermally labile polymeric coupling agent.  
     
     
         18 . The plastics floor tile of  claim 12  wherein said joining film is provided with perforations.  
     
     
         19 . The plastics floor tile of  claim 12  wherein said joining film is non-continuous and comprises a small number of pieces of film, each said piece spanning neighboring edges of adjacent said components.  
     
     
         20 . The plastics floor tile of  claim 12  wherein said lower surface is roughened.  
     
     
         21 . The plastics floor tile of  claim 12  wherein said component comprises a top wear layer of translucent plastics material, a printed decorative layer, and at least one backing layer.  
     
     
         22 . The plastics floor tile of  claim 12  wherein said plastics material is selected from the group consisting of polyvinyl chloride, polyolefins, acrylic polymers, polycarbonate polymers and ionomeric polymers.