Note: Descriptions are shown in the official language in which they were submitted.
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FLOOR TILE
BACKGROUND
1. Technical Field
[0001] Embodiments of the present invention relate generally to floor tiles
and, more
particularly, but not exclusively, to a floor tile that attaches to adjacent
floor tiles rather than
to the underlying surface.
2. Description of Related Art
[0002] Floor tiles are a universally popular type of floor covering, and are
commonly found
in personal residences, business offices, and industrial locations. They are
available in a
myriad of styles, sizes, colors, and patterns. Floor tiles are used in almost
every interior
location, including garages, as well as in outdoor locations such as balconies
and patios.
[0003] Most floor tiles have a finished surface that faces up, or outwards
from the floor.
This surface will generally have a color or pattern attractive to the user,
and be sufficiently
durable to be walked upon or to have furniture placed on it, while resisting
wear and
discoloration for an extended period of time. The tiles attach to the ground
by an adhesive
spread on their bottom surface.
[0004] Another type of tile attaches to adjacent tiles rather than to the
ground, and creates
a tile surface known as a "floating floor". Some tiles of this type use a
tongue and groove
system to connect to one another. In this system, one side or edge of a tile
will have a
flange or tongue, and another side will have a groove. The tongue from one
tile is pressed
or fit into the groove of an adjacent tile, securing their connection. A
floating floor tile has
an advantage of being relatively easily to install, since the floor being
covered does not
receive an adhesive and accordingly requires less preparation.
BRIEF SUMMARY
[0005] According to an aspect of the present invention, there is provided a
floor tile
comprising:
a first section having a finished surface and an opposing unfinished sectional
surface;
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a second section having a finished surface and an opposing unfinished
sectional
surface;
the first sectional surface being attached to the second sectional surface and
offset
from the second sectional surface, the offset defining a connecting edge along
the first and
second sectional surfaces,
wherein the first finished surface and the second finished surface are
opposing and
outward facing, and
wherein the floor tile is connectable to an adjacent floor tile via the
connecting
edge.
[0006] According to another aspect of the present invention, there is provided
a tile,
comprising:
a first section having first and second opposing sides, the first side being
finished,
the second side being unfinished and attachable to an unfinished side of
another tile
section, in an offset manner; and
a second section having first and second opposing sides, the first side being
finished, the second side being unfinished and attachable to an unfinished
side of another
tile section, in an offset manner,
wherein, when the second sides are attached to each other via the unfinished
sides, the offsets define a inter-tile connection section around a perimeter
of the tile.
[0007] According to yet another aspect of the present invention, there is
provided a floor
tiling system, comprising:
two reversible tiles, each tile having a first layer element offset from a
second layer
element, the layer elements having (i) a rectangular shape, (ii) a finished
side and (iii) an
opposing, unfinished side, the layer elements attachable by the unfinished
sides, the offset
resulting a strip of the first layer element extending beyond two sides of the
second layer
element and a strip of the second layer element extending beyond two sides of
the first
layer element,
wherein strips of the first layer elements are dimensioned and configured to
cooperate with strips of the second layer elements and strips of the second
layer elements
are dimensioned and configured to cooperate with strips of the first layer
elements, and
wherein the cooperation between strips yields selective interconnection of the
reversible tiles, the selected interconnection permitting selective relative
orientation of the
tiles and selection of the finished sides facing away from the floor.
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[0008] According to yet another aspect of the present invention, there is
provided a
method of making a floating floor tile, comprising:
providing a first section having a finished surface and an opposing unfinished
sectional surface;
providing a second section having a finished surface and an opposing
unfinished
sectional surface; and
adhering the sectional surfaces together in an offset manner by the unfinished
surfaces so that the sectional surface of the first section is offset from the
sectional surface
of the second section by a first predetermined distance along a length of the
second
sectional surface and by a second predetermined distance along a width of the
second
sectional surface.
[0009] These, additional, and/or other aspects and/or advantages of the
present invention
are: set forth in the detailed description which follows; possibly inferable
from the detailed
description; and/or learnable by practice of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The present invention will be further understood and appreciated from
the following
detailed description taken in conjunction with the drawings in which:
Figure 1A is a perspective view of a floor tile consistent with an embodiment
of the
present invention;
Figure 1B is a perspective view of the floor tile of Figure 1A, where the
floor tile is
turned over;
Figure 2A is a perspective view of four tiles of Figure 1A connected to each
other,
where each of the tiles are oriented with a common surface pattern facing up;
Figure 2B is a perspective view of four tiles of Figure 1A connected to each
other,
where each of the tiles are oriented with a common surface pattern facing up;
Figure 2C is a perspective view of three tiles of Figure 1A connected to each
other,
where the outer two tiles are oriented with one surface pattern facing up and
the middle tile
is oriented with a different surface pattern facing up;
Figure 3A is a perspective view of a floor tile consistent with an embodiment
of the
present invention; and
Figure 3B is an enlarged perspective view of a corner of the floor tile of
Figure 3A;
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Figures 4A-4C illustrate a method of manufacturing a floor tile consistent
with an
embodiment of the present invention, in which Figure 4A is a perspective view
of two floor
tile sections, Figure 4B is a perspective view showing the two floor tile
sections of Figure
4A being attached to make a floor tile consistent with an embodiment of the
present
invention, and Figure 4C is a perspective view of a floor tile consistent with
an embodiment
of the present invention, after manufacture and prior to installation.
DETAILED DESCRIPTION
[0011] Reference will now be made in detail to embodiment(s) of the present
invention,
examples of which are illustrated in the accompanying drawings, wherein like
reference
numerals refer to the like elements throughout. The embodiment(s) is/are
described below
to explain the present invention by referring to the figures.
[0012] Referring now to FIGS. IA and 113, there is shown a perspective view of
a floor tile
consistent with an embodiment of the present invention. As will be explained
in greater
detail below, floor tile 10 is a "floating floor" type of tile that attaches
to adjacent tiles rather
than to the underlying ground. Figure 113 is a view of the tile of FIG. IA in
which the tile is
inverted, or turned over to reveal an underside that is not visible in the
view of FIG. IA.
[0013] Floor tile 10 has two sections 12, each of which has a finished surface
14 and a
sectional surface 16. The finished surfaces 14 and sectional surfaces 16
occupy opposing
sides of their respective sections. To enhance clarity and ease of
explanation, the letter
suffixes "p" and "q" will be used to distinguish the two sections.
Accordingly, floor tile 10
has a first section 12p having a finished surface 14p and a sectional surface
16p, and has
a second section 12q having a finished surface 14q and a sectional surface
16q. In the
view of FIG. IA first section 12p is on top and second section 12q is on the
bottom, and
these positions are reversed in the view of FIG. 1 B.
[0014] By way of non-limiting example, first finished surface 14p, visible in
FIG. IA, is
shown as a woodgrain pattern, and second finished surface 14q, visible in FIG.
113, is
shown as a circle pattern. It is a feature of the floor tile of the present
embodiment that the
tile is reversible. As a result, either finished surface 14 can face up and be
the active tile
surface, with the opposing finished surface 14 facing down and in contact with
the ground.
It is to be appreciated that these particular patterns are non-limiting
examples only.
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Indeed, other patterns and/or combination of colors, patterns, textures, and
materials are
both contemplated and possible.
[0015] As shown in FIG. 1B, the sections have the same dimensions of a length
"y" and a
width "x". The sections are attached to each other back-to-back, but are
offset from a flush
connection, in which their respective corners would match, by a predetermined,
fixed
distance along their length and along their width. For greater clarity, offset
distances "dx"
and "dy" are shown on each of the figures. It can be seen from both figures
that each
section may be viewed as being offset or displaced in position relative to the
other section
by a distance dx along its width, or the "x" direction, and by a distance dy
along its length,
or the "y" direction.
[0016] It can further be seen that the offset positioning of sections 12
defines a connective
edge or strip 18 around the perimeter of floor tile 10. Connective edge 18 is
half on one
section and half on the other, as it is the portion of each sectional surface
16 that is not
covered by the opposing section. Accordingly, in FIG. 1A the portion of
connective edge
18 that is on second sectional surface 16q may be easily seen as a strip along
the long
edge of the tile having a length y and a width dx, and a strip along the short
edge of the tile
having a length x and a width dy. Similarly, in FIG. 1 B, the portion of
connective edge 18
that is on first sectional surface 16p may be easily seen as a strip along the
long edge of
the tile having a length y and a width dx, and a strip along the short edge of
the tile having
a length x and a width dy.
[0017] For greater clarity, a dashed line 20 is drawn on the figures to
indicate the hidden
edge of the bottom section in that figure. It is to be appreciated that the
hidden part of
connective edge 18 in each figure, designated 18', can be represented or
visualized as the
strip between dashed line 20 and the outer edge of the top section. In this
way, the portion
of connective edge 18 on sectional surface 16p may be seen as hidden
connective edge
18' in FIG. 1A, and the portion on sectional surface 16q may be seen as hidden
connective
edge 18' in FIG. 1 B. As a last note on terminology, due to their relative
position, the
portion of connective edge 18 occupying the sectional surface 16, or bottom,
of a top
section may be characterized as an "overhang", while the portion occupying the
sectional
surface 16, or top, of a bottom section may be characterized as an
"underhang".
Accordingly, hidden connective edges 18' in FIGS. IA and 1B are overhanging,
and visible
connective edges 18 may be called underhanging edges.
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[0018] Floor tiles 10 can be connected to each other by first turning each
tile so that the
desired finished surface 14 is facing up. The tiles are placed side-by-side so
that an
overhanging connective edge 18 on one tile faces an underhanging connective
edge 18 of
the adjacent tile. The tiles are pushed together so that the connective edges
18 are flush
with each other. Connective edges 18 may then be attached using an adhesive or
glue as
is known in the art. In some embodiments the adhesive is already placed on
connective
edge 18, and is shipped with a protective cover or sheet. In such cases the
sheet is
removed just prior to attachment of connective edges 18. In other embodiments
the
adhesive may be applied at the time of installation. The connected tiles 10
will form a
smooth and uninterrupted floor surface.
[0019] Examples of connected tiles are shown in FIGS. 2A, 2B, and 2C. In FIG.
2A the
active surface is the woodgrain pattern of finished surface 14p, and in FIG.
2B the active
surface is the circle pattern of finished surface 14q. Figure 2C shows a
variation in which a
circle pattern tile is sandwiched between two woodgrain pattern tiles. It is
to be
appreciated that in practice, some of the floor tiles 10 shown in FIGS. 2A,
2B, and 2C may
be cut in length by the installer to produce a more staggered and visually
pleasing
appearance.
[0020] The figures also show several dashed tile outlines to show where a
subsequent tile
might be installed, to indicate the manner in which tiles 10 may be connected.
Accordingly,
tiles may be connected long side to long side, as shown by tile outline 22,
short side to
short side, as shown by tile outline 23, or long and short sides together, as
shown by tile
outline 24. Tile outline 25 also shows that a tile may be placed long side to
short side.
[0021] It is to be appreciated that the dimensions of floor tile 10 may vary
over a wide
range while still retaining the characteristics of the present invention. The
width of
connective edge 18 along either dx or dy should be sufficiently large so that
there is
enough surface area to establish a strong and secure connection between tiles,
when the
adhesive is applied and the tiles are joined. The appropriate size may depend
on the
application. For example, a tile floor placed in a garage would have to
withstand the
pressure of an automobile upon it. In such a case a relatively wider
connective edge may
be appropriate, in order to obtain a stronger connection. By way of a non-
limiting example,
a tile found to be adequate in a garage floor has the dimensions of 36 inches
long, 12
inches wide, and 1 %4 inch wide for both dx and dy, i.e. all portions of
connective edge 18.
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In other embodiments, dx and dy may be slightly smaller or larger, for
example, 1 inch or 1
'/2 inches in width.
[0022] The distances dy may equal dx, so that connective edge 18 is uniform
all around
floor tile 10. Alternatively, dy may differ from dx. By way of a non-limiting
example, one
may be 1 % inches and the other 1 inch or 1 '/z inches. In designing a
finished floor using
floor tiles 10, for any two tiles that are joined, the respective overhanging
and
underhanging connective edges 18 preferably are substantially the same in
width.
[0023] When a tile is connected long side to long side, as shown in tile
outlines 22 and 24
in FIG. 2A, the connective edges 18 of the joined tiles each have the width
dx. Similarly,
when tiles are connected on their short sides, as shown in tile outlines 24
and 23 in FIGS.
2A and 2B respectively, the connective edges 18 of the joined tiles each have
the width dy.
Accordingly, when using a tile set in which dy and dx are different, these
types of
connections would not be a problem. However, when connecting a long side of a
tile to a
short side of another tile, as shown for example in tile outline 25 of FIG.
2B, the connection
is between dx from one tile and dy from another. Accordingly, a tile from the
same set
could not be used in that case as the long edge tile against a set of
previously installed
short tiles. In such a case, a substitute floor tile 10 from another set could
be selected
whose width dx matches the width dy of the previously installed short-edge
tiles.
[0024] Preferably, connected tiles have the same offset along the common
joining edge so
that when the tiles are attached, the respective connective edges 18 will fit
over one
another precisely, and the joined tiles will abut one another, leaving no gap
between them.
If there is a discrepancy in width there is a likelihood that a gap will occur
between the tiles.
For example, if one tile has connective edge 18 that is 1 '/4 inches wide and
the adjoining
tile has a connective edge that is 1 1/8 inches wide, there will be a 1/8 inch
gap formed.
[0025] Gaps are undesirable because they mar the appearance of the tile floor,
collect dirt,
and make the floor harder to clean. In some applications a gap between tiles
could lead to
one of the tiles becoming loose and dislodged. For example, in the case of a
tile floor
installed in a garage, it is common for water to fall on the floor from rain
or snow coming in
through an open garage door, or from a person's shoes or an automobile driven
into the
garage. Where the tile surface is smooth and uninterrupted by gaps, the water
will
eventually evaporate and be harmless. However, water that falls into a gap may
present a
problem to the stability of the tile floor. For example, if a car drives over
the gap, the heavy
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weight will press the water against the side of the tile. This will place a
high pressure
against the tile and may weaken the tile's attachment to its adjacent tile.
Alternatively, the
water may be forced under the tile, where it could be prevented from
evaporating and
cause further problems. If the garage is in a cold environment during winter
the water in
the gap could freeze and turn into ice. This would cause the water to expand,
which would
also exert a strong force or pressure against the tiles, weakening their
adhesion and
potentially dislodging one or both.
[0026] Floor tile 10 of the present embodiment can be made from any material
suitable for
a floor tile. An example of a material that is inexpensive and in common use
is vinyl.
Accordingly, in some embodiments of the invention, each section 12 can be
solid vinyl.
The finished surfaces 14 may be, for example, a color and/or pattern applied
to one
surface of the section, and the opposing, non-colored surface would be the
corresponding
sectional surface 16.
[0027] Additionally and/or alternatively, as Figures 3A and 3B illustrate,
instead of being
composed of a single layer, each or both section 12 could have two or more
layers or
laminations. For example, each section could have a layer 24 made of polyvinyl
chloride
(pvc) and have as another layer a plastic film 26 attached to a surface of pvc
layer 24. The
plastic film 26 could have a hardness, durability, color, and pattern suitable
for use as
finished surface 14. The opposing surface, on pvc layer 24, would be sectional
surface 16.
[0028] Figure 3A shows a floor tile 10 consistent with an embodiment of the
present
invention in which the sections 12 have the layers described above. In this
figure, the tile
is shown with several curves or waves along its length, to reflect the fact
that most
embodiments of floor tile 10 are made from soft and flexible material and are
therefore
inherently flexible. Figure 3B is an enlarged view of a corner of the floor
tile of FIG. 3A,
showing the layers in more detail. Accordingly, FIG. 3B shows a first pvc
layer 24p and
first film layer 26p from first section 12p, and second pvc layer 24q and
second film layer
26q from second section 12q. For greater clarity, connective edge 18, which is
part of
sectional layer 16q, is shown shaded in FIG. 3B.
[0029] An adequate thickness for pvc layer 24 has been found to be about 1.5
mm, or
approximately 0.094 inches. Film layer 26 is relatively much thinner.
Accordingly, floor tile
10 shown in FIGS. 3A and 3B is about 3 mm.
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[0030] A benefit this two-layer construction in comparison to single layer
construction, such
as one using solid vinyl, is that it is easier to make a greater variety and
more attractive
patterns for finished surface 14, as film layer 26 is a more versatile medium
than plain
vinyl. Another benefit is that the pvc used in pvc layer 24 is a relatively
stronger material
than plain vinyl. For some applications, such as in the floor of a garage,
where the floor tile
may be exposed to extremes of temperature, water, snow, and the weight of an
automobile, it is advantageous to have a tile formed from a stronger material
like pvc.
[0031] Alternatively, the floor tile 10 can have more than two layers. It is
to be appreciated
that floor tile 10 can be designed to have as many layers with specially
configured
characteristics as appropriate for the application. For example, if it is
desired to have a
softer feel or more give in the floor, a middle foam layer may be inserted
between pvc layer
24 and film layer 26.
[0032] Since floor tile 10 is reversible, and it is desirable for the tile
characteristics to be
the same regardless of which finished surface 14 is being used, it is
preferred that sections
12 be symmetrical, that is, where each section has the same number of layers
with the
same physical qualities. However, in at least one embodiment of the present
invention
sections 12 having a different number of layers and/or layers with different
qualities could
also be used.
[0033] Figures 4A, 4B, and 4C illustrate a method of manufacturing a floor
tile 10
consistent with an embodiment of the present invention. In these figures the
sections 12
are shown thicker for clarity.
[0034] The method begins, as shown in FIG. 4A, by first making or obtaining
the two
sections 12p and 12q, where the sections are separate and unattached. An
adhesive or
glue 28 is applied to the bottom, or sectional surfaces 16 of each section.
[0035] Figure 4B shows the process by which the sections are attached. Section
12p is
shown oriented the same as in FIG. 4A, with finished section 14p facing
upwards. Section
12q is inverted and placed across from section 12p so that sectional surfaces
16 face one
another. For illustration purposes, an offset plane 30 is shown in dashed line
in FIG. 4B.
Offset plane 30 has the same dimensions as section 12p, but is offset from
section 12p by
dx and dy for the desired predetermined distances along the section's width
and length.
The inverted section 12q is aligned with offset plane 30 and not with section
12p. The two
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sections are then brought together, as indicated by arrow 32, to the point of
contact, and
form a permanent connection or bond upon the adhesive hardening.
[0036] Figure 4C shows the completed floor tile 10, ready for packaging,
shipment, and
installation. In order to prevent uncovered adhesive 28 on connective edge 18
from drying
out and becoming unusable, a protective cover or sheet 34 such as wax paper is
applied to
the exposed edges. At the time of installation, sheet 34 is removed and the
adhesive
becomes available to connect the tile as described above.
[0037] As noted, the manufacturing process is preferably sufficiently precise
so that the
desired widths of dx and dy for a given set of tiles is substantially uniform
for the set.
While dx could be either the same as dy or different from dy for a given set
of tiles, the dx
values of the tiles preferably substantially match one another, and the dy
values preferably
substantially match one another.
[0038] As the foregoing illustrates, embodiments of the present invention
provide floor tiles
that have, unlike conventional tiles that have only a single floor quality or
finished surface,
two such surfaces. For example, floor tile 10 has been shown above with a
woodgrain
pattern surface and a circle pattern surface. Accordingly, the same tile could
be sold to
users that desire either a woodgrain surface pattern or a circle surface
pattern. All that
would need to be done would be to turn the tile at the point of installation
so that the
appropriate surface faces up.
[0039] This aspect of floor tile 10 may provide cost savings for tile
retailers, distributors,
and installers, due to simplified logistics and improvements in inventory
control. For
example, a buyer may anticipate demand of about 5000 woodgrain pattern tiles
and 5000
circle pattern tiles. However, the exact breakdown in any given season may be
difficult, if
not impossible, to know in advance. The actual demand may turn out to be, for
example,
6000 woodgrain pattern tiles and 4000 circle pattern tiles. To ensure that no
sales are lost,
the buyer may feel compelled to order 6500 of each of the two tile types, or
13,000 tiles
total. Accordingly, as a result of the inherent uncertainty in measuring
demand, the buyer
will incur additional costs for procurement and storage. In addition, an
excess of unsold
tiles of one type may result in additional carrying costs and/or heavy losses
due to
discounting.
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[0040] By contrast, a buyer may only need to order, for example, 10,000 to
11,000 floor
tiles 10 that have both types of surfaces, and be able to meet demand for both
types
regardless of the particular breakdown that year. Further, the risk of being
stuck with a
suddenly unpopular color or pattern may be reduced. Yet another benefit is
that new
colors or patterns could be introduced into the marketplace by placing them on
the reverse
side of tiles having patterns that are known to be popular. In this way, if
the new tile design
is unsuccessful, the tiles can still be used and not have to be returned or
discarded at a
loss.
[0041] Another advantage of floor tile 10 is that the section that contacts
the underlying
ground provides extra distance and insulation from the ground. This section
may be
thought of as being, in effect, a "second floor". This aspect of the invention
may be
particularly beneficial for tiles that are used in garages, balconies, patios,
or other locations
subject to extremes of temperature or climate. As noted, repeated extremes of
temperature over several seasons cause concrete to expand and contract, which
may
stress and break a tile placed too close to the ground. The ground-contacting
section of
floor tile 10 helps to dissipate or reduce the extent to which this shifting
in the ground
effects the top section and finished surface of the tile. As a result, floor
tile 10 may last
longer than a conventional tile used in that application, and/or may be able
to resist
breakdown entirely.
[0042] Although selected embodiment(s) of the present invention has/have been
shown
and described, it is to be understood that the present invention is not
limited to the
described embodiment(s). Instead, it is to be appreciated that changes may be
made to
this/these embodiment(s) without departing from the principles and spirit of
the invention,
the scope of which is defined by the claims and the equivalents thereof.
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