Background of the invention

[0001 ] The invention relates to a flooring loose lay element, in particular a prefabricated element with an upper portion made of a ceramic and/or stone material, for example ceramics, vitrified stoneware, granite, marble, etc, and a lower non-slip surface that is able to adhere to a floor foundation.

[0002] Specifically, but not exclusively, the invention can be applied to lay ceramic floors, for example of the low thickness/pressed or standard type, in which the floor comprises a plurality of these prefabricated elements. The elements can be used to make floors in both indoor and outdoor environments.

[0003] The prior art comprises so-called floating floors, i.e. modular floors that are made by assembling a plurality of elements above a levelled flat surface, for example a cement screed or a levelled pre-existing floor. In particular, prefabricated elements are known having foundations with a removable adhesive strip for assembling LVT (Luxury Vinyl Tile) vinyl flooring.

[0004] Floating floors have become very widespread. They indubitably have the advantage of offering rapid laying, without the use of glues, of being applicable to existing floors or levelled screed. This means that such floors are widely used above all in renovation work of environments because they make the floor installation work less invasive, faster and cheaper.

Summary of the invention

[0005] One object of the invention is to provide an element for floors that can be laid stably on a floor foundation and can be removed from the foundation after laying without causing any damage.

[0006] One advantage is to enable one or more elements of the floor to be removed without damaging the individual elements and/or the rest of the floor and/or the foundation.

[0007] One advantage is to enable even a single floor element to be removed and/or replaced easily and practically.

[0008] One advantage is to make a flooring loose lay element that can be laid on a foundation without the need for glues.

[0009] One advantage is to be able to lay rapidly and easily a floor made of ceramic or stone material (ceramics, vitrified stoneware, granite, marble, etc). [0010] One advantage is to enable a floor to be laid that is made of ceramic or stone material that does not require the application of adhesive.

[001 1 ] One advantage is to be able to make a loose lay floor made of ceramics, vitrified stoneware, granite, marble, etc, without leaving gaps between the elements of the floor.

[0012] One advantage is to make a floor made of ceramic or stone material (ceramics, vitrified stoneware, granite, marble, etc), in which it is possible not to grout the gaps after laying the floor without glue.

[0013] One advantage is to enable a ceramic floor (or floor made of granite, marble or another ceramic or stone material) to be laid without generating dirt (for example due to the use of adhesives).

[0014] One advantage is to give rise to a loose lay ceramic (or granite, marble etc) floor that can be dismantled (wholly or partially) very quickly and without requiring masonry work.

[0015] One advantage is to make available a ceramic floor (or a floor made of granite, marble or another ceramic or stone material) that enables even a single damaged or discoloured prefabricated element to be replaced easily and cheaply, in particular significantly limiting (compared with the retiling of a ceramic tile floor) both labour costs and the costs of the replacement material.

[0016] One advantage is to enable a ceramic (or granite, marble etc) floor to be obtained that is provided with the typical benefits of floating floors.

[0017] One advantage is to offer a prefabricated loose lay element that is suitable for replacing a ceramic (or granite, marble etc) tile, of traditional type intended for laying by glue, to make a floor.

[0018] One advantage is to provide a flooring loose lay element made of ceramic or stone material provided with limited thickness, for example similar to a thickness that is typical of a ceramic tile.

[0019] One advantage is to provide a prefabricated flooring loose lay element that is relatively uncomplicated and costly to produce.

[0020] One advantage is to make a prefabricated element that is suitable, like ceramic tiles, for coping with the high volumes requested by the market.

[0021 ] One advantage is to obtain a prefabricated element for floors provided with high mechanical resistance, in particular to shocks and/or impacts on the floor. [0022] One advantage is to ensure non-slip fixing of the floor elements, avoiding, in particular, side movements thereof.

[0023] In one embodiment, an element for floors comprises a ceramic and/or stone slab to which a multilayer portion is glued below that comprises an upper support layer, an intermediate reinforcing layer made of polymeric material with glass fibres and/or aluminium, a lower adhesion layer made of polymeric (vinyl) material, and non-slip means (a plurality of microprotrusions), integrated into the lower adhesion layer, to enable the element to be positioned stably and adheringly, in particular with microprotrusions configured as microsuction cups that adhere by suction to a floor foundation.

[0024] In one embodiment, a flooring loose lay element comprises a wear portion in the form of a slab made of ceramic or stone material (for example ceramics, granite, marble, vitrified stoneware, etc, in particular low thickness/pressed or standard ceramics), coupled (in particular by gluing) with an underlying multilayered base portion (backing portion) comprising at least one upper support layer (in polymeric, in particular vinyl, material), for example with a thickness that is variable from 0.5 to 5 mm, at least one intermediate reinforcing layer (made of material comprising glass fibre), for example with a thickness that is variable from 0.1 to 0.5 mm, at least one lower layer (made of vinyl material), for example of a thickness that is variable from 0.5 to 5 mm, and a plurality of microprotrusions (for example of a thickness that is variable from 0.1 to 1 mm) that emerge below the lower layer and are integrated into the lower layer, in particular configured as a microsuction cup structure, for adhering without glue (through friction and/or a vacuum) to a floor foundation. The floor will comprise two or more of these elements laid next to one another.

[0025] In one embodiment, a floor comprises a flexible underfloor layer (for example made of polymeric, in particular vinyl, material), extending (simply resting, without glue) on a floor foundation, and a plurality of loose lay elements resting on the underfloor layer, in which each loose lay element comprises a wear portion in the shape of a slab made of ceramic or stone material, coupled with an underlying base portion comprising at least one non-slip lower layer (in polymeric, in particular vinyl, material) with a plurality of microprotrusions, in particular shaped as a microsuction cup structure, that are coupled in contact with a plurality of microprotrusions, in particular shaped as a microsuction cup structure, which emerge from the upper surface of the underfloor layer, to promote the lateral fixing of the elements and the stability of the floor. [0026] The various layers of the multilayer base portion may be assembled by hot die- casting (with a continuous and/or discontinuous process). The lower base portion (backing portion made of vinyl material) and the (ceramic) upper wear portion may be coupled together by hot melt gluing (for example with polyurethane glue).

[0027] The prefabricated elements for floors made according to the invention are intended for laying on a levelled foundation, simply resting, remaining adhering to the foundation exploiting the gripping effect (through friction and/or a vacuum) generated by microprotrusions, for example shaped and arranged in such a manner as to give rise to a microsuction cup structure, which microsuction cups are integrated into the lower layer of (vinyl) polymeric material.

[0028] In one embodiment, the element for floors comprises a multilayer base portion (backing portion) that in turn comprises a supporting layer that has a side that is coupled (glued) directly with a ceramic and/or stone slab, and a lower layer made of vinyl material provided with microprotrusions (microsuction cups) with an adhesion and non-slipping effect.

[0029] The supporting layer may be made, for example, of (vinyl) polymeric material and/or of cork and/or of a high density fibre (HDF) panel and/or of a multilayer phenolic panel and/or of a mineral fibre panel.

[0030] Such objects and advantages, and still others, are achieved by an element and/or by a use and/or by a floor according to one or more of the claims set out below.

Brief description of the drawings

[0031 ] The invention will be better understood and implemented with reference to the attached drawings, which illustrate embodiments thereof by way of non-limiting examples.

[0032] Figure 1 is a perspective view of one embodiment of a prefabricated element for floors made according to the invention.

[0033] Figure 2 is a schematic perspective view of a portion of floor that is formed by connecting two prefabricated elements 1 and 1 ' according to the invention, illustrated in an assembly step of the fold down type.

[0034] Figure 3 illustrates schematically, in a vertical elevation, two prefabricated elements assembled for making a floor without a gap.

[0035] Figure 4 illustrates schematically, in a vertical elevation, two prefabricated elements assembled for making a floor with a gap.

[0036] Figure 5 shows some embodiments of patterns that are usable for making the lower surface with microprotrusions of the prefabricated element.

[0037] Figure 6 shows a hot press coupling step of the layers that form the base portion of the prefabricated element.

[0038] Figure 7 shows a coupling step through hot melt gluing by polyurethane adhesive of the base portion (backing portion) and of the (ceramic) wear portion.

[0039] Figure 8 illustrates schematically, in a vertical elevation, two prefabricated elements assembled for making a floor without a gap with the use of an underfloor layer spread over a foundation.

[0040] Figure 9 illustrates schematically, in a vertical elevation, two prefabricated elements assembled for making a floor with a gap with the use of an underfloor layer spread over a foundation.

Detailed description

[0041 ] With reference to the aforesaid figures, with 1 overall a prefabricated flooring loose lay element has been indicated. The element 1 may comprise, as in this embodiment, an upper wear portion 2 and a lower base portion 3. The wear portion 2 may be, in particular, glued onto the base portion 3 by at least one layer of adhesive 4. The wear portion 2 may comprise, in particular, at least one visible surface 5 made of at least one ceramic and/or stone material. The wear portion 2 may comprise, for example, at least one thickness that is not less than 1 or 2 mm (for example not more than 6, 8, 10 mm) of a ceramic and/or stone material. The wear portion 2 may comprise, in particular, a slab 6 made of a ceramic and/or stone material made of a single piece. In this specific case, the wear portion 2 comprises a ceramic slab 6 or tile of the low thickness/pressed type or of the standard type for floors.

[0042] The base portion 3 may comprise, in particular, at least one (upper) supporting layer 7, which may be made, for example, of (vinyl) polymeric material. The base portion 3 may comprise, in particular, at least one (intermediate) reinforcing layer 8 that may be made, for example, of a (polymeric) composite material that includes glass fibre and/or aluminium. The base portion 3 may comprise, in particular, at least one (lower) adhesion layer 9 that may be made, for example, of a (vinyl) polymeric material and is provided with non-slip means configured for providing adhesion to a surface (by friction and/or a vacuum). The non-slip means may comprise, as in these embodiments, a plurality of microprotrusions 10 which emerge from the lower surface of the adhesion layer 9. The non-slip means (microprotrusions 10) may be, in particular, integrated into the adhesion layer 9. In figure 5 possible embodiments of various conformations and arrangements are shown of the microprotrusions 10 on the surface of the adhesion layer 9. It is possible to use other patterns or arrangements of the microprotrusions 10, in addition to those of figure 5.

[0043] The supporting layer 7 may be made, for example, of vinyl material, in particular of stiff/flexible poly vinyl chloride (PVC) and/or of "waterproof core" vinyl having a density that is greater than 1.15 g/m ³ , for example with a thickness variable from 0.5 to 5 mm, or from 1 to 4 mm, in particular equal to about 2 mm.

[0044] The supporting layer 7 may be made, for example, of cork, in particular with a thickness varying from 1 to 8 mm, or from 2 to 6 mm, for example equal to about 3 mm. The supporting layer 7 may be made, for example, of high density fibre (HDF) or of a phenolic multilayer, in particular with a thickness varying from 1 to 10 mm, or from 3 to 8 mm, for example equal to about 6 mm. The supporting layer 7 may be made, for example, with a mixture of cork and tar, in particular with a thickness varying from 1 to 10 mm, or from 2 to 8 mm, for example equal to about 6 mm.

[0045] The supporting layer 7 may be made, for example, of a wood plastic composite (WPC) comprising, in particular, loads of polymeric material that are inserted into a wood- based matrix and may be selected, by way of non-limiting example, from the group of materials consisting of: high density polyethylene (HDPE), low density polyethylene (LDPE), poly vinyl chloride (PVC), polypropylene (PP), acrylonitrile butadiene styrene (ABS), polystyrene (PS), polylactic acid (PLA).

[0046] The supporting layer 7 may comprise, for example, a fibre cement panel and/or a mineral panel, in particular with a thickness comprised between 2 and 8 mm, for example equal to about 4 mm.

[0047] The supporting layer 7 may be made of any water and humidity-resistant material that is stable to heat.

[0048] The reinforcing layer 8 may be made, for example, of a (composite) glass fibre and/or aluminium material, in particular with a thickness comprised between 0.1 and 1 mm, or between 0.2 and 0.5 mm, for example equal to about 0.3 mm.

[0049] The adhesion layer 9 may be made, for example, of a polymeric material, in particular vinyl, such as for example of poly vinyl chloride (PVC). The adhesion layer 9 may be made, in other embodiments, of one or more materials selected from the group that includes: high density polyethylene (HDPE), low density polyethylene (LDPE), poly vinyl chloride (PVC), polypropylene (PP), acrylonitrile butadiene styrene (ABS), polystyrene (PS), polylactic acid (PLA).

[0050] The adhesion layer 9 may be provided, as said, with a plurality of microprotrusions 10, for example integrated into the layer, made of different arrangements and patterns (some embodiments are shown in figure 5). The thickness of the adhesion layer 9 may be comprised, in particular, between 0.5 and 5 millimetres, or between 1 and 3 millimetres, for example equal to about 1.5 millimetres.

[0051 ] The finished prefabricated element 1 or Γ may comprise, as in this specific case, four layers (slab 6 made of ceramic/stone material, supporting layer 7, reinforcing layer 8, adhesion layer 9) that may be coupled together by three adhesive layers 4 each of which may extend, at least partly, between each interface between the four aforesaid layers (slab 6 and layers 7, 8, 9), such as to assemble the element by gluing. The various layers (slab 6 and layers 7, 8, 9) may be joined, in particular, by hot gluing, also known as "hot- melt". The prefabricated element may comprise a different (greater or smaller) number of layers. The prefabricated element may comprise, for example, further supporting and/or reinforcing layers. The prefabricated element may comprise, for example, a slab 6 made of ceramic/stone material (ceramics, vitrified stoneware, granite, marble, stone, terracotta, etc) and an adhesion layer 9, without a supporting layer 7 and/or without a reinforcing layer 8.

[0052] Once assembled, the two (or more) prefabricated elements 1 , Γ may be arranged adjacent to one another so as to define a distance D between the side surfaces, for example a distance comprised between 2 and 4 mm (figure 4, laying with a gap). The two (or more) prefabricated elements 1 , 1 ' may be arranged contiguously to one another so as to be in reciprocal lateral contact or to define a minimum distance between the side surfaces, for example a distance comprised between 0 and 0.1 mm (figure 3, laying without a gap).

[0053] It is possible to arrange, on some (two) side faces of the prefabricated element, laying means, in particular spacers (for example in the shape of crosses or the like), to facilitate laying with a gap to form the floor on a foundation S. A prefabricated element 1 may be placed alongside another prefabricated element 1 ' (for example the same as the previously laid element 1 ). Figure 2 illustrates in a schematic manner a fold down assembly step and shows the simplicity of the floor laying.

[0054] Once laying of all the elements of the floor has terminated, it is possible, if it is desired, to fill any distance D between the various elements by sealing.

[0055] Each element 1 , can be detached from the foundation S, if necessary (by replacing or repairing), by simple lifting of the single element (for example using a suction cup and/or levering an edge of the element), without damaging the element to be used, the rest of the floor or the foundation.

[0056] It is possible to make the base portion 3 separately, by coupling together the various layers (supporting layer 7, reinforcing layer 8, adhesion layer 9) by hot die-casting, at high or low temperature, for example with a single press, or with a multilayer press, or with a continuous press (with laminating rollers). It is subsequently possible to couple the base portion 3 with the wear portion 2 (slab 6 made of ceramic/stone material) by gluing.

[0057] The prefabricated element 1 , 1 ' may thus be laid to rest directly on a levelled surface, for example on a base made of a cement material or on a pre-existing floor made of any material (ceramics, marble, stone, parquet, resilient materials, wood and derivatives thereof, etc). The prefabricated element can be rested without the need for glue and without the need to provide lateral engaging means (for example joints that click into place). The prefabricated element can be rested simply in a fold-down manner, also without a gap, or, for example, by inserting the spacer means (crosses or similar) to facilitate the formation of a correct gap, then possibly sealing the gap, for example with traditional technology.

[0058] The adhesion layer 9, owing to the non-slip means (microprotrusions 10 integrated into the layer), enables the prefabricated element to be fixed firmly in position, in particular avoiding side movements. It is in particular observed that the prefabricated element remains precisely and stably in the desired positions, without the need to take account of possible dilatations, as on the other hand occurs, for example, in traditional laying of ceramic tiles by gluing.

[0059] Figures 8 and 9 show two embodiments of flooring, respectively without a gap and with a gap between the elements 1 and , in which, before resting the various prefabricated elements 1 , , an underfloor layer 1 1 (formed for example of one or more flexible sheets) is spread (simply resting, in particular without glue) to cover the foundation S. The underfloor layer 1 1 may comprise, in particular, at least one upper surface made of polymeric material that will come into contact with the (lower) contact surface of each element 1 , 1 ' for floors. The upper surface of the underfloor layer 1 1 may comprise, as in these embodiments, non-slip means, for example in the shape of a plurality of protrusions 10 coupled with the protrusions 10 of the (above) lower contact surface of the adhesion layer 9 of each element 1 , . The plurality of protrusions 10 of the upper surface of the underfloor layer 1 1 may be shaped in such a manner as to make a structure of the microsuction cup type that couples with the (similar) non-slip structure of the layer 9.

[0060] The underfloor layer 1 1 , interposed between the floor elements 1 , 1 ' and the foundation S, may be extended on the foundation S in flexible sheets (of large dimensions), for example unwound from rolls or spread by sheets in a continuous module (in fan-fold manner). The underfloor layer 1 1 may comprise, in particular, sheets of polymeric material (vinyl material, PVC, polyethylene, etc) or of another material, for example of cork, with a polymeric layer coupled (glued) thereupon that has the microprotrusions 10.

[0061 ] It has been found that the (contact) coupling between the upper protrusions 10 of the layer 1 1 and the lower protrusions 10 of the layer 9 of the various floor elements 1 , 1 ' significantly increases adhesion and the non-slip properties of the elements, contributing to the stability of the floor.