Abstract:
The present invention is a tile system that does not require a grout or other material to be spread over the tiles during the installation process. Accordingly, the tile system includes tiles that carry a flange that attaches to adjacent tiles upon installation. The flange serves the function of the grout and eliminates the need for a separate grout compound. A tile in accordance with the present invention includes a primary tile component and a flange for attaching for other tiles.

Description:
FIELD OF THE INVENTION  
       [0001]     The present invention is directed generally toward floor and wall covering tiles. More particularly, it is directed towards a tile system that does not require a grout compound to be applied to the tiles after installation.  
       BACKGROUND OF THE INVENTION  
       [0002]     Ceramic tiles are widely used as a floor and wall covering in both residential and commercial applications. Tile is very versatile, and has been in use as a floor and wall covering for centuries. Tiles are available in a nearly unlimited color palette and may be installed in an equally unlimited number of designs. Tile is often a top choice for floor and wall coverings because of its great durability and aesthetic qualities.  
         [0003]     While many tiles are manufactured from ceramic compositions (baked clay), they may be made of a variety of natural or synthetic materials including, but not limited to, granite, quartz, marble, soapstone, plastic, wood, or any other suitable material.  
         [0004]     Tile provides a durable surface and may be coated to be substantially impervious to water and other liquids. When tiles are installed, they are generally laid side by side on a surface such as a floor or wall. Typically, an adhesive compound is used as a base to attach the tiles to a surface and then grout is spread over and between the tiles to further bind the tiles to the surface and to fill spaces between adjacent tiles. While not impervious to water and moisture, the grout provides a barrier to reduce moisture between and behind the tiles. This step of grouting the tiles is labor intensive and represents a significant portion of the labor involved in a typical tile installation.  
         [0005]     Due to the time and labor involved in tile installation, it is typically quite costly to have tile professionally installed. Accordingly, many homeowners desire to install tile in their own homes. Unfortunately, this is an extremely tedious process, and many homeowners do not wish to spend the time necessary for a satisfactory installation.  
         [0006]     In recent years, manufactures have attempted to produce do-it-yourself tile solutions that are easier to install. One such attempt is described in United States published patent application number US 2004/0031226 entitled “Pre-glued Tongue and Groove Flooring” by Miller et al. Miller et al. describes a laminated “tile” that uses a pre-applied glue for fastening the tiles together. While this system is easier to install than traditional tiles, it still requires a separate grout to be applied and uses a laminate material rather than a solid tile. A laminate material, is not likely to be as durable as more traditional materials such as ceramic or stone tiles. Additionally, because the Miller et al. tile system makes use of a laminated structure that is susceptible to moisture damage, the installer is required to apply a messy grout composition to the tiles as part of the installation process.  
         [0007]     A previous attempt to produce an easy to install tile is described in U.S. Pat. No. 2,693,102 entitled “Interlocking Wall Tile” by Luster et al. Luster et al. describes a synthetic wall tile system that snaps together. Unfortunately, the Luster et al. tile is not practicable with substantially ridged materials, such as ceramic, granite, or marble. The Luster et al. tiles are molded into a uniform structure of a single material and rigid materials could not be formed into an operable tab structure as taught in the patent. Such a limitation severely limits the aesthetic qualities available for the tiles and thereby reduces the marketability of the system.  
         [0008]     Accordingly, there is a need in the art for a tile system that is simple to install.  
         [0009]     Additionally, there is a need in the art for a tile system that does not require a grout or sealing compound to be applied to the tiles after installation.  
         [0010]     Further, there is a need in the art for an easy to install tile system that makes use of durable tile materials.  
         [0011]     Also, there is a need in the art for a tile system that primarily utilizes traditional tile materials, but eliminates the need for grout.  
       SUMMARY OF THE INVENTION  
       [0012]     The present invention is directed toward a covering for a planar surface comprising a first tile having at least a first and second first tile sidewall carrying a first flange along the respective sidewalls, a second tile having at least a first and second tile sidewall carrying a second flange along the respective sidewalls, the first flange being matingly adapted for attachment to the second flange carried by the second tile.  
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0013]     The invention will be more readily understood from a reading of the following specifications and by reference to the accompanying drawings forming a part thereof, wherein an example of the invention is shown and wherein:  
         [0014]      FIG. 1  is a top view illustration of a tile in accordance with an exemplary embodiment of the present invention;  
         [0015]      FIG. 2  is a plan view illustration of a tile in accordance with an exemplary embodiment of the present invention;  
         [0016]      FIG. 3  is a plan view illustration of two adjacent tiles in accordance with an exemplary embodiment of the present invention;  
         [0017]      FIG. 4  is a plan view illustration of two adjacent tiles in accordance with an exemplary embodiment of the present invention; and  
         [0018]      FIG. 5  is a top view illustration of a tile in accordance with an exemplary embodiment of the present invention. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0019]     Referring now to the drawings, in which like numerals refer to like parts throughout the several views,  FIG. 1  is a top view illustration of a tile  100  in accordance with an exemplary embodiment of the present invention.  
         [0020]     The present invention is directed toward a tile system that does not require the use of a separate grout compound during installation of the tiles. Rather, the tile system incorporates tiles having a flange  110  attached to the perimeter of each tile  100  and is attached to an adjacent tile  100  during installation. In accordance with an exemplary embodiment of the present invention, a tile  100  comprises a primary tile component  115  and a flange  110 . Typically, the primary tile component  115  may be a ceramic compound. Alternatively, the tile substrate  115  may be, but is not limited to, plastic, wood, stone, granite, marble, or any other suitable natural or synthetic material. Generically, the primary tile component  115  refers to an outer visible layer of the tile.  
         [0021]     Typically, the primary tile component  115  has a substantially planar outer surface with depending sidewalls. Flange  110  may be a single cut out piece which is positioned around the tile perimeter abutting the tile&#39;s sidewalls. Preferably flange  110  in an exemplary embodiment of the present invention is applied to the primary tile component  115  using a rapid injection mold die. Alternatively, any suitable method for adhering the flange  110  to the primary tile component  115  may be employed. For instance flange  110  may comprise distinct components which are separately adhered to the perimeter of the primary tile component. Preferably, the sidewalls have a predetermined height and the flange abuts the sidewalls at a height at least up to the mid-point of the sidewalls. Also, the flange may abut the entire perimeter of the tile.  
         [0022]     In an exemplary embodiment of the present invention, the flange  110 , may be of polymeric material and preferably is a polyurethane material, such as ELASTOCASTr70654 by BASF®. ELASTOCASTr70654 is an unpigmented, 77 to 79 Shore D urethane elastomer designed for cross-sections up to three inches which has some inherent tackiness. This system is based on the ELASTOCAST7073 system.  
         [0023]     The following data may be helpful in producing the material used in a flange  110  in accordance with an exemplary embodiment of the present invention. This data is provided for example only, and is not intended to limited the scope of the invention. Other compositions may be used to fabricate the flange  110 .  
                                                                             Mix Ratio @ 105 index:   100 parts of ELASTOCASTr7065R           Resin 771. parts of WUC 3192T           ISOCYANATE            Specific Gravity:   Resin   1/048 f/cc, 8.72 lbs./gal. @ 77° F.           Iso   1.22 g/cc, 10.2 lbs./gal. @ 77° F.       Viscosity:   Resin   1120 cps @ 77° F.           Iso   200 cps @ 77° F.            Typical Reactivity:   Hand mixed at 86° F. at 105 index           Gel time: 180 to 240 seconds            Recommended   Component   Resin 75-95° F.       processing conditions:   temperatures:   Iso 75-95° F.           Mold temperature:   130-160° F.           Demold time:   10-20 minutes                  
 
         [0024]     Alternatively, other polymer variations, such as polyamides, vinyl polymers and polyoletins may be used. Preferably, the flange  110  may be made, but is not so limited, from a material that is chemical resistant, stain resistant, non-porous, and formable to within sufficient precision. Additionally, it may be desirable for the flange  110  to have sealing qualities so as to impede the intrusion of moisture between and behind the tiles and adherence qualities so as to minimize or present movement or displacement of the tiles.  
         [0025]     The flange  110  may take a variety of forms. In an exemplary embodiment of the present invention, the flange  110  may be a dovetail configuration for matably engaging a correlated dovetail pattern on a second tile  100 . In such an arrangement, the two tiles  100  lock together to form a lock-joint. In addition to dovetail joints, any alternative locking joint may be used such as, but not limited to a tongue and groove joint. In another exemplary embodiment of the present invention, the flange  110  may lock two tiles  100  together using adhesive properties in the flange material. In such an arrangement, the flange  110  may be designed to provide sufficient tack so as to lock the tiles together through adhesion. In such an arrangement, it may be desirable to provide a removable backing strip on the exposed tacky surfaces of the flange  110  so that it will not collect dust and other particles prior to installation. Accordingly, the removable strip may be removed at the time of tile installation.  
         [0026]     The tile  100  may also include a base substrate  105 . The base substrate  105  may provide a base upon which the remainder of the tile elements are constructed. The base substrate  105  may also provide additional strength for the tile  100 . Because the base substrate  105  is covered by the primary tile component  115 , the appearance of the base substrate  105  may not be critical. Thus, it may be desirable to use a scrap tile material, or other inexpensive material, for the base substrate  105  to minimize costs. In an exemplary embodiment of the present invention, the primary tile component  115  is attached above the base substrate  105  using an adhesive component  112 . The adhesive component  112  may be the same polyurethane used for the flange  110 . Alternatively, the adhesive component  112  may be any adhesive suitable for binding the primary tile component  115  to the base substrate  105 .  
         [0027]     The primary tile component  115  may be disposed in an offset configuration as shown in  FIGS. 1 and 2 .  FIG. 2  illustrates a plan view of a tile  100  in accordance with an exemplary embodiment of the present invention. In such a configuration, a portion of the top surface of the base substrate  105  adjacent two of its side edges  106 ,  107  is exposed adjacent two side edges  116 ,  117  of the primary tile component. Additionally, two side edges  118 ,  119  of the primary tile component  115  hang over two of the side edges  108 ,  109  of the base substrate  105 . This configuration allows adjacent tiles  100  to overlap partially when installed on a floor or wall in a typical abutting arrangement.  
         [0028]     As shown in  FIG. 2 , adhesive  112  may be integral and of the same material as flange  110 . Adhesive  112  may be partially exposed on the upper surface of base substrate  105  enabling attachment of a second tile  100  as shown in  FIG. 3 .  
         [0029]     For some installations, it may be desirable to include an underlayment  205  that acts as a moisture or sound barrier. Additionally, the underlayment  205  may serve a surface leveling function. Further, the underlayment  205  may serve as an adhesive for attaching the tiles to an installation surface, such as a floor or a wall.  
         [0030]      FIG. 3  shows an excerpt of a plan view of two adjacent tiles  100  in accordance with an exemplary embodiment of the present invention. As shown in  FIG. 3 , two adjacent tiles (tile A and tile B) overlap when installed beside each other. The leading edge of the primary tile component  115   a  of tile A extends over the base substrate  105   b  of tile B. As shown in this figure, flange  110   b  which is attached to primary tile component  115   b  is utilized for abutting a sidewall of primary tile component  115   a.  This illustrates that while the preferred embodiment utilizes flange  110  around the entire perimeter of primary tile component  115 , some configurations may be had wherein, flange  110  is selectively located on certain predetermined sidewalls of primary tile component  115  such as only three sides or two sides.  
         [0031]     Alternatively, the base substrate  105  and the primary tile component  115  may be manufactured as a single piece. This combined piece may have a profile such that the overlapping configuration shown in  FIGS. 1-3  is duplicated without the use of separate base substrates  105  and primary tile components  115 . Further, the primary tile component  115  may be used alone without a base substrate  110 . In such an embodiment, adjacent tiles  100  would not overlap and the flange  110  of a first tile  100  would abut the flange  110  of a second tile  100 .  
         [0032]      FIG. 4  shows an excerpt of a plan view of two adjacent tiles  100  (tile A and tile B) in accordance with an exemplary embodiment of the present invention, wherein the primary tile component  415  is not disposed above a base substrate  105 . As is shown in  FIG. 4 , two primary tile components  415   a  and  415   b  lie adjacent one another and the flange  410   a  of tile A abuts the flange  410   b  of tile B. In such an arrangement, it may be desirable for the two flanges  410   a  and  410   b  to attach adhesively. Alternatively, the two flanges  410  may interlock as described above in a dovetail or other locking arrangement.  
         [0033]      FIG. 5  shows a top view of a tile  100  in accordance with an exemplary embodiment of the present invention. As shown in  FIG. 5 , the flange  110  may be formed with a plurality of dovetail connections to allow a locking joint with adjacent tiles. In such a configuration, a male dovetail member  505  may be inserted into a female dovetail member  510  during installation. Preferably, the dovetail components  505 ,  510  provide a tight fit so that minimal movement is allowed between tiles.  
         [0034]     Although various embodiments of the present invention have been described herein in detail, it will be appreciated by those skilled in the art, that variations may be made thereto without departing from the spirit of the invention or the scope of the appended claims.