U.S. patent application number 11/486908 was filed with the patent office on 2008-06-05 for moisture-resistant cover floor system for concrete floors.
Invention is credited to Lawrence M. Janesky.
Application Number | 20080127593 11/486908 |
Document ID | / |
Family ID | 39474158 |
Filed Date | 2008-06-05 |
United States Patent
Application |
20080127593 |
Kind Code |
A1 |
Janesky; Lawrence M. |
June 5, 2008 |
Moisture-resistant cover floor system for concrete floors
Abstract
A cover floor system for covering a sub floor is provided. The
cover floor system has a plurality of interlocking floor tiles. The
tiles have a cover floor surface and a grid of supporting legs
adapted to elevate the cover floor surface over the sub floor and
form a gap between the cover floor surface and the sub floor. At
least two tiles are coupled together with a lap joint. The lap
joint is formed by a first lap portion, disposed on one of the two
tiles, and a mating second lap portion on the other tile. The first
lap portion has a lower lap seating surface offset from the cover
floor surface. The mating second lap portion has an upper lap
surface seating against the lower lap seating surface and defining
a substantially continuous lap scene along interfacing sides of the
two tiles when the tiles are coupled.
Inventors: |
Janesky; Lawrence M.;
(Seymour, CT) |
Correspondence
Address: |
PERMAN & GREEN
425 POST ROAD
FAIRFIELD
CT
06824
US
|
Family ID: |
39474158 |
Appl. No.: |
11/486908 |
Filed: |
July 14, 2006 |
Current U.S.
Class: |
52/581 ;
52/591.1 |
Current CPC
Class: |
E04F 15/182 20130101;
E04F 15/02194 20130101; E04F 15/105 20130101; E04F 15/185 20130101;
E04F 15/186 20130101; E04F 15/18 20130101; E04F 2201/0138
20130101 |
Class at
Publication: |
52/581 ;
52/591.1 |
International
Class: |
E04F 15/18 20060101
E04F015/18; E04F 15/02 20060101 E04F015/02 |
Claims
1. A cover floor system for covering a floor, the system
comprising: a plurality of interlocking floor tiles, the tiles
having a cover floor surface and a grid of supporting legs adapted
to elevate the cover floor surface over the floor and form a gap
between the cover floor surface and floor; at least two of the
tiles being coupled together with a lap joint formed by a first lap
portion, disposed on one of the at least two tiles, and a mating
second lap portion disposed on another of the at least two tiles;
the first lap portion having a lower lap seating surface offset
from the cover floor surface, and the mating second lap portion
having an upper lap surface seating against the lower lap seating
surface and defining a substantially continuous lap seam along
interfacing sides of the at least two tiles when the at least two
tiles are coupled together.
2. The system of claim 1, wherein the cover floor surface extends
over the lap seam.
3. The system of claim 1, wherein the lower lap seating surface has
a hoop formed therein, and the upper lap surface has a pin
projecting therefrom and wherein, when the lower lap seating
surface and the upper lap surface are mated one to the other, the
pin is engaged through the hoop.
4. The system of claim 1, wherein the cover floor surface and the
lap joint substantially prevent water vapor and moisture from
passing through the floor cover floor surface, formed by the
interlocking tiles, to a space above the cover floor surface.
5. The system of claim 1, wherein the floor is a basement concrete
floor, and the gap between cover floor surface and basement floor
is arranged to allow water vapor and gasses to pass between the
cover floor surface and the concrete floor.
6. The system of claim 1, wherein the first lap portion comprises a
retaining surface, and wherein, the mating second lap portion
comprises a retaining tab, and wherein the retaining tab engages
the retaining surface preventing lifting of the cover floor surface
between the at least two interlocking tiles.
7. The system of claim 1, wherein at least one of the interlocking
tiles is anchored to the floor anchoring the system to the floor,
and at least another of the interlocking tiles unanchored to the
floor and is capable of movement relative to the floor.
8. The system of claim 1, wherein free play is built into
interlocking joints of the interlocking tiles allowing for relative
movement between interlocking tiles and floor.
9. The system of claim 1, wherein the pin extends to the floor and
supports the floor covering supporting surface.
10. The system of claim 1, wherein the interlocking floor tiles
comprise molded polypropylene.
11. The system of claim 1, wherein each of the interlocking tiles
is a substantial square tile having four sides, and wherein two of
the four sides comprise have the first lap portion disposed
thereon, and wherein another two of the four sides have the mating
second lap portion disposed thereon.
12. A cover floor system for covering a floor, the system
comprising: a plurality of interlocking floor tiles, the tiles
having a cover floor surface and a grid of supporting legs adapted
to elevate the cover floor surface over the floor and form a gap
between the cover floor surface and floor; the interlocking floor
tiles coupled together with lap joints capable of sealing
interfacing edges of adjoining tiles against infiltration of water
vapor and moisture between the interfacing edges; wherein at least
one of the interlocking tiles is anchored to the floor anchoring
the cover floor surface defined by interlocked tiles to the
floor.
13. The system of claim 12, wherein the lap joints provides
relative play between the interlocking tiles allowing unanchored
interlocking floor tiles to move relative to the floor.
14. The system of claim 12, further comprising a surface layer
superposed over the cover floor surface of the interlocking
tiles.
15. The system of claim 14, wherein the superposed layer is a
carpeting or vinyl layer.
16. The system of claim 12, wherein each interlocking floor tile
comprises a plurality of pins and a plurality of hoops for
interlocking the tiles.
17. The system of claim 12, wherein the interlocking floor tiles
are made of molded polypropylene.
18. A floor covering for covering a basement concrete floor, the
floor covering comprising: a super floor adapted to be superposed
over and supported by the concrete floor; a carpet or other floor
covering supported by the super floor; the super floor having a
plurality of interlocking floor tiles, the floor tiles having a
cover floor surface, upon which the carpet or other floor covering
is disposed; the interlocking floor tiles coupled together with a
floating interlocking joint providing relative play between the
interlocking floor tiles allowing the interlocking floor tiles to
move relative to each other; wherein, the floating interlocking
joint substantially prevents water vapor and moisture from passing
from the concrete floor through the cover floor surface to the
carpet or other floor covering.
19. The floor covering of claim 18, wherein the floating
interlocking joint is a floating lap joint, and is adapted to
accommodate relative movement between interlocking floor tiles due
to thermal expansion or contraction of the tiles.
20. The floor covering of claim 18, wherein at least one of the
interlocking floor tiles is fastened to the concrete floor, and
wherein, the interlocking floor tiles have a grid of supporting
legs adapted to allow water vapor and moisture to pass between the
cover floor surface and the concrete floor.
Description
RELATED APPLICATIONS
[0001] This application is related to U.S. patent application Ser.
No. 10/624,290 Filed Jul. 21, 2003 hereby incorporated by reference
in its entirety.
BACKGROUND
[0002] 1. Field of the Embodiments
[0003] The disclosed embodiments relate to a cover floor system for
covering sub floors and, such as a moisture resistant sub floor
tile system for covering concrete floors.
[0004] 2. Description of Earlier Related Developments
[0005] Concrete floors, particularly concrete floors installed or
poured over the dirt surfaces of sub-terranean rooms such as
basement living spaces of homes or the ground-level rooms or work
spaces of slab-homes or buildings, are particularly susceptible to
water vapor penetration. Such concrete floors may be covered with
plastic tiles or carpeting to improve their appearance and make
them more comfortable to the feel. However, concrete floors are
relatively porous and also conduct the cold temperature of the
ground, which can result in water vapor penetration and
condensation at the interior surface of the concrete floor, causing
separation of plastic floor tiles adhered thereto or causing a
moisture accumulation in carpeting adhered thereto or applied there
over, resulting in mold or mildew. Water vapor and water can
penetrate and diffuse through the porous concrete floor from the
dampness of the soil or ground beneath the concrete, and also
through cracks which can develop in the concrete and/or also can
penetrate through interfaces between the floor and the walls and/or
footings. As a result, sub-floors may be built over concrete floors
using wooden studs as spacers and covering them with plywood to
form an interior floor surface which is then covered by floor tile
or carpeting. Such a system is an insulation improvement, but takes
up to 2'' of headroom or more. Water vapor can be absorbed by the
wooden studs and plywood, resulting in mold, mildew, rot and odors,
and separation of tiles from the plywood floor. An alternative to
the finished surface being directly applied to the concrete or to a
wood based sub floor system with the finished surface being applied
to it as described is to provide a modular floor tile system where
the finished surface is made up of a series of interlocking plastic
tiles that are seated on the concrete. Such a system is disclosed
in U.S. Pat. No. 6,098,354. A problem with such a modular tile
system arises where water vapor from the concrete floor may still
penetrate into the room through the joints between the tiles. A
further problem arises in such a system where temperature changes
cause thermal expansion and contraction of the tiles. Here, with a
rigid interlocking system, the tiles are over constrained
potentially causing buckling, joint failure or gaps at the
peripheral edges. Accordingly, there is a desire to provide a sub
floor system upon which a finished surface may be applied that is
not over constrained and that prevents the migration of water vapor
from the concrete floor to the covering or the room.
SUMMARY OF THE EMBODIMENTS
[0006] In accordance with the first exemplary embodiment a cover
floor system for covering a sub floor is provided. The cover floor
system comprises a plurality of interlocking floor tiles. The tiles
have a cover floor surface and a grid of supporting legs adapted to
elevate the cover floor surface over the sub floor and form a gap
between the cover floor surface and the sub floor. At least two
tiles are coupled together with a lap joint. The lap joint is
formed by a first lap portion, disposed on one of the two tiles,
and a mating second lap portion on the other tile. The first lap
portion has a lower lap seating surface offset from the cover floor
surface. The mating second lap portion has an upper lap surface
seating against the lower lap seating surface and defining a
substantially continuous lap scene along interfacing sides of the
two tiles when the tiles are coupled.
[0007] In accordance with another exemplary embodiment a cover
floor system is provided. The floor system comprises a plurality of
interlocking floor tiles. The tiles have a cover floor surface and
a grid of supporting legs adapted to elevate the cover floor
surface over the sub floor and form a gap between the cover floor
surface and sub floor. The interlocking tiles are coupled together
with lap joints capable of sealing interfacing edges of adjoining
tiles against infiltration of water vapor and moisture between the
interfacing edges. At least one of the interlocking tiles is
anchored to the sub floor anchoring the cover floor surface of the
floor system.
[0008] In accordance with another exemplary embodiment a floor
covering for covering a basement concrete floor is provided. The
floor covering comprises a super floor and a carpet or other floor
covering. The super floor is adapted to be superposed over and
supporting by the concrete floor. The carpet or other floor
covering is supported by the super floor. The super floor has a
plurality of interlocking floor tiles. The floor tiles have a cover
floor surface upon which the carpet or other floor covering is
disposed. The tiles are coupled together with a floating
interlocking joint providing relative play between the interlocking
floor tiles allowing the interlocking floor tiles to move relative
to each other. The floating interlocking joint substantially
prevents water vapor and moisture from passing from the concrete
floor through the cover floor surface to the carpet or other floor
covering.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The foregoing aspects and other features of the exemplary
embodiments are explained in the following description, taken in
connection with the accompanying drawings, wherein:
[0010] FIG. 1 is an isometric view of a basement corner and a floor
system, incorporating features in accordance with an exemplary
embodiment, disposed on the basement floor;
[0011] FIG. 2 is an isometric view of the upper surface of a floor
tile of the floor system in FIG. 1;
[0012] FIG. 3 is an isometric view of the lower surface of the
floor tile in FIG. 2;
[0013] FIG. 4 is a plan view of the upper surface of the floor
tile;
[0014] FIG. 5 is a plan view of the lower surface of the floor
tile;
[0015] FIG. 6 is an isometric view of a corner of the upper surface
of the floor tile;
[0016] FIG. 7 is an isometric view of a corner of the lower surface
of the floor tile;
[0017] FIG. 8 is an end view of the floor tile as seen along view
lines 8-8 in FIG. 4;
[0018] FIG. 9 is another end view of the floor tile as seen along
view lines 9-9 in FIG. 4;
[0019] FIG. 10 is a section view of the floor tile taken along
lines 10-10 in FIG. 5;
[0020] FIG. 11 is a section view of the floor tile taken along
lines 11-11 in FIG. 5; and
[0021] FIG. 12 is a partial section view of a floating joint
between tiles of the floor system.
DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENT(S)
[0022] Referring to FIG. 1, there is shown an isometric view of a
basement corner having a floor and a cover or upper floor system 20
incorporating features in accordance with an exemplary embodiment.
Although the present invention will be described with reference to
the embodiments shown in the drawings, it should be understood that
the present invention can be embodied in many alternate forms of
embodiments. In addition, any suitable size, shape or type of
elements or materials could be used.
[0023] In the embodiment shown, a system 20 is provided for
flooring, through the floor surfaces of the flooring system, of
over for example, on-grade concrete floors and preventing water
vapor and moisture penetration through the floor surfaces of the
flooring system, of and for insulating them from the temperatures
of the surrounding soil. System 20 generally involves interposing
an insulating, thermal air-gap forming, cover floor 24, for example
made of high density plastic that acts as a barrier between
concrete floor 26 and carpet or other suitable floor covering 28.
Cover floor 24 may generally cover the concrete floor 26 of a
basement, or at least a desired portion thereof and provides a
floor surface 24S for supporting carpet or other floor covering 28.
Although the flooring system 20 of the exemplary embodiment will be
described below with specific reference to application onto a
basement floor, in alternate embodiments the flooring system may be
used with, and the features of the exemplary embodiment are equally
applicable to installation on any desired type of sub floor. In
FIG. 1, the floor covering system 20 is shown assembled to cover at
least a portion of the basement floor 26. For purposes of the
description the basement floor 26 will be referred to as a sub
floor in regards to the cover floor surface 26S formed by the cover
floor of the system 20. Flooring system 20 may generally be similar
to the floor cover system described in U.S. patent application Ser.
No. 10/624,290, filed Jul. 21, 2003 previously incorporated by
reference herein in its entirety.
[0024] In the exemplary embodiment, cover floor 24 is shown
fastened, for example at least at one location to the concrete
floor, preventing the cover floor from moving or shifting as a unit
over the sub floor, but does not over constrain the cover floor and
can accommodate relative movement between cover floor and sub
floor. For example, are to thermal expansion/contraction, as will
be described in greater detail further below. In alternate
embodiments, cover floor may not be fastened at all to concrete
floor. Free play may be built into the interlocking floor tiles to
allow for expansion and contraction. Cover floor 24 may comprise an
interlocking floor tiles 32, 34 and acts as a barrier to prevent
passage of water or water vapor from below the cover floor 24, for
example, due to plumbing, water heater leaks or flooding. The tiles
that make up cover floor 24 may be made from a suitable material,
such as plastic, (e.g. molded polypropylene or polyethylene). The
plastic material for example, may use no organic materials. As may
be realized, a plastic cover floor 24 will not delaminate in a
moist atmosphere and will not support mold and the consequences
thereof. Cover floor 24 has a solid, planar or flat upper surface
24S, that may be substantially impermeable to moisture and water
vapor and may support carpet 28 or padding 30 as an outer covering,
if desired. In alternate embodiments, the cover floor surface may
not be covered and may act as the primary floor surface. In
alternate embodiments, any suitable floor covering may be used in
combination with the cover floor. The cover floor surface 24S may
be elevated over the basement sub floor and isolated from the
concrete floor by a barrier air gap described below.
[0025] Water vapor can not penetrate the plastic barrier cover
floor 24 from the porous concrete either through the tiles, for
example, tiles 32, 34 or through the inter tile joints, for
example, joints 36, 38 between the plastic tiles. In this exemplary
embodiment, interlocking floor tiles 32, 34 are coupled together
with a lap joint 36, 38. The lap joint 36, 38 may be formed by a
first lap portion on tile 34 and a mating second lap portion on
tile 32. As will be described in greater detail below, the first
lap portion has a lower lap or seating surface, in the exemplary
embodiment, substantially parallel to, and offset from the floor
surface 24S. The mating second lap portion has an upper lap surface
positioned to seat against the seating surface of the first lap
portion. In the exemplary embodiment, the upper lap surface may be
parallel to, and offset from the floor surface 24S. In the
exemplary embodiment, the interlocking joint(s) 36,38 coupling the
floor tiles 32, 34 together and having in the exemplary embodiment
a, lap fit, formed by the first portion and the mating second
portion, may also be configured (as will be described further
below) to provide relative play between the interlocking floor
tiles allowing the interlocking floor tiles to thermally expand and
contract. Hence, the lap fit at the interlocking joints may be
referred to as a variable or floating lap and the joints, for
example joint(s) 36, 38 as floating lap joints. In the embodiment
shown, the floor cover surface 24S in cooperation with the lap
joint(s) 36, 38 may substantially prevent water vapor and moisture
from passing from the concrete floor to an interior space of the
basement. As a result, a water-resistant flooring system is
provided for insulating against dampness and cold penetration from
concrete sub-floors, and which will not be damaged by water
penetration from any direction or source, including above-floor
plumbing problems or flooding.
[0026] In greater detail now, and referring still to FIG. 1 in the
embodiment shown, the tiles that make up cover floor 24 may be
substantially similar to each other. In alternate embodiments, the
cover floor tiles may be different in size and shape. In the
exemplary embodiment, the tiles 32, 34 may have any desired size
and shape such as 6'', 12'', 17'', 24'' square or 48'' or even
4.times.8 rectangular sheets, and for example, about 3/8'' to 3/4''
thick, which fit or interlock together such as with a floating lap
joint, as will be described in more detail below. In alternate
embodiments, the tiles may have any desired size and shape. The
tiles, for example tiles 32, 34, that make up a flooring system,
may comprise a strong, substantially rigid, and substantially flat,
solid layer or panel of water-resistant or impervious plastic, such
as ABS, polyvinyl chloride, polyethylene, polypropylene or
polycarbonate, which is either molded with integral spaced plastic
legs or spacers such as studs or slots, or other raised areas on
the underside thereof. In alternate embodiments, the solid panel of
the tile may be laminated, bonded, or otherwise attached to a
separate water-resistant solid plastic barrier sheet which is
molded with integral spaced plastic legs or spacers such as studs,
slots or other raised and/or depressed areas on the underside
thereof. The spaced leg portions may contact the surface of the
concrete floor and thus space and support the underside of the flat
plastic panel from the surface of the concrete floor to provide an
insulating thermal air gap barrier space. The barrier space or gap
provided thereby may be of any suitable size, for example between
about 1/8'' and 1'' high, to admit and circulate any water vapor,
for example, penetrating up through or collecting on the concrete
floor beneath the cover floor layer 24. In the exemplary
embodiment, the air gap barrier space may provide a space network
within which the water vapor may circulate and come into
equilibrium with the water content of the porous concrete floor. As
a result, water condensation may be avoided or substantially
reduced by the spacers or leg portions which create the air gap
barrier space. Water vapor from the concrete floor cannot condense
within the air gap, and humid air from the basement living space
cannot penetrate the interlocked plastic tiles to condense on the
concrete floor. In alternate embodiments the barrier gap between
cover floor and sub floor may be vented, by passive or active
means, and exhausted for example outside the basement or other
suitable space. The top surfaces of the plastic panel may be planar
and may have a desired surface characteristic such as a decorative
design formed thereon, or the planar upper surface of the plastic
barrier tile layer may have a color which is aesthetic, or the tile
layer may be after-covered with a conventional ceramic or plastic
tile layer or with carpeting or a vinyl surface such as linoleum or
vinyl flooring.
[0027] Referring now to FIG. 2, there is shown an isometric view of
the upper surface 40 of floor tile 32. Referring also to FIG. 3,
there is shown an isometric view of the lower surface 44 of floor
tile 32. Referring also to FIG. 4, there is shown a plan view of
the upper surface 40 of floor tile 32. Referring also to FIG. 5,
there is shown a plan view of the lower surface 44 of floor tile
32. In the embodiment shown, plastic tile 32 is molded as a unitary
plastic tile element. In alternate embodiments, plastic tile 32 can
be formed with planar upper and lower surfaces with a number of
individual plastic studs or spacers and network walls, adhered to
the planar lower tile surface. In alternate embodiments, any
suitable method may be applied in fabricating tile 32. As noted
before, plastic tile board 32 may be in the form of a 12 inch
square tile board having opposed edges designed to form a lap
joint. In alternate embodiments any suitable size or shape may be
provided. Tile 32 has a first mating portion 50, 52 along two edges
and a second mating portion 54, 56 along the other two edges (see
FIGS. 2-3). The first mating portion is provided for mating with
corresponding complementary second mating portions on adjacent
tiles to lock the tiles to each other and produce a
substantially-continuous, smooth floor surface which is
substantially water impervious. The configuration of the first and
second mating portions shown in FIGS. 2-5 is merely exemplary, and
the tile mating portions may have any other suitable configuration
in alternate embodiments. As seen in FIGS. 2-4, in the exemplary
embodiment where each interlocking floor tile may have four sides
two of the four sides comprise the first portion, and the other two
of the four sides comprise the mating second portion. In the
exemplary embodiment, interlocking floor tile 32 comprises a number
of pins 80 and a matching number of hoops 82 (in alternate
embodiments more or fewer pins and hoops may be provided).
[0028] As seen in FIG. 1, the cover floor 24 is formed from
multiple tiles, each provided with complimentary mating first and
second portions, the tiles may be interlocked in any manner where
the hoops and the pins align. For example, two tiles 32, 32A may be
connected in line with each other or tiles 32, 34 may be offset one
from another as shown in FIG. 1 for example the amount of lateral
offset between tile edges may a multiple of the pitch 84 shared by
the pins and the hoops. As noted before, in the exemplary
embodiment, the interlocking floor tiles are coupled together with
a lap joint formed by the first mating portion and a mating second
portion of the tiles. As seen in FIG. 2, first portion 50, 52 has a
lower lap surface 86 (see also FIG. 6). In the exemplary embodiment
the lower lap surface, that forms a lap seat for the second mating
portion, may be substantially parallel to and offset from the floor
covering supporting surface. In alternate embodiments, the lower
lap surface may have any desired configuration. In the exemplary
embodiment, the lower lap surface has a hoop(s) 82 formed therein.
The lower lap surface forms a substantially continuous surface
along corresponding edges of the tile. The mating second portion
54, 56 has an upper lap surface 88 generally disposed to complement
the lower lap surface 86. Hence, in the exemplary embodiment, the
upper lap surface may be parallel to and offset from the floor
cover surface 40, though in alternate embodiments the upper lap
surface may have any desired shape. In the embodiment shown, upper
lap surface 88 is shown having molded recesses 90 (see also FIG.
7). In alternate embodiments, molded recesses 90 may not be
provided. In the embodiment shown, the lower lap surface of a tile
32 mates with the upper lap surface of a corresponding mating tile
34. In the exemplary embodiment the lower lapped surface may be
movable relative to the mating upper lap surface of the
corresponding tile as will be described below. As generally
described before and seen best in FIG. 3, each tile 32, 34 has a
solid planar upper surface 40 and a discontinuous under surface
comprising spaced support studs or legs and wall sections which
project a distance from the undersurface of the tile to contact the
supporting surface, of the sub floor such as the concrete basement
floor. In the exemplary embodiment shown in FIG. 3, the
undersurface comprises spaced intermediate network wall sections
which project a lesser distance from the undersurface of the tile
and do not contact the surface of the supporting floor. As
discussed before the resulting space network operates to inhibit
condensation on the surfaces of the barrier space between the
underside and sub floor. The network sections shown in FIG. 3 is
merely exemplary, generally comprising a wall grid work, to form
substantially square compartments, with diagonal, intermediate
height, bracing walls and a central post or support leg of maximum
height. In order to provide a circulation airspace beneath the tile
32 openings or ports are provided in the perimeter walls to enable
any water vapor to circulate or be moved through an air circulation
network beneath all areas of each tile and across the joint of
mating tiles. Air circulation spaces are provided between adjacent
tiles between the lap joints along adjacent edges of each tile. In
the exemplary embodiment shown, floor tile 32 has a floor covering
surface 40 and an array of supporting legs 58, 60, 62 adapted to
allow water vapor and moisture to pass between the floor covering
surface 40 and the concrete floor. Plastic tile 32 are molded to
have integral spaced plastic support studs or legs 58, 60 or wall
sections 62 projecting a maximum distance from the underside 64 of
supporting surface 40 to form lower tile surface 44 that contacts
the concrete sub floor. Legs or studs 58, 60 and wall sections 62
are repeated and shown for example in staggered and offset rows
such that the tile is uniformly supported. These sections may have
any desired height such as 1/8'' up to about 1'', for example about
3/8'', and may be closely spaced and staggered in rows, as shown,
for desired tile support and stability. Intermediate plastic grid
sections 66, 68, 70, 72 of intermediate height are also provided,
allowing air and vapor to freely pass between the bottom of the
sections 66-72 and sub floor when the tile is seated with the full
height leg or wall sections against the sub floor. Intermediate
sections also provide structural integrity to tile 32 in order to
effectively support desired loads. (See also FIGS. 8-9, that show
respective end views of the representative tile 32, and FIGS. 10-11
showing different sections/views illustrating the sections of tile
32 and passages and network array formed thereby.) In the exemplary
embodiment, intermediate wall sections may also define the airspace
network that is continuous and open, and serves as thermal break
and accumulator of water vapor under the tile cover floor surface.
In the exemplary embodiment, grid sections 68-72 may further define
the array of insulation spaces or chamber provided on the underside
of the tile board and over the interconnect air space network
separating the tile surface 40 and basement floor. In the
embodiment shown, studs or legs 58, 60 or wall sections 62 may be
spaced from each other to provide a desired distribution of the
interconnected airspace network, under each tile, and hence under
the cover floor 24 (see FIG. 1) to prevent water vapor passing
between concrete floor and cover floor from being isolated in any
chambers created by the tile legs or standoffs, so that the water
vapor does not condense into water under tile 32. As noted before,
the interconnected airspace under the cover floor 24 allows drying
of any water that may temporarily collect under the floor tiles,
(e.g. water from an above-floor plumbing leak, water heater leak,
etc. or water from a periodic groundwater leak such as from the
floor-wall joint of the foundation). As also noted before, a vent
(not shown) may be provided to vent the space between the concrete
floor surface and the underside of the tiles. For example, this can
be done passively, such as at the edge of the floor, or actively,
such as with a fan, to blow air under or to draw air from under the
floor and exhaust it into a desired space (e.g. an interior
collector) or outside of the building, to dry the space under the
floor either continuously or only when desired.
[0029] Referring now to FIG. 6, there is shown an isometric view of
a corner of the upper (i.e. floor) surface 40 of floor tile 32.
Referring also to FIG. 7, there is shown an isometric view of a
corner of the lower surface 44 of exemplary floor tile 32. As noted
previously, lower lap surface 86 that forms the lower seating
surface of the coupling lap joints, may be in the exemplary
embodiment, generally, parallel to surface 40 and offset from the
cover floor complement lap surface (formed by surface 40) by an
amount 92 (see FIG. 6). Distance amount 92 may be about equal to
thickness 94 of portion 54, that in the exemplary embodiment may
extend from surface 40 making up upper lap surface 88. In alternate
embodiments, the lapping portions of tiles may have any other
desired shapes forming a lap fit joint when the tiles are mated. As
seen best in FIG. 6, in the exemplary embodiment the lower lap
surface has hoops 82 formed therein. Hoops 82 have a radius portion
98 and a notched portion 100 (see FIG. 7). A retaining surface 102
may be provided to engage with a retaining tab of a tile mated to
tile 32. As seen in FIGS. 6-7, in the exemplary embodiment, the
lower lap surface 86 forms a substantially continuous surface
penetrated by hoops 82. In alternate embodiments, the hoops may be
separate and independent from the lower lap surface. In other
alternate embodiments, the lower lap surface may have mating pins,
similar to pins 80, formed thereon. Complementing lap portion 54
has upper lap surface 88 positioned to seat in a complementary
manner on the lower lap surface 86 (of a mating tile). In the
exemplary embodiment, the upper lap surface may be generally
parallel to and offset from the floor covering supporting surface
40. In the embodiment shown, upper lap surface 88 is shown having
molded recesses 90. This may provide increased seating pressure
between lap surfaces. In alternate embodiments, molded recesses 90
may not be provided. As seen best in FIG. 7, pin 80 and resiliently
flexible retaining tab 104 are provided coupled to upper lap
surface 88. In the exemplary embodiment pin 80, tab 104 shown, form
in effect a cross sectionally resiliently variable coupling pin. In
the exemplary embodiment, pin 80 may have a general a c-shaped
cross section. In alternate embodiments, any suitable shape may be
provided. The shape of the pin 80 may allow relative movement in
the loop 82 (as indicated by arrow A in FIG. 7). Retaining tab 104
is provided to bias and engage a retaining surface of a tile mated
to tile 32 to provide a firm but pliant coupling between tiles. In
the embodiment shown, the lower lap surface mates with the upper
lap surface of a corresponding tile and is movable relative to the
upper lap surface of the corresponding tile.
[0030] Referring now to FIG. 12, there is shown a section view of
an exemplary resiliently floating lap joint 50 between floor tile
32 and floor tile 34. The interlocking floor tiles 32, 34 are
coupled together with a lap joint similar to lap joint 36 having a
first lap portion and a mating second lap portion. As seen in FIG.
12, the lap joint 50 provides relative play between the
interlocking floor tiles allowing the interlocking floor tiles to
move relative to each other, for example due to thermally expansion
and contraction. Lower lap surface 86' is provided parallel to
surface 42 and offset from the cover floor surface 42 by an amount
92 about equal to thickness 94 of portion 54 extending from surface
40 making up upper lap surface 88. The lower lap surface 86' has
hoop 82' formed therein. Hoops 82' have a radius portion 98' and a
notched portion 100'. A retaining surface 102' may be provided to
engage with resiliently flexible retaining tab 104 of tile 32 mated
to Tile 34. Retaining tab 104 may have lead a lead in portion 116,
that may be tapered or ramped, allowing the extension portion 118
of tab 104 to resiliently deflect during assembly (in the direction
indicated by arrow R in FIG. 12) to the point where tab 104 clears
retaining portion 102', snapping in position. Engagement portion
120 interfaces with retaining portion 102' and may be tapered to
allow nominal clearance or to preload the lap joint together as
shown in FIG. 12. Engagement portion 120 has length 122 that is
greater than desired resilient flexure 114, such that engagement
portion 120 does not disengage the retaining portion 102' during
expansion and contraction of the tiles or from other movement.
Here, the lower lap surface 86' forms a substantially continuous
surface surrounding hoops 82'. As seen in FIG. 12, lap portion 54
has upper lap surface 88 seated against lower lap surface 86. Pin
80 may be tapered, for example at section 124, enabling ease of
assembly. In the exemplary embodiment, retaining tab 104 engagement
of retaining surface 102' prevents the interlocking floor tiles
from separating in direction 112 and creating discontinuities in
the floor covering supporting surface. In the embodiment shown, the
lower lap surface 86' mates with the upper lap surface 88 of tile
32 and is movable in direction 108 relative to the upper lap
surface of the corresponding tile. The relative play is enabled
with clearance 114 provided between pin 80 and hoop 82'. That is
capable of accommodating relative movement in the direction
indicated by arrow A in FIG. 7 (out of plane of the figures in FIG.
12) Clearance 114 allows pin 80 to move in direction 108 relative
to hoop 82'. In the embodiment shown, the joint may be provided
with additional sealant 110, for example, such as silicone or a
gasket to further enhance the isolation between the concrete to the
flooring.
[0031] Referring now again to FIG. 1, as noted before, in the
exemplary embodiment one or more tiles 32 may be anchored (via
fasteners, adhesive, etc.) to the basement sub floor 26. Relative
movement between coupled tiles (anchored and unanchored), due to
thermal expansion/contraction, may be accommodated in the exemplary
embodiment by the movable lap joints. Anchorment of the cover floor
tiles facilitates an improved installation and fit or any surface
floor covering 28, 30 (e.g. carpeting, vinyl flooring, etc.)
preventing shifting, distortion and/or potential lifting of the
surface covering that may result from the movement of the cover
floor 24S as a unit.
[0032] It should be understood that the foregoing description is
only illustrative of the invention. Various alternatives and
modifications can be devised by those skilled in the art without
departing from the invention. Accordingly, the present invention is
intended to embrace all such alternatives, modifications and
variances which fall within the scope of the appended claims.
* * * * *