ANTI-SLIP FLOOR TILE ASSEMBLY WITH INLAID TILES AND METHOD OF MAKING AN ANTI-SLIP FLOOR TILE

A floor tile is disclosed that includes a metal frame, a backing plate, and a plurality of tiles assembled to the metal frame and the backing plate. The metal frame defines a plurality of openings, and has a thickness T. The openings are separated by a plurality of connected strips that are coated with an anti-slip coating. The backing plate is attached to a bottom side of the metal frame. The plurality of tiles are each assembled into one of the plurality of openings with the backing plate supporting the tiles. The tiles have a height H that is less than T and have a top surface that is recessed below the anti-slip coating on the connected strips.

TECHNICAL FIELD

This disclosure is directed to a method of making an anti-slip floor tile and the floor tile made by the method.

BACKGROUND

Floor tiles are used in a wide variety of applications and are used for their aesthetic appeal, durability, and ease of installation. Floor tile products may be made of ceramic, glass, granite, marble, wood and other hard surface materials. One problem with such floors is that they may become slippery when wet when used in areas such as building lobbies or commercial kitchens. These types of flooring applications are frequently exposed to surface hazards such as water and spilled food, beverages, and cooking products.

This disclosure is directed to solving the above problems and other problems as summarized below.

SUMMARY

According to one aspect of this disclosure, a floor tile is disclosed that includes a metal frame, a backing plate, and a plurality of tiles assembled to the metal frame and the backing plate. The metal frame defines a plurality of openings, and has a thickness T. The openings are separated by a plurality of connected strips that are coated with an anti-slip coating. The backing plate is attached to a bottom side of the metal frame. The plurality of tiles are each assembled into one of the plurality of openings with the backing plate supporting the tiles. The tiles have a height H that is less than T and have a top surface that is recessed below the anti-slip coating on the connected strips.

According to other aspects of this disclosure, the floor tile may further comprise an adhesive applied between the tiles and both the plurality of openings and the backing plate that bonds the tiles to the openings and backing plate.

The metal framework may be aluminum and the anti-slip coating may be a stainless steel coating.

The connected strips may extend in a linear array or may be curved. The connected strips may be formed from a single panel by forming holes in a blank or may be formed separately and then welded together.

The anti-slip coating is a metal coating that is metalized (applied by plasma stream deposition) on the plurality of intersecting strips. The anti-slip coating may be applied by other metal-on-metal application technique provided that the coating provides a textured surface.

According to another aspect of this disclosure, a method is disclosed for making a floor tile. The method includes the following steps beginning with the step of providing a metal frame defining a plurality of openings. Applying an anti-slip coating to an upper surface of the metal frame. Attaching a base plate to a bottom surface of the metal frame. Applying an adhesive between the tiles and both the openings in the metal frame and the base plate. Assembling a plurality of tiles with each tile being assembled into one of the plurality of openings to secure the tiles in the openings on the base plate with a top surface of the tiles being recessed relative the upper surface of the metal frame.

According to other aspects of the method, the method may also include the step of punching the plurality of openings to form the metal frame.

The step of applying the anti-slip coating may be performed by spraying a molten metal coating on the top surface of the metal frame.

The metal framework is preferably made of aluminum, or an aluminum alloy, but may also be formed of another metal such as stainless steel, steel, copper, brass, or the like. The anti-slip coating is preferably stainless steel or a stainless steel alloy but may also be formed of another metal.

According to another aspect of this disclosure, a floor tile is disclosed that includes a metal framework that defines a plurality of connected strips. The plurality of connected strips are coated with an anti-slip coating. A plurality of tiles are assembled to the metal framework between the plurality of connected strips. The tiles have an upper surface that is recessed below the top surface of the connected strips when installed.

According to other aspects of the floor tile, the tiles may be ceramic tiles, glass tiles, marble tiles, wood tiles, or granite tiles.

The plurality of tiles may be attached to the metal framework and the base plate by an adhesive.

The metal framework may define openings that extend from a bottom surface of the metal framework to the top surface of the metal framework.

The above aspects of this disclosure and other aspects will be described below with reference to the attached drawings.

DETAILED DESCRIPTION

Referring toFIGS.1and2, a floor tile assembly10is illustrated inFIG.1that includes a metal framework12(hereinafter “framework”) and a plurality of tiles14. The framework12may also be referred to as a metal tile support panel, or a metal tile. The metal framework is supported on a base plate16that also supports the tiles14. The tiles14are assembled to the framework12and permanently affixed with an adhesive (not shown) applied between the framework12, the base plate16and the tiles14. An anti-slip coating18is applied to the framework by spraying molten metal on an upper surface20of the framework12. The molten metal spray may also be applied to the base plate16.

As shown inFIGS.3and4, the framework12is preferably made of aluminum or an aluminum alloy to minimize the weight of the floor tile assembly10. Alternatively, the framework12may be made of steel, stainless steel, or another metal or metal alloy. A plurality of openings22are cut in the upper surface20of the framework12. The openings22as shown are square, but the openings22may be rectilinear, circular, ovate, or irregular in shape depending upon the shape of the tiles14that are assembled to the framework12. The openings22are separated by strips24formed on the upper surface20that are coated with the anti-slip coating16and is shown by stippling on the upper surface20. The openings22are each adapted to receive a tile14.

The anti-slip coating18is preferably made of a stainless steel alloy to provide a surface that does not corrode and provide a hard, durable surface covering the framework12. The stainless steel alloy is preferably applied to the upper surface20by spraying molten stainless steel from welding rods (not shown) in an arc-welding process onto the upper surface18. The process is described in applicant's prior U.S. Pat. No. 5,711,118 the disclosure of which is incorporated by reference.

The tiles14are preferably ceramic tiles that provide a durable surface and offer flexibility in design and an aesthetically pleasing appearance. Alternatively, the tiles14may be made of marble, glass, wood, fiberglass, plastic, granite, or the like. The tiles14may be rectilinear, circular, ovate, or irregular in shape. The tiles14are shown with small dots on their top surface inFIG.4.

FIG.5is a cross-section taken through the line5-5inFIG.3. The tiles14are shown to be disposed in the openings22inFIG.6. The anti-slip coating18is applied to the framework12and is above the surface of the tiles14when the tiles are attached to a floor to assure that a person walking on the floor tile assembly10(shown inFIG.1) will contact the anti-slip coating18on the strips24formed between the tiles14.

Referring toFIGS.5and6, the openings22have a depth D and the tiles14have a height H that is less than D The tiles have a top surface26that is recessed below the anti-slip coating18on the strips24.

The tiles14are secured to the framework12by a conventional tile adhesive (not shown) applied between the tiles14and the openings22. The adhesive is primarily applied between a bottom surface28of the tiles14and to a supporting upper surface30of the openings22. The upper surface30provides support for the tiles14. Any gaps between the lateral sides32of the tiles and the openings22may be filled with adhesive.

Referring toFIG.7, a method of making the floor tile assembly ofFIGS.1-6is illustrated by a flow chart. According to the method, a metal blank is provided at40that is then punched at42to form the plurality of openings22in the framework12. The upper surfaces20of the framework12is abraded at44by shot-blasting to clean and roughen the upper surfaces20. At46, a molten metal anti-slip coating18is sprayed on an upper surface of the framework12and may also be applied to the base plate below the openings22. At52, an adhesive is applied between the tiles14and the openings22at50and the tiles14are assembled into the openings22. An optional aspect of the method is that the portion of the anti-slip coating18applied to the base plate16exposed in the openings22increases the roughness of the base plate and improves the adhesion of the tiles to the framework12. The adhesive is cured at54and, after curing, the floor tiles10are attached to a floor with a tile adhesive at56.

The embodiments described above are specific examples that do not describe all possible forms of the disclosure. The features of the illustrated embodiments may be combined to form further embodiments of the disclosed concepts. The words used in the specification are words of description rather than limitation. The scope of the following claims is broader than the specifically disclosed embodiments and also includes modifications of the illustrated embodiments. In addition, the features of various implementing embodiments may be combined to form further embodiments of the invention.