U.S. patent application number 10/960177 was filed with the patent office on 2006-04-20 for groutless tile system.
Invention is credited to Silvano Cornia.
Application Number | 20060080910 10/960177 |
Document ID | / |
Family ID | 36148963 |
Filed Date | 2006-04-20 |
United States Patent
Application |
20060080910 |
Kind Code |
A1 |
Cornia; Silvano |
April 20, 2006 |
Groutless tile system
Abstract
The present invention is a tile system that does not require a
grout or other material to be spread over the tiles during the
installation process. Accordingly, the tile system includes tiles
that carry a flange that attaches to adjacent tiles upon
installation. The flange serves the function of the grout and
eliminates the need for a separate grout compound. A tile in
accordance with the present invention includes a primary tile
component and a flange for attaching for other tiles.
Inventors: |
Cornia; Silvano; (Plano,
TX) |
Correspondence
Address: |
TROUTMAN SANDERS LLP
600 PEACHTREE STREET , NE
ATLANTA
GA
30308
US
|
Family ID: |
36148963 |
Appl. No.: |
10/960177 |
Filed: |
October 7, 2004 |
Current U.S.
Class: |
52/177 |
Current CPC
Class: |
E04F 15/02 20130101;
E04F 13/08 20130101; E04F 2201/095 20130101 |
Class at
Publication: |
052/177 |
International
Class: |
E04F 15/00 20060101
E04F015/00 |
Claims
1. A tile comprising: a substantially rigid primary tile portion
having an upper surface and a first side edge, and a second side
edge; a flange adjacent at least said first and second side edges
of said substantially rigid primary tile portion; and said flange
being manufactured from material more resilient than said
substantially rigid primary tile portion.
2. The tile of claim 1 wherein said flange is manufactured from
polymeric material.
3. The tile of claim 1 wherein said primary tile component is
ceramic.
4. The tile of claim 1, wherein said first tile sidewalls have a
predetermined height and said first flange extends at least up to
the midpoint of said sidewall.
5. The tile of claim 1, wherein said first tile has a perimeter and
said first flange abuts the entire perimeter.
6. The tile of claim 1, wherein said first flange is made from a
material different than said ceramic tile.
7. The tile of claim 1, wherein said first flange is a polyurethane
based material.
8. The tile of claim 1, wherein said first flange is
ELACTOCASTr70654.
9. A covering for a planar surface comprising: a first tile having
at least a first and second first tile sidewall carrying a first
flange along said respective sidewalls, a second tile having at
least a first and second tile sidewall carrying a second flange
along said respective sidewalls; said first flange being matingly
adapted for attachment to said second flange carried by said second
tile.
10. The covering for a planar surface of claim 1, wherein said
first tile sidewalls have a predetermined height and said first
flange extends at least up to the midpoint of said sidewall.
11. The covering for a planar surface of claim 1, wherein said
first tile has a perimeter and said first flange abuts the entire
perimeter, and said second tile has a perimeter and said second
flange abuts the entire perimeter.
12. The covering for a planar surface of claim 1, wherein said
first tile is a ceramic tile.
13. The covering for a planar surface of claim 4, wherein said
first flange is made from a material different than said ceramic
tile.
14. The covering for a planar surface of claim 1, wherein said
first flange is a polyurethane based material.
15. The covering for a planar surface of claim 1, wherein said
first flange is ELACTOCASTr70654.
16. The covering for a planar surface of claim 1, wherein said
first flange further comprises a first interlocking structure that
is operative to interlock with said second flange on said second
tile.
17. The covering for a planar surface of claim 8, wherein said
first interlocking structure is a dovetail.
18. The covering for a planar surface of claim 8, wherein said
first interlocking structure is a groove.
19. The covering for a planar surface of claim 8, wherein said
second flange further comprises a second interlocking structure
that is operative to interlock with said first flange.
20. The covering for a planar surface of claim 11, wherein said
second interlocking structure is a protrusion.
21. The covering for a planar surface of claim 1 further including
a base substrate carrying said first tile.
22. A tile comprising: a base substrate having an upper surface, a
lower surface, a first side edge, and a second side edge; a primary
tile portion having an upper surface, a lower surface, a first side
edge, and a second side edge, wherein said primary tile portion is
carried by said base substrate and offset such that a portion of
the upper surface of said base substrate adjacent the first side
edge of the base substrate protrudes beyond the first side edge of
the primary tile portion, and a portion of the lower surface of
said primary tile portion adjacent the second side edge of the
primary tile portion protrudes beyond the second side edge of the
base substrate; and a first flange adjacent the first side edge of
said primary tile portion.
23. The tile of claim 22, wherein said base substrate is a ceramic
tile.
24. The tile of claim 22, wherein said primary tile portion is a
ceramic tile.
25. The tile of claim 22, wherein said first flange is manufactured
from a polymeric based material.
26. The tile of claim 22, wherein said first flange is manufactured
from ELACTOCASTr70654.
27. The tile of claim 22, further comprising: a first adhesive
component between the base substrate and the primary tile portion
for adhering the base substrate to the primary tile portion.
28. The tile of claim 22, wherein an exposed portion of said
adhesive component extends beyond the first side edge of the
flange.
Description
FIELD OF THE INVENTION
[0001] The present invention is directed generally toward floor and
wall covering tiles. More particularly, it is directed towards a
tile system that does not require a grout compound to be applied to
the tiles after installation.
BACKGROUND OF THE INVENTION
[0002] Ceramic tiles are widely used as a floor and wall covering
in both residential and commercial applications. Tile is very
versatile, and has been in use as a floor and wall covering for
centuries. Tiles are available in a nearly unlimited color palette
and may be installed in an equally unlimited number of designs.
Tile is often a top choice for floor and wall coverings because of
its great durability and aesthetic qualities.
[0003] While many tiles are manufactured from ceramic compositions
(baked clay), they may be made of a variety of natural or synthetic
materials including, but not limited to, granite, quartz, marble,
soapstone, plastic, wood, or any other suitable material.
[0004] Tile provides a durable surface and may be coated to be
substantially impervious to water and other liquids. When tiles are
installed, they are generally laid side by side on a surface such
as a floor or wall. Typically, an adhesive compound is used as a
base to attach the tiles to a surface and then grout is spread over
and between the tiles to further bind the tiles to the surface and
to fill spaces between adjacent tiles. While not impervious to
water and moisture, the grout provides a barrier to reduce moisture
between and behind the tiles. This step of grouting the tiles is
labor intensive and represents a significant portion of the labor
involved in a typical tile installation.
[0005] Due to the time and labor involved in tile installation, it
is typically quite costly to have tile professionally installed.
Accordingly, many homeowners desire to install tile in their own
homes. Unfortunately, this is an extremely tedious process, and
many homeowners do not wish to spend the time necessary for a
satisfactory installation.
[0006] In recent years, manufactures have attempted to produce
do-it-yourself tile solutions that are easier to install. One such
attempt is described in United States published patent application
number US 2004/0031226 entitled "Pre-glued Tongue and Groove
Flooring" by Miller et al. Miller et al. describes a laminated
"tile" that uses a pre-applied glue for fastening the tiles
together. While this system is easier to install than traditional
tiles, it still requires a separate grout to be applied and uses a
laminate material rather than a solid tile. A laminate material, is
not likely to be as durable as more traditional materials such as
ceramic or stone tiles. Additionally, because the Miller et al.
tile system makes use of a laminated structure that is susceptible
to moisture damage, the installer is required to apply a messy
grout composition to the tiles as part of the installation
process.
[0007] A previous attempt to produce an easy to install tile is
described in U.S. Pat. No. 2,693,102 entitled "Interlocking Wall
Tile" by Luster et al. Luster et al. describes a synthetic wall
tile system that snaps together. Unfortunately, the Luster et al.
tile is not practicable with substantially ridged materials, such
as ceramic, granite, or marble. The Luster et al. tiles are molded
into a uniform structure of a single material and rigid materials
could not be formed into an operable tab structure as taught in the
patent. Such a limitation severely limits the aesthetic qualities
available for the tiles and thereby reduces the marketability of
the system.
[0008] Accordingly, there is a need in the art for a tile system
that is simple to install.
[0009] Additionally, there is a need in the art for a tile system
that does not require a grout or sealing compound to be applied to
the tiles after installation.
[0010] Further, there is a need in the art for an easy to install
tile system that makes use of durable tile materials.
[0011] Also, there is a need in the art for a tile system that
primarily utilizes traditional tile materials, but eliminates the
need for grout.
SUMMARY OF THE INVENTION
[0012] The present invention is directed toward a covering for a
planar surface comprising a first tile having at least a first and
second first tile sidewall carrying a first flange along the
respective sidewalls, a second tile having at least a first and
second tile sidewall carrying a second flange along the respective
sidewalls, the first flange being matingly adapted for attachment
to the second flange carried by the second tile.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The invention will be more readily understood from a reading
of the following specifications and by reference to the
accompanying drawings forming a part thereof, wherein an example of
the invention is shown and wherein:
[0014] FIG. 1 is a top view illustration of a tile in accordance
with an exemplary embodiment of the present invention;
[0015] FIG. 2 is a plan view illustration of a tile in accordance
with an exemplary embodiment of the present invention;
[0016] FIG. 3 is a plan view illustration of two adjacent tiles in
accordance with an exemplary embodiment of the present
invention;
[0017] FIG. 4 is a plan view illustration of two adjacent tiles in
accordance with an exemplary embodiment of the present invention;
and
[0018] FIG. 5 is a top view illustration of a tile in accordance
with an exemplary embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] Referring now to the drawings, in which like numerals refer
to like parts throughout the several views, FIG. 1 is a top view
illustration of a tile 100 in accordance with an exemplary
embodiment of the present invention.
[0020] The present invention is directed toward a tile system that
does not require the use of a separate grout compound during
installation of the tiles. Rather, the tile system incorporates
tiles having a flange 110 attached to the perimeter of each tile
100 and is attached to an adjacent tile 100 during installation. In
accordance with an exemplary embodiment of the present invention, a
tile 100 comprises a primary tile component 115 and a flange 110.
Typically, the primary tile component 115 may be a ceramic
compound. Alternatively, the tile substrate 115 may be, but is not
limited to, plastic, wood, stone, granite, marble, or any other
suitable natural or synthetic material. Generically, the primary
tile component 115 refers to an outer visible layer of the
tile.
[0021] Typically, the primary tile component 115 has a
substantially planar outer surface with depending sidewalls. Flange
110 may be a single cut out piece which is positioned around the
tile perimeter abutting the tile's sidewalls. Preferably flange 110
in an exemplary embodiment of the present invention is applied to
the primary tile component 115 using a rapid injection mold die.
Alternatively, any suitable method for adhering the flange 110 to
the primary tile component 115 may be employed. For instance flange
110 may comprise distinct components which are separately adhered
to the perimeter of the primary tile component. Preferably, the
sidewalls have a predetermined height and the flange abuts the
sidewalls at a height at least up to the mid-point of the
sidewalls. Also, the flange may abut the entire perimeter of the
tile.
[0022] In an exemplary embodiment of the present invention, the
flange 110, may be of polymeric material and preferably is a
polyurethane material, such as ELASTOCASTr70654 by BASF.RTM..
ELASTOCASTr70654 is an unpigmented, 77 to 79 Shore D urethane
elastomer designed for cross-sections up to three inches which has
some inherent tackiness. This system is based on the ELASTOCAST7073
system.
[0023] The following data may be helpful in producing the material
used in a flange 110 in accordance with an exemplary embodiment of
the present invention. This data is provided for example only, and
is not intended to limited the scope of the invention. Other
compositions may be used to fabricate the flange 110.
TABLE-US-00001 Mix Ratio @ 105 index: 100 parts of ELASTOCASTr7065R
Resin 771. parts of WUC 3192T ISOCYANATE Specific Gravity: Resin
1/048 f/cc, 8.72 lbs./gal. @ 77.degree. F. Iso 1.22 g/cc, 10.2
lbs./gal. @ 77.degree. F. Viscosity: Resin 1120 cps @ 77.degree. F.
Iso 200 cps @ 77.degree. F. Typical Reactivity: Hand mixed at
86.degree. F. at 105 index Gel time: 180 to 240 seconds Recommended
Component Resin 75-95.degree. F. processing conditions:
temperatures: Iso 75-95.degree. F. Mold temperature:
130-160.degree. F. Demold time: 10-20 minutes
[0024] Alternatively, other polymer variations, such as polyamides,
vinyl polymers and polyoletins may be used. Preferably, the flange
110 may be made, but is not so limited, from a material that is
chemical resistant, stain resistant, non-porous, and formable to
within sufficient precision. Additionally, it may be desirable for
the flange 110 to have sealing qualities so as to impede the
intrusion of moisture between and behind the tiles and adherence
qualities so as to minimize or present movement or displacement of
the tiles.
[0025] The flange 110 may take a variety of forms. In an exemplary
embodiment of the present invention, the flange 110 may be a
dovetail configuration for matably engaging a correlated dovetail
pattern on a second tile 100. In such an arrangement, the two tiles
100 lock together to form a lock-joint. In addition to dovetail
joints, any alternative locking joint may be used such as, but not
limited to a tongue and groove joint. In another exemplary
embodiment of the present invention, the flange 110 may lock two
tiles 100 together using adhesive properties in the flange
material. In such an arrangement, the flange 110 may be designed to
provide sufficient tack so as to lock the tiles together through
adhesion. In such an arrangement, it may be desirable to provide a
removable backing strip on the exposed tacky surfaces of the flange
110 so that it will not collect dust and other particles prior to
installation. Accordingly, the removable strip may be removed at
the time of tile installation.
[0026] The tile 100 may also include a base substrate 105. The base
substrate 105 may provide a base upon which the remainder of the
tile elements are constructed. The base substrate 105 may also
provide additional strength for the tile 100. Because the base
substrate 105 is covered by the primary tile component 115, the
appearance of the base substrate 105 may not be critical. Thus, it
may be desirable to use a scrap tile material, or other inexpensive
material, for the base substrate 105 to minimize costs. In an
exemplary embodiment of the present invention, the primary tile
component 115 is attached above the base substrate 105 using an
adhesive component 112. The adhesive component 112 may be the same
polyurethane used for the flange 110. Alternatively, the adhesive
component 112 may be any adhesive suitable for binding the primary
tile component 115 to the base substrate 105.
[0027] The primary tile component 115 may be disposed in an offset
configuration as shown in FIGS. 1 and 2. FIG. 2 illustrates a plan
view of a tile 100 in accordance with an exemplary embodiment of
the present invention. In such a configuration, a portion of the
top surface of the base substrate 105 adjacent two of its side
edges 106, 107 is exposed adjacent two side edges 116, 117 of the
primary tile component. Additionally, two side edges 118, 119 of
the primary tile component 115 hang over two of the side edges 108,
109 of the base substrate 105. This configuration allows adjacent
tiles 100 to overlap partially when installed on a floor or wall in
a typical abutting arrangement.
[0028] As shown in FIG. 2, adhesive 112 may be integral and of the
same material as flange 110. Adhesive 112 may be partially exposed
on the upper surface of base substrate 105 enabling attachment of a
second tile 100 as shown in FIG. 3.
[0029] For some installations, it may be desirable to include an
underlayment 205 that acts as a moisture or sound barrier.
Additionally, the underlayment 205 may serve a surface leveling
function. Further, the underlayment 205 may serve as an adhesive
for attaching the tiles to an installation surface, such as a floor
or a wall.
[0030] FIG. 3 shows an excerpt of a plan view of two adjacent tiles
100 in accordance with an exemplary embodiment of the present
invention. As shown in FIG. 3, two adjacent tiles (tile A and tile
B) overlap when installed beside each other. The leading edge of
the primary tile component 115a of tile A extends over the base
substrate 105b of tile B. As shown in this figure, flange 110b
which is attached to primary tile component 115b is utilized for
abutting a sidewall of primary tile component 115a. This
illustrates that while the preferred embodiment utilizes flange 110
around the entire perimeter of primary tile component 115, some
configurations may be had wherein, flange 110 is selectively
located on certain predetermined sidewalls of primary tile
component 115 such as only three sides or two sides.
[0031] Alternatively, the base substrate 105 and the primary tile
component 115 may be manufactured as a single piece. This combined
piece may have a profile such that the overlapping configuration
shown in FIGS. 1-3 is duplicated without the use of separate base
substrates 105 and primary tile components 115. Further, the
primary tile component 115 may be used alone without a base
substrate 110. In such an embodiment, adjacent tiles 100 would not
overlap and the flange 110 of a first tile 100 would abut the
flange 110 of a second tile 100.
[0032] FIG. 4 shows an excerpt of a plan view of two adjacent tiles
100 (tile A and tile B) in accordance with an exemplary embodiment
of the present invention, wherein the primary tile component 415 is
not disposed above a base substrate 105. As is shown in FIG. 4, two
primary tile components 415a and 415b lie adjacent one another and
the flange 410a of tile A abuts the flange 410b of tile B. In such
an arrangement, it may be desirable for the two flanges 410a and
410b to attach adhesively. Alternatively, the two flanges 410 may
interlock as described above in a dovetail or other locking
arrangement.
[0033] FIG. 5 shows a top view of a tile 100 in accordance with an
exemplary embodiment of the present invention. As shown in FIG. 5,
the flange 110 may be formed with a plurality of dovetail
connections to allow a locking joint with adjacent tiles. In such a
configuration, a male dovetail member 505 may be inserted into a
female dovetail member 510 during installation. Preferably, the
dovetail components 505, 510 provide a tight fit so that minimal
movement is allowed between tiles.
[0034] Although various embodiments of the present invention have
been described herein in detail, it will be appreciated by those
skilled in the art, that variations may be made thereto without
departing from the spirit of the invention or the scope of the
appended claims.
* * * * *