U.S. patent application number 11/576707 was filed with the patent office on 2008-04-24 for substrate element, modular tiling element, system of interlocking mechanisms and method of tiling.
Invention is credited to Albertus Nicolaas Heyns.
Application Number | 20080092473 11/576707 |
Document ID | / |
Family ID | 35519897 |
Filed Date | 2008-04-24 |
United States Patent
Application |
20080092473 |
Kind Code |
A1 |
Heyns; Albertus Nicolaas |
April 24, 2008 |
Substrate Element, Modular Tiling Element, System Of Interlocking
Mechanisms And Method Of Tiling
Abstract
A substrate element 14 with a face 18 is provided, which
includes two attachment formations 28,30 that extend along edges of
the element that protrude beyond the face and two attachment
formations 38,40 that extend along two edges of the element that
are recessed from the face. The attachment formations on each
protruding edge are complementary to the attachment formations on
each recessed edge. One attachment formation 28 on a protruding
edge and its complementary attachment formation 38 on a recessed
edge of an adjacent element, are lockingly engagable to form a
lockable set of attachment formations. One attachment formation 30
on a protruding edge and its complementary attachment formation 40
on a recessed edge of an adjacent element, are slidingly engagable
with an interference fit to form an adjustable set of attachment
formations. The invention also extends to a modular tiling element
12, a system of interlocking mechanisms and a method of tiling, all
incorporating the substrate element.
Inventors: |
Heyns; Albertus Nicolaas;
(Heldervue, ZA) |
Correspondence
Address: |
DALINA LAW GROUP, P.C.
7910 IVANHOE AVE. #325
LA JOLLA
CA
92037
US
|
Family ID: |
35519897 |
Appl. No.: |
11/576707 |
Filed: |
October 5, 2005 |
PCT Filed: |
October 5, 2005 |
PCT NO: |
PCT/ZA05/00151 |
371 Date: |
April 5, 2007 |
Current U.S.
Class: |
52/385 ;
52/592.2; 52/612; 52/747.11 |
Current CPC
Class: |
E04F 15/082 20130101;
E04F 13/08 20130101; E04F 15/02194 20130101; E04F 2290/023
20130101; Y02B 30/24 20130101; E04F 15/087 20130101; Y02B 30/00
20130101; E04F 2201/0115 20130101 |
Class at
Publication: |
052/385 ;
052/592.2; 052/612; 052/747.11 |
International
Class: |
E04C 2/04 20060101
E04C002/04; E04B 1/41 20060101 E04B001/41; E04F 19/00 20060101
E04F019/00; E04B 2/08 20060101 E04B002/08 |
Foreign Application Data
Date |
Code |
Application Number |
Oct 5, 2004 |
ZA |
2004/5332 |
Claims
1-28. (canceled)
29. A substrate element (14) for a modular tiling element (12),
said substrate element defining: a generally planar face (18); at
least two attachment formations (28),(30) extending along at least
one protruding edge of the substrate element, protruding beyond the
face; and, at least two attachment formations (38),(40) extending
along at least one recessed edge of the substrate element, recessed
from the face, the attachment formations on each protruding edge
being complementary to the attachment formations on each recessed
edge, wherein one attachment formation (28) on a protruding edge
and its complementary attachment formation (38) on a recessed edge
of an adjacent substrate element, are lockingly engagable to form a
lockable set of attachment formations, and one attachment formation
(30) on a protruding edge and its complementary attachment
formation (40) on a recessed edge of an adjacent substrate element,
are slidingly engagable with an interference fit to form an
adjustable set of attachment formations.
30. The substrate element as claimed in claim 29, wherein the
complementary attachment formations in an adjustable set include a
recess defined proximate an edge of one substrate element and a
complementary protuberance, extending from an edge of the adjacent
substrate element, the protuberance being receivable in the recess
formation with an interference fit, but with play in a direction
that is generally coplanar with at least one of the substrate
elements.
31. The substrate element as claimed in claim 30, wherein the
complementary attachment formations in a lockable set include a
recess defined proximate an edge of one substrate element and a
complementary, resilient clip formation, extending from an edge of
the adjacent substrate element, the clip formation being receivable
in the recess in a clipping-fashion.
32. The substrate element as claimed in claim 31, wherein the
protuberance of the adjustable set and the clip formation of the
lockable set, are spaced apart with a groove defined between them,
and in that the recesses of the adjustable set and the lockable set
are similarly spaced apart with a tongue extending between them,
the tongue being receivable in a pinching-fashion in the groove,
when the adjustable set and lockable set of attachment formations
engage.
33. The substrate element as claimed in claim 32, wherein the
protuberance of the adjustable set and the clip formation of the
lockable set, are spaced further apart than the recesses of the
adjustable set and the lockable set.
34. The substrate element as claimed in claim 29, wherein the face
has a rectangular outline and in that the substrate element
includes two protruding edges, protruding beyond the face on two
sides of the substrate element, and two recessed edges, recessed
from the edges of the face, on the two remaining sides of the
substrate element.
35. The substrate element as claimed in claim 34, wherein each of
the protruding edges has the form of a flange.
36. The substrate element as claimed in claim 35, wherein a utility
groove is defined in at least one of the flanges.
37. The substrate element as claimed in claim 35, wherein a
fastening slot is defined in at least one of the flanges.
38. The substrate element as claimed in claim 29, wherein a
plurality of rib formations and recesses are defined on the
face.
39. The substrate element as claimed in claim 29, wherein a
plurality of rib formations and recesses are defined on an
underside of the substrate, opposite from the face.
40. The substrate element as claimed in claim 29, wherein the
substrate element has a solid construction, in which no holes are
defined.
41. The substrate element as claimed in claim 29, configured with
at least one spacer, protruding from the substrate element, between
the face and a protruding edge of the substrate element, generally
perpendicularly to the face.
42. The substrate element as claimed in claim 29, wherein the
substrate element includes at least one marking, disposed at a
location corresponding a fraction of the length of the face.
43. The substrate element as claimed in claim 29, wherein the
substrate element includes at least one marking, corresponding to a
laying direction of the substrate element.
44. The substrate element as claimed in claim 29, wherein said
modular tiling element (12) comprises said substrate element (14)
and a surface layer of cladding material (16) bonded to the
substrate element in that the surface layer is bonded to the face
(18) of the substrate element.
45. The substrate element as claimed in claim 44, wherein the
surface layer of cladding material and the face of the substrate
element are of the same general size and are bonded together,
generally in register.
46. The substrate element as claimed in claim 44, wherein the
cladding material comprises a ceramic tile.
47. The substrate element as claimed in claim 44, wherein the
cladding material comprises a stone tile.
48. The substrate element as claimed in claim 44, wherein the
bonding between the cladding material and the face of the substrate
element is complete.
49. A method of tiling comprising: preparing modular tiling
elements (12) by bonding surface layers of cladding material (16)
to substrate elements (14) as claimed in claim 1; moving the tiling
elements (12) into a side-by-side arrangement with their edges in
abutment; and, engaging complementary formations defined on the
edges of adjacent tiling elements, wherein a lockable set (28),(38)
of the complementary engagement formations lock the edges of
adjacent tiling elements together and an adjustable set (30),(40)
of the complementary engagement formations engage with a slidable
interference fit, allowing relative movement between adjacent
tiling elements, generally along the common plane of the tiling
elements, while the complementary formations remain in
engagement.
50. The method as claimed in claim 49, further comprising attaching
the substrate elements to a support structure.
51. The method as claimed in claim 49, further comprising attaching
the substrate elements to the support structure by fasteners
extending through flanges of the substrate elements, protruding
beyond edges of the surface layer of cladding material.
52. The method as claimed in claim 50, wherein the substrate
elements are interlocked and free floating on the support
structure.
53. A tiling system (10) laid in accordance with the method as
claimed in claim 49, wherein the tiling system comprises modular
tiling element (12) comprising: a generally planar face (18); at
least two attachment formations (28),(30) extending along at least
one protruding edge of the substrate element, protruding beyond the
face; at least two attachment formations (38),(40) extending along
at least one recessed edge of the substrate element, recessed from
the face, the attachment formations on each protruding edge being
complementary to the attachment formations on each recessed edge,
wherein one attachment formation (28) on a protruding edge and its
complementary attachment formation (38) on a recessed edge of an
adjacent substrate element, are lockingly engagable to form a
lockable set of attachment formations, and one attachment formation
(30) on a protruding edge and its complementary attachment
formation (40) on a recessed edge of an adjacent substrate element,
are slidingly engagable with an interference fit to form an
adjustable set of attachment formations; and, wherein said modular
tiling element (12) comprises said substrate element (14) and a
surface layer of cladding material (16) bonded to the substrate
element in that the surface layer is bonded to the face (18) of the
substrate element.
54. The system as claimed in claim 53, wherein the upper faces of
the surface layers of adjacent tiling elements are aligned to
provide a smooth surface.
55. The system of as claimed in claim 53, wherein said interlocking
mechanisms, defined on flanges (24) of the substrate elements (14)
at protruding edges, wherein the engagement of the attachment
formations (28),(30),(38),(40) of adjacent substrate elements allow
the substrate elements to move longitudinally and transversely to
the engaged attachment formations.
56. The system as claimed in claim 54, wherein the engagement of
the attachment formations form a pincher lock.
Description
FIELD OF THE INVENTION
[0001] This invention relates to the provision of cladding such as
stone or ceramic tiles for floors, walls and ceilings of buildings,
or the like. In particular, the invention relates to a substrate
element, a modular tiling element, a system of interlocking
mechanisms and a method of tiling.
BACKGROUND TO THE INVENTION
[0002] Sheets of cladding materials, such as stone or ceramic tiles
are typically rectangular or square and are typically produced with
certain standardised dimensions. However, the dimensions of the
tiles vary to some extent and these variations complicate the task
of a tiler, who strives to avoid uneven spacing and/or alignment of
tiles, when tiling. These problems can be avoided by cutting the
tiles to standard dimensions in a process called "rectification",
but this process is very costly. The problems can also be avoided
by selecting tiles of similar or identical dimensions, for being
installed together, but this process is also costly. Tilers can
attempt to compensate for the variations in dimensions of tiles by
laying tiles spaced widely apart, but the wide spacing is
unsightly. The use of skilled labour in all these attempt to
resolve problems relating to varying dimensions of tiles, is very
costly.
[0003] Conventional installation of stone and ceramic tiles is by
means of adhering the tile to a substructure with an adhesive like
tile cement. Various complementary materials are use in the
installation process for preventive purposes and to assist the
tiler. A plastic layer can be installed to prevent damp and
specialised board to prevent cracking of tiles through movement in
the substructure. Spacers are used to create even grout lines.
These materials, waste generated during installation, and labour
make the process of tiling costly and cumbersome.
[0004] Innovative flooring improvements offer solutions to
installation problems by means of floor elements which snap, click
or lock together in order to interconnect and form a floor covering
which "floats" on a substructure without being fastened to it.
These systems have inherent disadvantages like the inability to be
fastened to a substructure and therefore have only a decorative as
opposed to structural and decorative quality. Damaged elements
cannot be removed individually without disassembling the whole
floor. Disassembly cannot be done without damage to the various
elements of the floor. Floor elements have no means to secure the
fastening of these elements on a wall or ceiling, which limits
application.
[0005] Where elements have a means to secure fastening to a
substructure, these elements lack the ability to lock. There is a
need to prevent interconnected elements from moving during
installation or when adjustments are being made. A hold could be
created between elements by introducing an interference factor
between the interconnecting profiles of complementary elements.
This, however, will prevent longitudinal movement or unencumbered
adjustment.
[0006] Systems which are not fasted to a substructure lack
load-being strength and overall flexural strength. The systems are
designed to interconnect without regard for these requirements.
Solutions to tiling and installation problems are offered without
commercial viability or the consideration of practical
implications; e.g. the applicant is aware of an incident where
thirty percent of the tiled area of an exhibition display of an
innovation system broke when visitors walked on it.
[0007] U.S. Pat. No. 2,200,382 (Clark) and U.S. Pat. No. 4,840,825
(Aristodimou), both disclose tiling systems in which sheets of
cladding material are attached to substrates, which in turn are
attached to support structures such as existing walls, by fasteners
extending through protuberances of bottom layers of the substrates.
Adjacent substrates engage each other in tongue-and-groove fashion.
These attachments neither have the structural integrity nor the
secured fastening to bear the load of heavier cladding materials,
e.g. to bear stone and ceramic tiles on walls, with the result that
the tiling systems disclosed by these patents are flawed and
limited in application. If these systems are used to clad a wall
with heavier cladding materials, the fastening layer will tear and
the system will collapse. The system can also not function as
floating floors without fastening.
[0008] German Patent 2 246 778 (Kreibaum), discloses a similar
cladding system to those of Clark and Aristodimou, but in which the
tiling material is in the form of a composite wooden sheet and in
which fasteners extend through the entire substrate, thus improving
structural strength. However, substrates of particleboard are
described, which do not have significant structural strength, and
the disclosure only mentions attachment of the substrate to a
support structure in the form of an existing wall. Adjacent
elements of tiling material are also glued together on the
particleboard substrate. Kreibaum did not envisage a tiling system
for various commercial materials nor one with universal
application.
[0009] U.S. Pat. No. 6,247,286 (Heyns) discloses a tiling system
similar to that of Kreibaum, but in which the substrate
significantly contributes to structural strength of the tiling
material and the support structure, e.g. by forming a drywall.
Further, the tiling system disclosed by Heyns allows some degree of
sliding movement between adjacent substrates, due to the sliding
tongue-and-groove engagement of the substrates, but is prone to
shifting. Heyns' tiling system can also be used for a variety of
cladding materials, including stone cladding. The system, however,
could not free float without fastening. The tongue-and-groove
engagement of substrates provided interconnection but not
interlocking, which results in an inability of the elements forming
the system to remain in place during installation. Further, two
edges of the tiling material are unsupported by the substrate and
would not withstand much working load.
[0010] WO 03/040491 (Della Pepa) discloses a substrate in the form
of a paving frame defining holes that allow it to be bonded to
stone cladding, with the result that the stone cladding is not
supported under its entire underside, so that it would not be able
to withstand the working loads to which flooring is subjected. The
use of footfall material underneath the cladding material is also
described, but if the footfall material is flexible, the cladding
material will not be sufficiently supported under load, and will
break. Due to the profile of the rubber gasket and the need for it
to be tightly supported, the cladding sheets or tiles must conform
precisely to the required dimensions of the support frame, so the
system does not tolerate much deviation form the required
dimensions. Further, two edges of each cladding sheet extend above
the attachment formations for attaching adjacent substrates
together, so that these edges are not supported by the
substrate.
[0011] The Della Pepa application has some apparent similarities to
the Heyns patent and the description appears to be mainly
repetitive of the Heyns patent.
[0012] Other prior cladding systems include flooring elements that
are attached to each other by engagement of complementary
tongue-and-groove formations, or variations thereon, combined with
locking engagement of auxiliary attachment formations. These
locking engagements prevent any movement between adjacent flooring
elements and the systems do not make provision for the attachment
of stone or ceramic tiling cladding material to a substrate or
elements to a support structure. These lock, snap or click systems,
as they are known, were designed specifically for floors and
prevent movement between interlocked elements and were designed for
such elements to be glued to a substructure or to float freely
without being fastened to a substructure.
[0013] The objects of the invention include the provision of means
for installation of a cladding material such as tiles, which is
easy to implement and which compensates easily for inconsistencies
in dimensions of elements of the cladding material, e.g.
inconsistent dimensions of tiles, while matching or preferably
exceeding the aesthetic and functional qualities of known
techniques.
[0014] These objects are broadly stated and are met by the
invention which holds a very large number of advantages that will
be clear from the description below to a person skilled in the art
and while not being limited thereto, the advantages include:
multifunctional utility flanges that can accommodate electrical
conduits, water channeling, heating elements, attachment, and the
like; allowing for longitudinal and lateral/transversal movement of
tiles; providing thermal and moisture barriers; protection for
tiles prior to and during installation; reduction of waste;
detachability and reusability of tiles; etc.
[0015] The objects of the invention include providing a tiled
covering of stone or ceramic tiles comprising a system of modular
tiling elements, that can easily be attached together in an evenly
spaced, close arrangement and that can also be attached to a
supporting substructure such as an existing wall, floor or ceiling,
or a supporting framework. A surface cladding material, like stone
or ceramic tile, bonded to a substrate forms the modular tiling
element. The object of the invention further include providing a
tiled covering that has sufficient structural integrity to bear the
loads of the cladding material and working loads, even if not
attached to a support structure. Further objects of the invention
include providing modular tiling elements of which the surface
cladding material can individually be removed after
installation.
[0016] The objects of the invention include providing a
commercially viable system of tiling which incorporates practical
solutions to problems facing the hard surface division of the
flooring industry. This is achieved by the invention through the
amelioration of the disadvantages or prior art and by the
introduction of novel and distinguishing features.
[0017] It is an object of the invention to create an inclusive,
commercially viable tiling system for ceramic, stone and the like
cladding materials to form a floor, wall, ceiling or roof covering
which is affordable.
[0018] It is an object of the invention to provide a standardised
tiling module for use in the tiling system to construct a tiled
covering.
[0019] It is an object of the invention to provide the tiling
module with a commercial and affordable surface cladding material
of ceramic, marble, granite or the like materials which rests
completely on a substrate to which it is bonded.
[0020] It is an object of the invention to provide the cladding
material of the tiling module with a substrate which fully protects
it whilst supporting it.
[0021] It is an object of the invention to provide the tiling
module with a substrate which will strengthen it and increase the
load-bearing quality of the module.
[0022] It is an object of the invention to provide the module with
a substrate which can interlock with other substrates and, in doing
so, enable modules to interlock.
[0023] It is an object of the invention to provide modules which
interlock to form a tiling system which has increased overall
flexural strength.
[0024] It is an object of the invention to provide the tiling
module with a substrate which when interlocked with the substrates
of other modules will form a thermal insulation barrier of a wall,
floor or roof.
[0025] It is an object of the invention to provide a substrate to
the module with a means of securing the interlocking with the
substrates of other complementary modules utilising a system of
interlocking mechanisms.
[0026] It is an object of the invention for the modules to be able
to move longitudinally or laterally/transversally when in an
interlocked position with another or other modules.
[0027] It is an object of the invention to provide a tiling module
used in a tiling system which is able to compensate for height,
width and length tolerances in the manufactured cladding or tiling
material.
[0028] It is an object of the invention to provide the tiling
module with a substrate which can resist water, moisture and
damp.
[0029] It is an object of the invention to provide the tiling
module with a substrate which has translucent qualities for a
combination with a translucent cladding material to form a module
with translucent characteristics.
[0030] It is an object of the invention to provide an inclusive
tiling system utilising interlocking tiling modules to design and
construct floors, walls and roofs primarily for the residential
market, and to clad these floors, walls and roofs with a high
quality and elegant surface covering.
[0031] It is an object of the invention to provide a tiling system
which will eliminate costly labour and installation materials.
[0032] It is an object of the invention to provide a tiling system
where a single damaged tile can easily be removed and replaced
after a floor, wall or roof had been installed, without damage to
adjacent tiling modules.
[0033] It is an object of the invention to provide a tiling system
where pre-selection of colour, grain and type of cladding takes
place prior to installation.
[0034] It is an object of the invention to provide a tiling system
which will reduce waste during installation.
[0035] It is an object of the invention to provide a tiling system
which prevents cracking or warping of the cladding material due to
movement in the substructure.
[0036] It is an object of the invention to provide a versatile
tiling system which can be merely decorative by being installed
through interlocking the tiling modules, or which add to structural
integrity by being fastened to a substructure.
[0037] It is an object of the invention to provide a user-friendly
tiling system which is inclusive and comprehensive and easy to
install by an unskilled person.
[0038] It is an object of the invention to provide a tiling system
which will assist the installer.
[0039] It is an object of the invention to provide a system that is
detachable and reusable.
[0040] It is an object to the invention to provide a tiling system
where the modules utilised in the system install in a flat
position.
[0041] It is an object of the invention to provide a system where
grout lines can be manipulated.
[0042] It is an object of the invention to provide a tiling system
which can be formed independently and "locked in" by perimeter
fasteners to form an independent floor or part of a floor.
[0043] It is an object of the invention to provide a tiling system
which has material cost-saving implications.
[0044] It is an object of the invention to provide a tiling system
where breakage or damage to the cladding materials during
installation is limited.
[0045] It is an object of the invention to provide a tiling module
which will eliminate or overcome damage to the edges of the
cladding material by protecting it.
[0046] It is an object of the invention to provide a standardised
tiling module which can be produced on a cost-effective commercial
basis by means of a simple mechanical and automated process.
[0047] It is an object of the invention to provide a standardised
tiling module and tiling system which can be utilised by
architects, interior designers and quantity surveyors to plan and
design floors, walls, roofs and the like by integrating various
cladding materials and designs into an inclusive and comprehensive
system.
[0048] It is an object of the invention to provide a tiling module
which can be utilised in the manufacture of furniture surfaces and
panels for office partitioning.
[0049] It is an object of the invention to provide a substrate
which is designed with thermal insulation features.
[0050] It is an object of the invention to provide a substrate
designed to allow for the removal and replacement of cladding
material after installation.
[0051] It is an object of the invention to provide a substrate
which can be produced through a single manufacturing process.
[0052] It is an object of the invention to provide a substrate
which can absorb excess adhesive into recessed areas in order for
the tiling module to be pressed to the required thickness during
the lamination process.
[0053] It is an object of the invention to provide a substrate with
utility flanges on at least one, but preferably two adjacent sides
of the substrate.
[0054] It is an object of the invention to provide substrate
utility flanges with grooves for the laying of under-floor heating
elements or electrical conduits.
[0055] It is an object of the invention to provide substrate
utility flanges with a channel for water direction.
[0056] It is an object of the invention to provide substrate
utility flanges where compensation for tolerances in the cladding
material can take place.
[0057] It is an object of the invention to provide substrate
utility flanges with recessed slots for fastening elements like
nails or screws.
[0058] It is an object of the invention to provide substrate
utility flanges with installation guides to assist with design and
installation.
[0059] It is an object of the invention to provide substrate
utility flanges with spacers which form protective barriers for the
cladding material, an axis for installation direction and a
grout-line guide.
[0060] It is an object of the invention to provide substrate
utility flanges which provide a means of securing the interlocking
of substrates.
[0061] It is an object of the invention to provide a system of
interlocking mechanisms on at least one flange and one adjacent
side of the substrate, but preferably on two adjacent flanges and
the two opposite sides of the substrate.
[0062] It is an object of the invention to provide interlocking
mechanisms on two adjacent sides of the substrate which have a
multifunction quality.
[0063] It is an object of the invention to provide within the
interlocking mechanisms of the substrate a means of securing the
overlapping cladding material of one module to the exposed
substrate of an adjoining complementary module.
[0064] It is an object of the invention to provide within the
interlocking mechanisms of the substrate a means of stabilising
interlocking tiling modules.
[0065] It is an object of the invention to provide within the
interlocking mechanisms of the substrate a means of locking two
complementary modules together and still allow for longitudinal and
lateral/transversal movement within the locked mode.
[0066] According to a further object of the invention there is
provided a tiled covering for a wall, floor, ceiling or roof which
has an elegant, expensive appearance and where the cladding tiles
are aligned in a smooth array.
[0067] These and other objects of the present invention are
achieved in the preferred embodiments disclosed below by providing
a tiling system which utilises a standardised tiling module,
comprising a surface layer of cladding material and a substrate
element of structural material oriented in a fixed relation to the
underside of the surface layer of cladding material. The substrate
element supports and protects the surface layer on a supporting
structure.
BRIEF DESCRIPTION OF THE INVENTION
[0068] According to a first aspect of the invention there is
provided a substrate element for a modular tiling element, said
substrate element defining:
[0069] a generally planar face;
[0070] at least two attachment formations extending along at least
one protruding edge of the substrate element, protruding beyond the
face; and
[0071] at least two attachment formations extending along at least
one recessed edge of the substrate element, recessed from the face,
the attachment formations on each protruding edge being
complementary to the attachment formations on each recessed
edge,
[0072] wherein one attachment formation on a protruding edge and
its complementary attachment formation on a recessed edge of an
adjacent substrate element, are lockingly engagable to form a
lockable set of attachment formations, and one attachment formation
on a protruding edge and its complementary attachment formation on
a recessed edge of an adjacent substrate element, are slidingly
engagable with an interference fit to form an adjustable set of
attachment formations.
[0073] The complementary attachment formations in an adjustable set
may include a recess defined proximate an edge of one substrate
element and a complementary protuberance, extending from an edge of
the adjacent substrate element, the protuberance being receivable
in the recess formation with an interference fit, but with play in
a direction that is generally coplanar with at least one of the
substrate elements.
[0074] The complementary attachment formations in a lockable set
may include a recess defined proximate an edge of one substrate
element and a complementary, resilient clip formation, extending
from an edge of the adjacent substrate element, the clip formation
being receivable in the recess in a clipping-fashion.
[0075] The protuberance of the adjustable set and the clip
formation of the lockable set, may be spaced apart with a groove
defined between them, and the recesses of the adjustable set and
the lockable set may be similarly spaced apart with a tongue
extending between them, the tongue being receivable in a
pinching-fashion in the groove, when the adjustable set and
lockable set of attachment formations engage.
[0076] The protuberance of the adjustable set and the clip
formation of the lockable set, may be spaced further apart than the
recesses of the adjustable set and the lockable set.
[0077] The face may have a rectangular outline and the substrate
element may include two protruding edges, protruding beyond the
face on two sides of the substrate element, and two recessed edges,
recessed from the edges of the face, on the two remaining sides of
the substrate element. The two protruding edges may protrude from
adjacent sides of the substrate element and the recessed edges may
be recessed from the remaining two adjacent edges.
[0078] Each of the protruding edges may have the form of a flange
and a utility groove and/or a fastening slot may be defined in at
least on of the flanges.
[0079] A plurality of rib formations and recesses may be defined on
the face and/or on an underside of the substrate, opposite from the
face. Alternatively, the substrate element may have a solid
construction in which no holes are defined.
[0080] The substrate element may include at least one spacer,
protruding from the substrate element, between the face and a
protruding edge of the substrate element, generally perpendicularly
to the face.
[0081] The substrate element may have at least one marking disposed
at a location that corresponds to a fraction of the length of the
face and/or at least one marking that corresponds to a laying
direction of the substrate element.
[0082] According to another aspect of the invention there is
provided a modular tiling element comprising a substrate element
and a surface layer of cladding material bonded to the substrate
element, wherein the substrate element is as described hereinabove
and the surface layer is bonded to the face of the substrate
element. The tiling element thus has most of the characteristics of
the substrate element described hereinabove.
[0083] The surface layer of cladding material and the face of the
substrate element may be of the same general size and may be bonded
together, generally in register and the bonding between the
cladding material and the face of the substrate material may be
complete, i.e. there are no coplanar parts of the cladding material
that is not bonded and needs to be kept free of adhesive.
[0084] The cladding material may comprise a ceramic and/or stone
tile.
[0085] According to a further aspect of the invention there is
provided a method of tiling, said method comprising:
[0086] preparing modular tiling elements by bonding surface layers
of cladding material to substrate elements as described
hereinabove;
[0087] moving the tiling elements into a side-by-side arrangement
with their edges in abutment;
[0088] engaging complementary formations defined on the edges of
adjacent tiling elements;
[0089] wherein a lockable set of the complementary engagement
formations lock the edges of adjacent tiling elements together, and
an adjustable set of the complementary engagement formations engage
with a slidable interference fit, allowing relative movement
between adjacent tiling elements, generally along the common plane
of the tiling elements, while the complementary formations remain
in engagement.
[0090] The substrate elements may be attached to a support
structure and the substrate elements may be attached to the support
structure by fasteners extending through flanges of the substrate
elements, protruding beyond edges of the surface layer of cladding
material. Alternatively, the substrate elements may be attached
together and may be free floating on the support surface.
[0091] According to yet a further aspect of the invention there is
provided a tiling system laid in accordance with the method as
described hereinabove, wherein the tiling system comprises tiling
elements as described hereinabove.
[0092] The upper faces of the surface layers of adjacent tiling
elements may be aligned to provide a smooth surface.
[0093] According to yet a further aspect of the invention there is
provided a system of interlocking mechanisms, defined on the
flanges of a substrate elements as described hereinabove, wherein
the engagement of the attachment formations of adjacent substrate
elements allow the substrate elements to move longitudinally and
transversely to the engaged attachment formations. The engagement
of the attachment formations may form a pincher lock.
BRIEF DESCRIPTION OF THE DRAWINGS
[0094] Some of the objects of the invention have been described
above. Other objects and advantages of the invention will appear
from the description that follows. For a better understanding of
the present invention and to show how the same may be carried into
effect, the invention will now be described, by way of non-limiting
example, with reference to the accompanying diagrammatic
drawings.
[0095] In the drawings:
[0096] FIG. 1 shows an exploded, sectional side view of a cladding
system in accordance with a first embodiment of the invention;
[0097] FIG. 2 shows a bottom view of a substrate element of the
cladding system of FIG. 1;
[0098] FIG. 3 shows a side elevational view of the substrate
element of FIG. 2;
[0099] FIG. 4 shows a top plan view of the substrate element of
FIG. 2;
[0100] FIG. 5 shows a side elevational view of the substrate
element of FIG. 4;
[0101] FIG. 6 shows a three-dimensional view of a modular
structural element of the tiling system of FIG. 1;
[0102] FIG. 7 shows an exploded top plan view of the cladding
system of FIG. 1;
[0103] FIG. 8 shows a detail, exploded sectional side view of the
engagement of two adjacent substrate elements of the cladding
system of FIG. 1;
[0104] FIGS. 9 to 12, each show alternative configurations for the
engagement formations of cladding systems in accordance with a
second, third, fourth and fifth embodiment of the invention,
respectively;
[0105] FIGS. 13 to 15 show process steps for the engagement of the
substrate elements of the cladding system of FIG. 1;
[0106] FIG. 16 shows a side elevational view of the cladding system
of FIG. 1, showing a protective spacer, protruding adjacent each
surface layer of cladding material;
[0107] FIG. 17 shows a sectional side view of the cladding system
of FIG. 1;
[0108] FIG. 18 shows a cladding system in accordance with a sixth
embodiment of the invention;
[0109] FIG. 19 shows a sectional side view of engaged structural
elements of the cladding system of FIG. 1, with an oversized
surface layer;
[0110] FIG. 20 shows a sectional side view of engaged structural
elements of the cladding system of FIG. 1, with an undersized
surface layer;
[0111] FIG. 21 shows a three-dimensional, part sectional view of
the cladding system of FIG. 1;
[0112] FIG. 22 shows an exploded sectional side view of the
cladding system of FIG. 1, in a vertical orientation for use in
exterior cladding;
[0113] FIG. 23 shows a top plan view of a modular structural
element in accordance with a seventh embodiment of the invention;
and
[0114] FIGS. 24 to 27 show detailed views of engaged attachment
formations of the substrate elements of the cladding system of FIG.
1.
DETAIL DESCRIPTION OF THE DRAWINGS
[0115] Referring to the drawings, a tiling system in accordance
with the invention is generally indicated by reference numeral 10.
Where similar components in other preferred embodiments of the
invention are shown, the same reference numerals are used as for
the first preferred embodiment, with suffixes referring to the
subsequent preferred embodiments.
[0116] Referring to FIGS. 1 to 8, 16, 17, 21, and 24 to 27, a
tiling system 10 in accordance with a first preferred embodiment of
the invention includes a number of modular tiling elements 12, each
comprising a substrate element 14 and a surface layer of cladding
material, in the form of a tile 16, bonded to the substrate
element.
[0117] Each substrate element 14 is a unitary moulded unit of a
suitable material, even though it may appear from some of the
drawings as if it has a four layer construction. The substrate
element 14 can be made of a plastic material, metal, wood,
composite, or other material that has substantial structural
strength. In a preferred embodiment, the substrate element 14 is
produced as a complete unit through injection moulding, from
polystyrene or polyurethane. It can also be machined, cast or
formed. If the cladding system 10 is required to be translucent,
the substrate element 14 should be made of translucent
material.
[0118] The substrate element 14 defines a generally planar, square
face 18 onto which the tile 16 can be bonded with a suitable
adhesive. A number of ribs 22 are defined on the face 18 to
increase the structural strength of the face. A number of recesses
20 are defined between the ribs 22 and form air cavities, when a
tile 16 is attached to the face 18. The air cavities assist in
providing thermal insulation and also allow the bond between the
tile 16 and face 18 to be severed, if the tile has to be removed
from the tiling system 10, after installation, e.g. if the tile is
broken or damaged.
[0119] The entire under surface of the tile 16 is adhesively bonded
to the face 18 of the substrate element 14, which assists in
automation of the bonding process, since no parts of the underside
of the tile has to be kept free of adhesive.
[0120] The substrate element 14 has two edges that protrude beyond
the face 18 and form utility flanges 24, on adjacent sides of the
substrate element. Recesses 26 are defined along the other two
edges of the substrate element that are recessed from the face 18.
When adjacent tiling elements 12 are attached together in the
tiling system 10, each utility flange 24 is received in the recess
26 of the adjacent tiling element, so that the tile 16 extends over
the utility flange.
[0121] On each utility flange 24, a recess in the form of a
longitudinal locking groove 28 is defined adjacent the face 18, and
a recess in the form of a longitudinal adjustment groove 30 is
defined along an edge of the flange. An upper tongue formation 32
has its base between the locking groove 28 and adjustment groove
30, and extends above the adjusting groove. A lower tongue 34
extends below the adjustment groove 30.
[0122] On the two edges of the substrate element 14 defining the
recesses 26, an upper protuberance 36 extends to the edge of the
tile 16 and defines the edge of the face 18 on its top. At the
bottom of the edge of the upper protuberance 36, a longitudinal
resilient clip formation 38 is defined, that is complementary to
the locking groove 28. A recess tongue 40 extends laterally from
the substrate element 14 in the recess 26 and defines a
longitudinal protuberance 42 above its edge, the recess tongue 40
being complementary to the adjustment groove 30. A recess groove 44
is defined between the upper protuberance 36 and the recess tongue
40, and is complementary to the upper tongue 32. A further recess
45 is defined underneath the recess tongue 40, and is complementary
to the lower tongue 34.
[0123] Each locking groove 28 and the clip formation 38 of the
adjacent substrate element 14, together form a lockable set of
attachment formations, while each adjustment groove 30 and the
complementary protuberance 42 of the adjacent substrate element 14,
together form an adjustable set of attachment formations.
[0124] The locking groove 28 has a width that is substantially more
than the width of the clip formation 38 and is spaced laterally
from the adjustment groove 30. The clip formation 38 and
protuberance 42 are also spaced apart laterally, but are spaced
apart further than the locking groove 28 and adjustment groove
30.
[0125] Two protective spacers 46 extend upwardly from the substrate
element 14, between the face 18 and the utility flanges 24. When
the tile 16 is bonded to the face 18, it is positioned in close
abutment with the spacers 46, to protect the tile. The spacers 46
also define grout lines and act as axes during the installation
process.
[0126] A plurality of rib formations 48 are defined in the
underside 50 of the substrate element 14 in register with the upper
ribs 22, to provide added structural strength. A plurality of
recesses 52 are defined between the rib formations. The rib
formations 48 and ribs 22 provide structural strength for the
substrate element 14, especially when the substrate element has to
bear compression working loads applied to the tile 16, while the
recesses 52 provide thermal insulation.
[0127] The substrate element 14 lends strength to the tile 16,
resulting in a reduced likelihood of damage to the tile during
handling, transportation, installation, and use. The strength of
the tiling element 12 is further enhanced by the scattered
arrangement of attachment formations (i.e. spaced apart
horizontally) by which adjacent tiling elements are attached
together, and via which loads are transferred between adjacent
tiling elements, for flexural strength of the tiling system 10.
[0128] A part of the locking groove 28 is deeper than the rest of
the locking groove, and forms a utility groove 53, which can serve
as a conduit for conductors of heating elements, or the like.
[0129] In use, when a support structure such as an existing wall,
wooden or concrete floor, ceiling or roof, or a framework for a
wall, floor, ceiling or roof, or the like, has to be clad with any
suitable cladding material, such as tiles 16, a plurality of the
modular tiling elements 12 are prepared by bonding the tiles 16 to
the substrate elements 14. The tiling elements 12 are placed in a
generally coplanar arrangement, as shown in FIG. 7 of the drawings
and are moved closer together in a side-by-side arrangement, with
their edges in abutment. The orientation of the tiling elements 12
should all be the same, so that each utility flange 24 is brought
into engagement with a recess 26 of the adjacent tiling element and
so that the complementary formations of the utility flange and the
recess can engage.
[0130] Adjacent tiling elements 12 can be in register, or can be
staggered relative to each other. Markings 55 are provided on the
utility flanges 24 that indicate fractions of the lengths of the
tiles 16, i.e. the markings are provided at quarter and half
positions along the edges of the tiles, to assist a user in
positioning adjacent tiling elements 12 in a staggered orientation.
As can be seen in FIG. 6 of the drawings, further markings 57 are
provided to indicate the direction of installation or to show the
orientation of a surface pattern of the tile 16, or the like.
[0131] Referring to FIGS. 13 to 15 of the drawings, when the tiling
elements 12 are moved into abutment, the clip formation 38 is first
received in the locking groove 28. As can be seen in FIG. 14 of the
drawings, the upper protuberance 36 does not need to flex in any
degree to allow the clip formation 38 to engage the locking groove
28, since the tiling element 12 defining the clip formation can be
brought downwardly into engagement with the adjacent tiling
element, with the recessed tongue 40 clearing the upper tongue 42.
Once the lockable set of engagement formations, i.e. the clip
formation 38 and locking groove 28, are engaged as shown in FIG. 14
of the drawings, the tiling elements 12 are locked into engagement,
but can move laterally relative to each other, with the clip
formation 38 moving from side to side within the much wider locking
groove 28.
[0132] Referring to FIG. 15 of the drawings, the adjacent tiling
elements 12 are moved closer together, so that the recess tongue 40
and protuberance 42 are received in the adjustment groove 30. At
the same time, the upper tongue 32 is received in the recess groove
44 and the lower tongue 34 is received in the complementary recess
45 defined below the recess tongue 40 of the adjacent tiling
element. The engagement of the respective tongues 32,40,34 and
their complementary grooves 44,30,45 assist in keeping the tiling
elements 12 in engagement, prevents the edges of the tiling
elements from moving up or down relative to each other, holds the
lockable and adjustable sets of attachment formations 28,38,42,54
in engagement, assists in distributing load bearing between
adjacent structural elements 12, and provides stability when the
tiling system 10 is supported on an uneven support structure.
[0133] The engagement of the complementary attachment formations is
better illustrated in FIGS. 24 to 27 of the drawings. A wide
adjustment recess 54 is defined in the upper surface of the
adjustment groove 30, in which the protuberance 42 is receivable.
The adjustment recess 54 is much wider than the protuberance 42, so
that the protuberance can be moved from side to side within the
adjustment recess, thus allowing adjacent tiling elements 12 to
move laterally relative to each other, while the protuberance 42
and adjustment recess 54 remain in adjustable engagement. However,
the respective widths of the adjustment groove 30 and the recess
tongue 40, including the respective heights of the adjustment
recess 54 and the protuberance 42, are such that the protuberance
is received in the adjustment recess with an interference fit.
Adjacent tiling elements 12 are thus held tightly in a side-by-side
position and, although they can move laterally relative to each
other, the resistance of the interference fit between the
protuberance 42 and adjustment recess 54 first has to be overcome,
before they can move. They can also not be moved completely apart,
as described above, as a result of the engagement of the clip
formation 38 in the locking groove 28. The attachment of adjacent
tiling elements 12 prevent unwanted shifting of the tiling elements
12 during installation, but can allow movement thereafter.
[0134] The tiles 16 that can be used in the tiling elements 12, can
be of any suitable cladding material such as marble, granite or
other stone tiles, glass, mirrors, plastics, a combination of these
materials, or the like. However, in the case of some cladding
materials, such as ceramic tiles, the cost of producing these tiles
is substantially less if some variations in the dimensions of the
tiles is permitted. The faces 18 of the substrate elements 14 are
generally sized to have the same dimensions as standard rectangular
or square tiles 16, but if a tile is slightly larger than the face,
an edge of the tile will protrude beyond the end of the upper
protuberance 36, as shown in FIG. 19. In such a case, when the
tiling element 12 including the oversize tile 16 is brought into
engagement with the adjacent tiling element, the clip formation 38
will be received in the locking groove 28 and the protuberance 42
will be received in the adjustment recess 54, as described
hereinabove, but a small space 56 will be left between the ends of
the respective tongue formations 32,40,34 and their complementary
groove formations 44, 30,45. It is to be appreciated that the
oversized tile 16 can abut the spacer 46 closely, so that the
spacing between the adjacent tiles 16 is not affected by the
oversize of the tile.
[0135] Referring to FIG. 20, if a tile 16 is smaller than the face
18, the upper protuberance 36 will protrude beyond the edge of the
tile. When adjacent tiling elements 12 are installed, the clip
formation 38 is received in the locking groove 28 and the
protuberance 42 is received in the adjustment recess 50, as
described hereinabove, with the substrate elements 14 of the
adjacent tiling elements 12 abutting as closely together as they
can, but a space 58 is left between the undersize tile 16 and the
spacer 46. This space 58 can be filled up with a suitable filler,
such as grout. The spaces between adjacent tiles 16, above the
spacers, 46 in all the applications of the invention, can be filled
with a suitable filler, such as grout, and the spacers 46 assist in
providing relatively consistent gaps between the tiles, to be
grouted.
[0136] When a tiller assembles the tiling system 10, each of the
tiling elements 12 are brought into a close abutting relationship
with adjacent tiling elements, and the lateral play between tiling
elements allowed by the engagement of the protuberance 42 and the
adjustment recess 54, is used to compensate for small variances in
the dimensions of the tiles 16. Similarly, longitudinal movement
between tiling elements 12 can be used to compensate for variations
in the widths of tiles 16.
[0137] The tiling system 10 is designed to have sufficient
structural strength to bear the loads of the tiles 16, which are
supported on their entire undersides by the substrate elements 14,
and any working loads that can be applied to the tiles. If desired,
the tiling elements 12 can be attached to a support structure by
fasteners such as nails that can extend through the utility flanges
24. The fasteners can be applied in the utility grooves 53 or in
fastening slots 59 defined in the utility flanges, so that their
heads are recessed within the utility grooves. However, if the
tiling elements 12 are not so attached, they can move slightly
relative to each other, as a result of the interference fit between
the protuberances 42 and adjustment recesses 54, while being locked
together by the engagement of the clip formations 38 in the locking
grooves 28. The movement between the tiling elements 12 can allow
them to compensate for movements in the supporting structure, such
as thermal stress, moisture related deformation, structure ageing,
and the like, thus avoiding the deformations from placing the tiles
16 under stress. It should be borne in mind that most tiles 16 are
hard, but brittle, especially if they include imperfections and are
thus susceptible to break, when placed under stress.
[0138] As shown in FIG. 22, the tiling system 10 can be used in
exterior cladding, to serve as so-called "siding" or when roofs are
constructed. However, the tiling elements 12 should be installed
with their utility flanges 24 extending upwardly, so that the water
that impinges on the tiles 16 is prevented by gravity, from seeping
between tiling elements 12 and is thus prevented from reaching the
support structure covered by the substrate elements 14. The utility
groove 53 further acts as a channel for water seepage direction and
assists in draining water that may have entered between the tiles
16, so that the tiling system 10 provides a water and damp
resistant cover to the underlying support structure, without the
need for a damp resistant underlayment.
[0139] Referring to FIGS. 9 to 12, in the second, third, fourth and
fifth preferred embodiments of the invention, respectively,
alternative attachment formations in the adjustable set are shown,
which can be used as substitutes for the protuberance 42 and the
adjustment recess 54. Numerous other alternative attachment
formations can be used without being limited by these illustrative
examples. In the second preferred embodiment of the invention shown
in FIG. 9, a protuberance 42.2 is shown, which can engage with a
plurality of complementary recesses 60, each of approximately the
same width as the protuberance 42.2. In the third preferred
embodiment of the invention shown in FIG. 10, a number of tooth
formations 62 are provided on the recess tongue 40.3, that can
engage with corresponding tooth formations inside the adjusting
groove 30.3. The fourth preferred embodiment of the invention shown
in FIG. 11, includes an enlarged edge 64 of the recess tongue 40.4
that is receivable in a complementary enlarged part of the
adjusting groove 30.4. In the fifth preferred embodiment of the
invention shown in FIG. 12, the entire recess flange 40.5 has a
rounded, widened appearance and is receivable in a complementary
adjusting groove 30.5.
[0140] Referring to FIG. 18, in a sixth preferred embodiment of the
invention, the orientation of the recess tongue 40.6 and adjusting
groove 30.6 has been inverted, but the engagement of the adjacent
structural elements 12.6 is achieved in much the same way as in the
first preferred embodiment of the invention.
[0141] Referring to FIG. 23, in a seventh preferred embodiment of
the invention, a substrate element 14.7 is shown, that is the same
as the substrate element of the first embodiment of the invention,
except that four tiles 16.7 are bonded to the face of the substrate
element, with spacers 46.7 extending between the tiles. It is to be
appreciated that, while the invention has been described for use
with rectangular or square tiles 16, it is equally applicable for
any shape or size of tile, e.g. a tile that is quadrilateral or
irregular in shape.
[0142] In another preferred embodiment of the invention, a
plurality of tiling elements 12 are interlocked and checked or
locked in along the perimeter by fastening elements to form an
independent floor held down by its own weight. The invention thus
allows for selective fastening of the tiling elements 12, which can
be interlocked and free floating, or can be interlocked and
fastened to its supporting structure.
[0143] In another preferred embodiment of the invention, the
substrate element 14 of the tiling element 12 is made of a
translucent material which, in combination with a translucent
surface cladding material like onyx or glass, would result in a
tiling module with translucent qualities.
[0144] In the preferred embodiments of the invention described
above, the interlocking mechanisms of the substrate elements 14
protect the exposed flanges 24 of the substrate elements of
complementary tiling modules. The interlocking mechanisms of the
substrate layer secure the overlapping part of one tiling element
12 to the exposed overlapped flange 24 of a complementary tiling
element by forming a clipping lock within the interlocking
mechanism. The protection of each utility flange 24 by the adjacent
tiling element 12, allows the utility groove 53 to remain
functional after installation.
[0145] In the preferred embodiments of the invention described
above, the interlocking mechanisms of the substrate elements 14
provide a manner of overlap between two complementary tiling
elements 12 in order to create additional flexural strength in the
tiling system 10, while the interlocking of tiling elements 12,
gives the system increased load bearing strength.
[0146] It is an advantage of the invention illustrated, that an
ordinary unskilled person is able to install the tiling system 10.
Complementary tiling elements 12 can be installed in a flat
position, as opposed to an angled position where an element is
hinged, which creates installation problems. The preferred
embodiments of the invention thus provide a tiling system which
will eliminate costly labour, installation materials and
processes.
[0147] The invention illustrated further holds the advantage of
universal application without the need for modification, in that it
provides for a standardised method of installation, irrespective of
the particular application.
[0148] According to another preferred embodiment of the invention,
the tiling modules can be detached and reinstalled at another
location without damage.
* * * * *