Abstract:
Landscaping/building tile systems comprising a plurality of individual tiles secured by a plurality of interlocking fastening strips. In one aspect, the tile systems comprise a plurality of tile sections, each of which includes a plurality of individual tiles, that can be secured together to form a single, unitary mat.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     1. Field of the Invention  
         [0002]     The present invention relates generally to an interlocking tile system for use in landscaping and architectural applications. In another aspect, the invention relates to a system comprising a plurality of tile sections secured together by a lattice structure of interlockable fastening strips.  
         [0003]     2. Description of the Prior Art  
         [0004]     Landscaping and architectural tiles are particularly popular building materials because of their attractiveness and durability. Architectural tiles, particularly those used indoors as flooring and wall covering, are commonly made of ceramic, porcelain, or natural stone materials which makes the tiles particularly suitable for high-traffic, moisture prone areas. Conventionally, indoor architectural tiles are laid on a surface one at a time and must be secured together using grout. Occasionally, depending upon the wear and tear inflicted upon the tiles, the grout must be replaced. Also, the grout is susceptible to mold and mildew which can lead to discoloration thereof and damage the aesthetic qualities of the tile system.  
         [0005]     Landscaping tiles are useful in creating outdoor walkways, patios, borders and the like and most commonly are made from durable materials that are relatively weather resistant. Like the indoor architectural tiles, landscaping tiles are conventionally laid one at a time and must be generally tightly packed so as to prevent weeds from growing up therebetween. In some applications (particularly on uneven terrain) it may be necessary to apply cement between the tiles in order to hold them in place relative to each other. Also, these conventional tile systems, which are relatively inflexible once set into place, are susceptible to damage caused by freezing and thawing cycles of the ground.  
       OBJECTS AND SUMMARY OF THE INVENTION  
       [0006]     It is, therefore, an object of the present invention to provide an interlocking tile system enabling relatively quick assembly of large sections of tiles into a single, unitary mat that does not require grout to hold the individual tiles in place.  
         [0007]     It is a further object of the invention to provide a tile system that is sufficiently flexible to follow the natural contours of a surface and to account for the swelling and contraction of the surface due to temperature changes.  
         [0008]     It should be understood that the above-listed objects are only exemplary, and not all the objects listed above need be accomplished by the invention described and claimed herein.  
         [0009]     Accordingly, one aspect of the present invention concerns a tile system comprising: (a) a plurality of tile sections, each tile section including (i) a plurality of individual tiles cooperatively defining a plurality of transversely extending channels, and (ii) a mesh attached to at least some of the tiles; and (b) a plurality of interlockable fastening strips received in the transversely extending channels and securing the tile sections to one another.  
         [0010]     Another aspect of the present invention concerns a tile system comprising: (a) a plurality of individual tiles cooperatively defining a plurality of transversely extending channels; (b) a mesh attached to at least some of the tiles; (c) a plurality of spacer blocks attached to at least a portion of the mesh opposite the tiles; and (d) a plurality of elongated, interlockable fastening strips received in the transversely extending channels and securing the tiles to one another.  
         [0011]     A further aspect of the present invention concerns a method of laying tile comprising the steps of: (a) placing first and second tile sections next to one another, each of the tile sections including a plurality of individual tiles and a mesh attached to at least some of the individual tiles, the individual tiles cooperatively defining first transversely extending channels within each of the tile sections, the first and second tile sections cooperatively defining a second transversely extending channel therebetween; (b) placing a first interlocking fastening strip in at least a portion of the first channel of the first tile section and in at least a portion of the first channel of the second tile section, the first fastening strip intersecting the second channel; and (c) placing a second interlocking fastening strip in the second channel between the first and second tile sections, the second fastening strip interlocking with the first fastening strip. 
     
    
     BRIEF DESCRIPTION OF THE DRAWING FIGURES  
       [0012]     A preferred embodiment of the present invention is described in detail below with reference to the attached drawing figures, wherein:  
         [0013]      FIG. 1  is an expanded view of an interlocking tile system with a lattice structure of interlocking strips that overlap between tile sections;  
         [0014]      FIG. 2  is an exploded view of an interlocking tile system showing the individual tiles, intermediate mesh, spacer blocks, and interlocking strips;  
         [0015]      FIG. 3  is a close-up cross-sectional view of an interlocking tile system laid upon a surface;  
         [0016]      FIG. 4  depicts a tile anchoring system comprising a screw-type auger and washer with a section of tile shown in phantom;  
         [0017]      FIG. 5  is a top view of a wedge-shaped tile section;  
         [0018]      FIG. 6  is a top view of a plurality of the tile sections shown in  FIG. 6  arranged to form a curved tile system;  
         [0019]      FIG. 7  is a top view of a tile system having a pre-designed image formed by the assembly of a plurality of tile sections; and  
         [0020]      FIG. 8  is a top view of another tile system having a pre-designed imaged formed therein. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0021]     Referring initially to  FIG. 1 , a tile system  10  is shown comprising a plurality of tile sections  12 , each of which includes a plurality of individual tiles  14 . Fastening strips  16 ,  18  are used to couple and lock tile sections  12  together. The assembly of tile system  10  is described in more detail below.  
         [0022]     As shown in  FIG. 2 , tile section  12  includes a plurality of individual tiles  14  coupled together by a durable mesh section  20 . Preferably, mesh section  20  is secured to the bottom surface  22  of tiles  14  by a first adhesive layer  24  (see  FIG. 3 ). Spacer blocks  26  are secured to mesh  20  by a second adhesive layer  28 . In alternate preferred embodiments, mesh  20  may also be embedded within tiles  14  during fabrication thereof and spacer blocks  26  eliminated.  
         [0023]     Tile section  12  comprises a plurality of transversely extending channels  28 ,  30  defined by the edges of the plurality of individual tiles  14 . A plurality of fastening strips  16  are set in channels  28  which run substantially parallel to each other. Strips  16  comprise a plurality of grooves  32  which extend from the top edge  34  of the strip to some point above the bottom edge  36  of the strip. Preferably, grooves  32  extend to some point proximate the mid-point between the top and bottom edges  34 ,  36  of strip  16 . Grooves  32  are positioned at the intersection of channels  28  and  30 .  
         [0024]     Strips  18  comprise a plurality of grooves  38  which extend from the bottom edge  40  of strip  18  to some point below the top edge  42  of the strip. Preferably, grooves  38  extend to some point proximate the mid-point between top and bottom edges  40 , 42  of strip  18 . Strips  18  are placed in channels  30  which also run substantially parallel to each other, but intersect channels  28  is a substantially perpendicular manner. It is not always necessary for channels  28 ,  30  to run parallel to each other, respectively, or intersect in a substantially perpendicular manner. As explained in the discussion of  FIGS. 5 and 6  below, these channels may be oblique relative to each other and intersect in an oblique manner. Grooves  38  are positioned at the intersection of channels  28  and  30  and mate with grooves  32  formed in strips  16 . This interlocking action of strips  16  and  18  creates a unitary lattice structure that occupies at least a portion of the space between tiles  14  and operates to fix tiles  14  in position.  
         [0025]     Strips  16 ,  18  comprise a plurality of fastening tabs  44  attached to the respective bottom edges  36 ,  40  thereof. Tabs  44  are generally hook-shaped and configured for insertion through mesh  20 . The generally hook-shaped structure of tabs  44  prevents the withdrawal of tabs  44  from mesh  20  and, consequently, the removal of strips  16 ,  18  from channels  28 ,  30 . Spacer blocks  26  operate to space mesh  20  from the surface  46  ( FIG. 3 ) upon which tile system  10  is applied and give channels  28 ,  30  added depth so as to facilitate insertion of tabs  44  through mesh  20 . In those embodiments that omit spacer blocks  26 , i.e., where mesh  20  is embedded in tiles  14  during fabrication thereof, mesh  20  is placed at some point between the top and bottom surfaces of tile  14 , and preferably at some point closer to the bottom surface than the top surface of tile  14 .  
         [0026]     Strips  16 ,  18  are placed in channels  28 ,  30  so that only a portion of strip  16 ,  18  is located entirely within channels  28 ,  30  of any one particular tile section  12 . It is preferable for at least a portion of strips  16 ,  18  be positioned in at least a portion of channels  28 ,  30  of adjacent tile sections  12 . Thus, adjacent tile sections  12  are secured together by strips  16 ,  18  and formed into unitary tile system  10 . Any portions of strips  16 ,  18  which extend beyond the outer boundaries of tile system  10  may be trimmed away as necessary.  
         [0027]     Turning now to  FIG. 3 , a cross-sectional view of tile system  10  is shown after being laid upon surface  46 . Preferably, tile system  10  is installed on the ground and is useful for forming a tile patio, walkway, or simply a decorative landscaping feature; however, tile system  10  may also be used indoors. After a plurality of tile sections  12  are laid upon surface  46 , fastening strip  16  is inserted into channel  28  and fastening tabs  48  are inserted through mesh  20 . The tabs  48  illustrated in  FIG. 3  depict an alternate embodiment than tabs  44  illustrated in  FIGS. 1 and 2 . Tabs  48  comprise a more arrow-like, or even pyramidal, shape as opposed to hook-shaped tabs  44 . As shown, surface  46  provides a relatively level grade for tile system  10 . In such an arrangement, it is not necessary to permanently couple system  10  with surface  46 . The weight of system  10  is sufficient to keep it in relatively fixed position with respect to surface  46 .  
         [0028]     Tile system  10  may also be used with uneven or sloping terrain. In such applications, the tile system  10  may be secured to the ground using an anchor  50  to prevent erosion of the underlying soil. In the embodiment illustrated in  FIG. 4 , one tile  14  and the corresponding spacer block  26  are removed from tile system  10  by cutting through mesh  20 . A retaining plate  52  is placed in the void left by tile  14 . Plate  52  comprises an outer lip  54  which rests upon the top surfaces of tiles  14  adjacent to the void. Plate  52  further includes a circumferential inwardly and downwardly sloping sidewall  56  which terminates in a recessed surface  58 . Recessed surface  58  includes a central annular orifice formed therein which enables anchor  50  to be inserted therethrough. The shaft  62  of anchor  50  is helically flighted so that anchor  50  will bore into the ground when rotated. Anchor  50  also contains a hex-head  60  so that a wrench or socket may be used to rotate and drive anchor  50  into the ground. Washer  64  provides a resting surface for hex-head  60  and prevents hex-head  60  from passing through the annular orifice of recessed surface  58 . The anchoring system shown in  FIG. 4  allows anchor  50  to be located entirely below the grade of tiles  14  thereby reducing the potential stumbling hazard presented by anchor  50 .  
         [0029]     Tiles  14  may be constructed of any natural or synthetic material suitable for use as tiling. Preferred tile materials include porcelain, concrete, stone, aggregate, brick, synthetic resin material (such as PVC, polypropylene, or polyethylene), metal, glass, wood, other cellulose-based materials, and combinations thereof. Preferably, the tile material is relatively fairly weather resistant, especially if tiles  14  are used in an outdoor application.  
         [0030]     Likewise, mesh  20  is preferably formed from a durable, moisture resistant material. Preferably, the mesh material is also be relatively flexible enabling anchoring tabs  44  to pass therethrough without breaking. Preferred mesh materials include, natural and synthetic resin materials (such as rubber, polypropylene, polyethylene, nylon), natural and synthetic fibrous materials, and metals such as stainless or galvanized steel. The size of mesh  20  is selected in conjunction with the size of the locking tabs  44  used therewith. Mesh  20  is large enough to permit insertion of tabs  44  therethrough (taking into account some slight deformation of the mesh), but fine enough to prevent withdrawal of tabs  44  therefrom.  
         [0031]     Fastening strips  16 ,  18  are also formed of a durable, moisture resistant material. The strip material is preferably more rigid than the mesh material, but is still capable of some flexing, particularly for applications in which channels  28 ,  30  are slightly curved. Examples of these types of applications are shown in  FIGS. 5 and 6 . Preferred fastening strip materials include both natural and synthetic resin materials such as those described above, and metals such as stainless or galvanized steel. The aesthetic qualities presented by the fastening strip material is also an important quality because at least portion of the strips will be visible when strips  16 ,  18  are installed in channels  28 ,  30 . In this regard, the color of strips  16 ,  18  may be selected so as to contrast with the tiles, and may be of differing widths to further accentuate various features of tile system  10 .  
         [0032]      FIGS. 5 and 6  depict wedge-shaped tile sections  66  that can be used to create curved portions in a tile system  68 . Wedge-shaped sections  66  may be manufactured as such, or, more preferably, formed by cutting a rectangular tile section  12  with an appropriate tile cutting tool. The wedge-shaped sections  66  may be used to create curving walkways or borders around objects such as trees and shrubs. It is important to note, however, that the invention is not limited to merely rectangular tile sections  12  or wedge-shaped sections  66 . Tile sections of virtually any shape may be cut and used with the present invention. Also, it is within the scope of the invention to use individual tiles that are non-rectangularly shaped (i.e., triangular, hexagonal, octagonal, curvilinear, etc.). It is also possible for differing tile shapes to be used in the same tile section. For example, rectangular tiles may lay adjacent triangular tiles, all of which being bound together by the same mesh  20 . Of course, the shape of the tiles may affect the channels formed between adjacent tiles, and thus alter the configuration of the lattice structure formed by fasting strips  16 ,  18 .  
         [0033]     Tiles  14  are secured together in such an manner so as to be flexible enough to accommodate being placed on uneven surfaces and still allow water to permeate therebetween and reach the underlying surface. However, tiles  14  and fastening strips  16 ,  18  are placed close enough together so as to prevent grass or weeds from growing in between tiles  14 . Optionally, adhesive or mortar applied to the bottom surfaces of spacer blocks  26  may be used to fixedly secure tile system  10  when system  10  is to be used in an architectural setting or as a high-traffic walkway.  
         [0034]      FIGS. 7 and 8  depict exemplary decorative designs which may be formed with the present invention. As shown in  FIG. 7 , tile system is in the form of an United States flag having alternating rows of tiles  70 ,  72  for the flag stripes and an field  74  having alternating tiles  14  representing the stars. This tile system  10  may be packaged and sold as a complete unit enabling the purchaser to install this particular design in a preferred location.  FIG. 8  is a fanciful design pattern formed by a plurality of identical tile sections  12  formed into a tile system  10 .  
         [0035]     The preferred forms of the invention described above are to be used as illustration only, and should not be used in a limiting sense to interpret the scope of the present invention. Obvious modifications to the exemplary embodiments, set forth above, could be readily made by those skilled in the art without departing from the spirit of the present invention.  
         [0036]     The inventor hereby states his intent to rely on the Doctrine of Equivalents to determine and assess the reasonably fair scope of the present invention as it pertains to any apparatus not materially departing from but outside the literal scope of the invention as set forth in the following claims.