Abstract:
A floor tile comprising: a first section having a finished surface and an opposing unfinished sectional surface; 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.

Description:
BACKGROUND 
       [0001]    1. Technical Field 
         [0002]    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. 
         [0003]    2. Description of Related Art 
         [0004]    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. 
         [0005]    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. 
         [0006]    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 
       [0007]    According to an aspect of the present invention, there is provided a floor tile comprising: 
         [0008]    a first section having a finished surface and an opposing unfinished sectional surface; 
         [0009]    a second section having a finished surface and an opposing unfinished sectional surface; 
         [0010]    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, 
         [0011]    wherein the first finished surface and the second finished surface are opposing and outward facing, and 
         [0012]    wherein the floor tile is connectable to an adjacent floor tile via the connecting edge. 
         [0013]    According to another aspect of the present invention, there is provided a tile, comprising: 
         [0014]    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 
         [0015]    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, 
         [0016]    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. 
         [0017]    According to yet another aspect of the present invention, there is provided a floor tiling system, comprising: 
         [0018]    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, 
         [0019]    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 
         [0020]    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. 
         [0021]    According to yet another aspect of the present invention, there is provided a method of making a floating floor tile, comprising: 
         [0022]    providing a first section having a finished surface and an opposing unfinished sectional surface; 
         [0023]    providing a second section having a finished surface and an opposing unfinished sectional surface; and 
         [0024]    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. 
         [0025]    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 
         [0026]    The present invention will be further understood and appreciated from the following detailed description taken in conjunction with the drawings in which: 
           [0027]      FIG. 1A  is a perspective view of a floor tile consistent with an embodiment of the present invention; 
           [0028]      FIG. 1B  is a perspective view of the floor tile of  FIG. 1A , where the floor tile is turned over; 
           [0029]      FIG. 2A  is a perspective view of four tiles of  FIG. 1A  connected to each other, where each of the tiles are oriented with a common surface pattern facing up; 
           [0030]      FIG. 2B  is a perspective view of four tiles of  FIG. 1A  connected to each other, where each of the tiles are oriented with a common surface pattern facing up; 
           [0031]      FIG. 2C  is a perspective view of three tiles of  FIG. 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; 
           [0032]      FIG. 3A  is a perspective view of a floor tile consistent with an embodiment of the present invention; and 
           [0033]      FIG. 3B  is an enlarged perspective view of a corner of the floor tile of  FIG. 3A ; 
           [0034]      FIGS. 4A-4C  illustrate a method of manufacturing a floor tile consistent with an embodiment of the present invention, in which  FIG. 4A  is a perspective view of two floor tile sections,  FIG. 4B  is a perspective view showing the two floor tile sections of FIG.  4 A being attached to make a floor tile consistent with an embodiment of the present invention, and  FIG. 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 
       [0035]    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. 
         [0036]    Referring now to  FIGS. 1A and 1B , there is shown a perspective view of a floor tile  10  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.  FIG. 1B  is a view of the tile of  FIG. 1A  in which the tile is inverted, or turned over to reveal an underside that is not visible in the view of  FIG. 1A . 
         [0037]    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  12   p  having a finished surface  14   p  and a sectional surface  16   p,  and has a second section  12   q  having a finished surface  14   q  and a sectional surface  16   q.  In the view of  FIG. 1A  first section  12   p  is on top and second section  12   q  is on the bottom, and these positions are reversed in the view of  FIG. 1B . 
         [0038]    By way of non-limiting example, first finished surface  14   p,  visible in  FIG. 1A , is shown as a woodgrain pattern, and second finished surface  14   q,  visible in  FIG. 1B , 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. Indeed, other patterns and/or combination of colors, patterns, textures, and materials are both contemplated and possible. 
         [0039]    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. 
         [0040]    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  16   q  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. 1B , the portion of connective edge  18  that is on first sectional surface  16   p  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. 
         [0041]    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  16   p  may be seen as hidden connective edge  18 ′ in  FIG. 1A , and the portion on sectional surface  16   q  may be seen as hidden connective edge  18 ′ in  FIG. 1B . 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. 1A and 1B  are overhanging, and visible connective edges  18  may be called underhanging edges. 
         [0042]    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. 
         [0043]    Examples of connected tiles are shown in  FIGS. 2A ,  2 B, and  2 C. In  FIG. 2A  the active surface is the woodgrain pattern of finished surface  14   p,  and in  FIG. 2B  the active surface is the circle pattern of finished surface  14   q.    FIG. 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 ,  2 B, and  2 C may be cut in length by the installer to produce a more staggered and visually pleasing appearance. 
         [0044]    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. 
         [0045]    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 1¼ inch wide for both dx and dy, i.e. all portions of connective edge  18 . In other embodiments, dx and dy may be slightly smaller or larger, for example, 1 inch or 1½ inches in width. 
         [0046]    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 1¼ inches and the other 1 inch or 1½ 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. 
         [0047]    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. 
         [0048]    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 1¼ inches wide and the adjoining tile has a connective edge that is 1⅛ inches wide, there will be a ⅛ inch gap formed. 
         [0049]    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&#39;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 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&#39;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. 
         [0050]    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 . 
         [0051]    Additionally and/or alternatively, as  FIGS. 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 . 
         [0052]      FIG. 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  10  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.  FIG. 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  24   p  and first film layer  26   p  from first section  12   p,  and second pvc layer  24   q  and second film layer  26   q  from second section  12   q.  For greater clarity, connective edge  18 , which is part of sectional layer  16   q,  is shown shaded in  FIG. 3B . 
         [0053]    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. 
         [0054]    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. 
         [0055]    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 . 
         [0056]    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. 
         [0057]      FIGS. 4A ,  4 B, and  4 C 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. 
         [0058]    The method begins, as shown in  FIG. 4A , by first making or obtaining the two sections  12   p  and  12   q,  where the sections are separate and unattached. An adhesive or glue  28  is applied to the bottom, or sectional surfaces  16  of each section. 
         [0059]      FIG. 4B  shows the process by which the sections are attached. Section  12   p  is shown oriented the same as in  FIG. 4A , with finished section  14   p  facing upwards. Section  12   q  is inverted and placed across from section  12   p  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  12   p,  but is offset from section  12   p  by dx and dy for the desired predetermined distances along the section&#39;s width and length. The inverted section  12   q  is aligned with offset plane  30  and not with section  12   p.  The two 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. 
         [0060]      FIG. 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. 
         [0061]    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. 
         [0062]    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. 
         [0063]    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. 
         [0064]    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. 
         [0065]    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. 
         [0066]    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.