Acoustical vinyl flooring with side coupling elements

Abstract

An acoustical vinyl tile having an integral acoustical layer is disclosed. The vinyl tile includes a vinyl portion, an acoustical portion, and an adhesive layer for fixing the vinyl portion to the acoustical portion. The acoustical portion comprises a crumb rubber component and a polyurethane foam component. The acoustical portion can include 10-40% crumb rubber and 60-90% polyurethane foam. The vinyl tile may also include a coupling feature for coupling to an adjacent vinyl tile. The coupling feature may be in the form of interconnecting tongue and groove elements formed along opposite sides of the vinyl tile so that adjacent vinyl tiles can be coupled together. The tongue and groove elements may incorporate integrated mechanical coupling elements such as, for example, interlocking tabs and spaces. In use, the tongue and groove elements may be arranged and configured to be snap-fitted together.

What is claimed is: 
     
         1 . A vinyl tile, comprising:
 a vinyl portion;   an acoustical portion including a rubber component, a polyurethane component, and a binder component;   an adhesive layer for fixing the vinyl portion to the acoustical portion; and   a coupling feature disposed on a side of the vinyl tile, the coupling feature for positively coupling the vinyl tile to an adjacent vinyl tile.   
     
     
         2 . The vinyl tile of  claim 1 , wherein the acoustical portion comprises 10-40% crumb rubber and 60-90% polyurethane foam. 
     
     
         3 . The vinyl tile of  claim 1 , wherein the binder comprises a polyurethane binder. 
     
     
         4 . The vinyl tile of  claim 3 , wherein the vinyl portion comprises polyvinylchloride. 
     
     
         5 . The vinyl tile of  claim 1 , further comprising a wear layer disposed on a surface of the vinyl portion. 
     
     
         6 . The vinyl tile of  claim 1 , wherein the vinyl portion comprises a vinyl backing layer, a print layer and a clear wear layer. 
     
     
         7 . The vinyl tile of  claim 6 , wherein the vinyl backing layer, the print layer and the clear wear layer are bonded together via hot mold compression. 
     
     
         8 . The vinyl tile of  claim 1 , wherein the coupling feature includes a tongue element or a groove element for engaging a corresponding groove and tongue of an adjacent vinyl tile to couple the vinyl tile to the adjacent vinyl tile. 
     
     
         9 . The vinyl tile of  claim 8 , wherein the tongue and groove elements are formed in the vinyl portion. 
     
     
         10 . The vinyl tile of  claim 8 , wherein the tongue and groove elements incorporate mechanical coupling features so that when the tongue element of the vinyl tile engages the groove element of an adjacent vinyl tile, or when the groove element of the vinyl tile engages the tongue element of the adjacent vinyl tile, the mechanical coupling features lock the vinyl tile to the adjacent vinyl tile. 
     
     
         11 . The vinyl tile of  claim 10 , wherein the tongue and groove elements include corresponding interlocking tabs and spaces. 
     
     
         12 . The vinyl tile of  claim 8 , wherein the tongue and groove elements are arranged and configured to be snap-fitted together. 
     
     
         13 . The vinyl tile of  claim 1 , wherein the adhesive layer is a polyurethane adhesive layer. 
     
     
         14 . A method of making a vinyl tile, comprising:
 providing a vinyl slab portion;   providing an acoustical slab portion comprising a mixture of crumb rubber, polyurethane foam and a resin binder;   bonding the vinyl slab portion to the acoustical portion;   forming one of a tongue element or a groove element into a side of the vinyl tile.   
     
     
         15 . The method of  claim 14 , wherein providing a vinyl slab portion comprises stacking a vinyl backing layer, a print film layer, and a clear wear layer on top of a moldboard and molding the layers together using a hot press. 
     
     
         16 . The method of  claim 15 , further comprising coating the vinyl slab portion with a polyurethane layer. 
     
     
         17 . The method of  claim 15 , wherein providing an acoustical slab portion comprises:
 mixing the crumb rubber, the polyurethane foam and the resin binder;   curing the mixture;   cooling the cured mixture to form a cooled roll; and   cutting a layer from the cooled roll.   
     
     
         18 . The method of  claim 14 , wherein bonding the vinyl slab portion to the acoustical portion comprises:
 applying a polyurethane adhesive to a surface of the acoustical slab portion;   applying the vinyl slab portion to the adhesive coated surface of the acoustical slab portion; and   applying force to the acoustical slab portion and the vinyl slab portion for a predetermined time.   
     
     
         19 . The method of  claim 17 , further comprising pressing the bonded vinyl slab portion and the acoustical slab portion in a press having die, the die cutting the slab into vinyl tiles of a predetermined shape and size. 
     
     
         20 . The method of  claim 15 , wherein the vinyl slab portion comprises polyvinylchloride.