Patent Publication Number: US-2011061328-A1

Title: Tile Connector

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of U.S. Provisional Application No. 61/276,572, filed Sep. 14, 2009, which is incorporated by reference herein in its entirety. 
    
    
     TECHNICAL FIELD 
     This disclosure generally relates to an apparatus and method for installing modular floor coverings in a non-permanent manner. More particularly, this disclosure relates to an apparatus and method for installing modular tiles without permanently adhering the tiles to the floor. 
     BACKGROUND 
     Modular floor coverings (e.g., carpet tiles) are typically installed by applying a permanent adhesive to the flooring surface and positioning the tiles on top of the adhesive. However, such methods often cause damage to the underlying flooring surface when the tile is removed. Thus, there is a need for a non-permanent means of securing tiles to one another while providing sufficient stability to withstand normal use. 
     SUMMARY 
     This disclosure is directed generally to a connector or fastener for modular floor coverings (e.g., carpet tiles). The connector is placed between the bottom of the carpet tile and the flooring surface (or other intermediate surface, such as an underlayment or pad). The connector may be used to join adjacent tiles to one another along a seam between the tiles and/or along the peripheral edges of the tiles. The connectors maintain the tile in a removably fixed position on the flooring surface without permanently adhering (i.e., gluing) the tiles to the flooring surface. 
     The connector generally includes a pair of opposed faces or surfaces. The first, upper surface or face of the connector may comprise a tile-engaging layer for contacting the bottom surface of the tile. The tile-engaging layer may comprise a material that generally operative for preventing movement of the tiles relative to one another, for example, a non-permanent adhesive, a coating that provides a high coefficient of friction surface, or any combination thereof. The second, lower surface or face of the connector may comprise a floor-contacting layer. If desired, the floor-contacting layer may comprise a material that is generally operative for preventing slipping or movement of the tiles on the floor (or any intermediate layer between the floor and the tiles), such that the connector maintains the tile in position but without permanently adhering the tile to the flooring surface. Materials that may be suitable for use as the floor-contacting layer may include a low tack adhesive, a slip resistant material, or any combination thereof. 
     The connector may have various shapes and dimensions. In general, the connector may be shaped and dimensioned so that the connector can be used without substantially overlapping another connector. In this manner, the assembly of tiles (i.e., the adjoined tiles) may remain as level as possible for steady positioning on the flooring surface. 
     In one embodiment, the connector may have a major linear dimension that is approximately equal to an integer multiple of the length of the tile. In one variation of this embodiment, the connector may extend substantially along the length of the seam between two or more tiles, such that the connector underlies substantially the entire length of the seam. In another variation of this embodiment, the connector may extend along approximately one-half the length of the seam. In such an embodiment, where multiple connectors are used, a pair of adjacent connectors may collectively extend along the length of the seam. 
     In another embodiment, the connector may have a major linear dimension that is less than an integer multiple of the length of the tile. In such an embodiment, the connector may underlie less than the entire length of the seam, such a portion of the adjacent tiles may remain separate from one another (i.e., adjacent to, but unconnected to one another). 
     In one particular exemplary embodiment, the connector includes at least one end having a substantially right isosceles triangular shape. The end may be adapted to substantially fittedly abut at least one another connector along an adjacent perpendicular seam between tiles, where needed. 
     Other features, aspects, and embodiments will be apparent from the following description and accompanying figures. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The description refers to the accompanying drawings, in which like reference characters refer to like parts throughout the several views, and in which: 
         FIG. 1A  is a schematic top plan view of an exemplary connector for modular floor coverings; 
         FIG. 1B  is a schematic cross-sectional view of the connector of  FIG. 1A , taken along a line  1 B- 1 B; 
         FIG. 1C  is a schematic cross-sectional view of the connector of  FIG. 1B , including a removable release liner on each side of the connector; 
         FIG. 1D  is a schematic enlarged, partial view of one end of the connector of  FIG. 1A  in isolation; 
         FIG. 1E  is a schematic partial view of four connectors of  FIG. 1A  fittedly abutting one another; 
         FIG. 1F  is a schematic top plan view of an exemplary modular floor covering assembly using a plurality of connectors of  FIG. 1A ; 
         FIG. 1G  is a schematic end elevation view of the assembly of  FIG. 6 , taken along a line  1 G- 1 G; and 
         FIGS. 2-7  are schematic top plan views of other exemplary modular floor covering assemblies using various connectors. 
     
    
    
     DESCRIPTION 
       FIG. 1A  illustrates a top plan view of an exemplary connector  100  for being secured to the underside of a modular floor covering, for example, carpet tiles. The connector  100  generally spans across at least one seam between two or more tiles to connect the tiles to one another without permanently adhering the tile to the underlying surface, as will be discussed further below. 
     As shown in  FIG. 1B , the connector  100  includes a plurality of layers in a superposed, facing relationship with one another. The connector  100  generally includes a first side (e.g., face or surface)  102  for being in contact with the bottom surface (i.e., underside) of one or more tiles and a second side (e.g., face or surface)  104  for being proximate to the floor (e.g., in contact with the floor or any underlayment disposed on the floor). It will be appreciated that the illustrated embodiment is exemplary only, and that various other embodiments contemplated by this disclosure may have fewer or more layers, as needed for a particular application. 
     Viewing  FIG. 1B  in more detail, the connector  100  includes a substrate  106  for example, a layer of paper or polymer film. While countless substrates may be used, in one exemplary embodiment, the substrate  106  may comprise a polyolefin film, for example, a polyethylene film. In another exemplary embodiment, the substrate  106  may comprise a polyester film. The substrate  106  may have any suitable thickness, for example, from about 1 mil to about 5 mil, for example, from about 1.5 mil to about 3 mil, for example, about 2 mil. However, other suitable thicknesses and ranges thereof are contemplated. 
     A tile-engaging layer  108  may overlie or be disposed on a first side of the substrate  106 . The outermost surface of tile-engaging layer  108  may define the first side or surface  102  of the connector, such that the tile-engaging layer  108  receives and/or is in contact with at least a portion of the underside or bottom of the tile. The tile-engaging layer  108  may generally comprise any suitable material operative for restricting the motion of the tile relative to the connector and to any other tile that the connector is in contact with (i.e., any adjoined tile). 
     In one embodiment, the tile-engaging layer  108  may comprise an adhesive material, for example, a medium to high tack adhesive. The adhesive material may be a substantially continuous layer (as shown), or may be a discontinuous layer (e.g., a random or non-random pattern of adhesive). The level of adhesion may be semi-permanent or non-permanent, such that the adhesive is sufficiently strong to adhere the connector  100  to the tile, but not so strong that the connector cannot be separated from the tile and/or repositioned without destruction or delamination of the connector  100 . Although numerous adhesives may be suitable, in one exemplary embodiment, the adhesive may comprise an acrylic adhesive, for example, 350 High Holding Adhesive, commercially available from 3M (Minneapolis, Minn.). The adhesive may have any suitable coat weight or thickness, for example, from about 0.25 mil to about 3 mil, for example, from about 0.7 mil to about 2 mil, for example, about 1.1 mil. However, other suitable thicknesses and ranges thereof may be used. Thus, in one exemplary embodiment, the tile connector  100  may include an uppermost (i.e., tile-engaging) layer  108  comprising about 1.1 mil acrylic adhesive, and a substrate  102  comprising an about 2 mil polyester film. However, numerous variations are contemplated. 
     In another embodiment, tile-engaging layer  108  may comprise a slip resistant material, for example, a non-adhesive material having a relatively high coefficient of friction. Examples of such materials include, but are not limited to, natural or synthetic polymeric coatings, for example, polyolefin coatings, natural rubber coatings, any other suitable material, or any combination thereof. 
     If desired, a floor-contacting layer  110  may overlie or be disposed on a second side of the substrate  106  opposite the tile-contacting layer  102 . The floor-contacting layer  110  may comprise any suitable material that is operative for preventing movement of the connector  100  (and any tiles joined to the connector) on the floor. Examples of materials that may be suitable include, but are not limited to, a low-tack, non-permanent adhesive, a non-slip material (i.e., a slip resistant material) having a sufficiently high coefficient of friction (such as those described above in connection with layer  108 ), a protective material, any other suitable material, or any combination thereof. Alternatively, in some embodiments, layer  110  may be omitted, such that the bottom side of the substrate  106  is a floor-contacting surface of the connector  100 . Thus, in another exemplary embodiment, the tile connector  100  may include an uppermost (i.e., tile-engaging) layer  108  comprising about 1.1 mil acrylic adhesive, a substrate  102  comprising an about 2 mil polyester film, and a lowermost (e.g., floor-contacting) layer  110  comprising a polymeric non-slip coating, for example, polyethylene. However, numerous variations are contemplated. 
     Turning now to  FIG. 1C , if desired, the tile connector may be provided with a release liner  112 ,  114  on one or both sides of the tile connector  100 , for example, where one or both of layers  108 ,  110  comprise an adhesive or tacky material. Although countless materials may be used for such liners, in one exemplary embodiment, one or both liners  112 ,  114  may comprise a coated paper, for example, a polyolefin coated paper. In one specific example, release liner  112  and/or release liner  114  (where used) may comprise polyethylene coated Kraft paper (coated on one or both sides, as needed) having a basis weight of from about 50 to about 150 lb/ream (3000 sq. ft.), for example, from about 70 to about 120 lb/ream, for example, about 90 lb/ream. Thus, in still another exemplary embodiment, the tile connector  100  may include a release liner  112  comprising an about 90 lb/ream Kraft paper, polyethylene coated on both sides, a tile-engaging layer  108  comprising about 1.1 mil acrylic adhesive, and a substrate  102  comprising an about 2 mil polyester film. Such a structure may be commercially available from 3M under the trade name 3M™ Sheet and Screnn Label Materials 7218SA Clear. The connector  100  optionally may include a lowermost (e.g., floor-contacting) layer  110  comprising a polyethylene non-slip coating, and optionally, a release liner  114 . However, numerous variations are contemplated. 
     The tile connector  100  can have any suitable shape and dimensions. In the example illustrated in  FIG. 1A , the tile connector  100  is generally elongate in shape, and includes a pair of opposed edges  116  (e.g., lengthwise edges  116 ) that are substantially parallel to one another and a pair of pointed or chamfered ends, generally indicated at  118 . As shown in  FIG. 1D , which illustrates one end  118  of the connector  100  in isolation, each end  118  of the connector  100  may include a pair of oblique (or chamfered) end edges  120  that extend from respective ends of edges  116  convergently towards an endpoint  122 . The endpoint  122  may comprise a vertex between the two end edges  120 , which collectively define an angle α. In the illustrated embodiment, α may be about 90 degrees, such that the end  118  of the connector  100  is generally right isosceles triangular in shape. In such an embodiment, each end edge  120  of the connector  100  is shaped to fittedly abut (i.e., substantially abut) an end edge  120  of another connector  100 , such that the lengthwise centerlines CL of the connectors  100  generally form a right angle β with respect to one another, as shown in  FIG. 1E  (which only shows one end of each connector). 
     Further, as shown in  FIG. 1E , since each end  118  of the connector  100  may about two other connectors along end edges  120 , the ends  118  (and endpoints  122 ) of up to four connectors  100  may fittedly abut one another without needing to overlap (i.e., superpose or extend across) one another. In this configuration, the four connectors  100  generally define a cross shape with the centerlines CL of the connectors  100  generally being arranged perpendicularly to one another, intersecting at or proximate to their endpoints  122  ( FIG. 1D ). This arrangement of connectors facilitates joining a plurality of tiles along their seams, which are generally perpendicular to one another. 
     In some embodiments, the major linear dimension (e.g., length) L of the tile connector  100  may be an integer multiple of the length of the edge of the tile for which the connector is intended for use, such that the connector generally extends along the length of at least one tile. Thus, for an about 12 by about 12 inch tile, the connector  100  may have a major linear dimension of about 12 inches, about 24 inches, about 36 inches, and so on. Where the major linear dimension is about 12 inches, the connector is dimensioned to extend substantially along the entire length of the edge of one tile. Where the major linear dimension is about 24 inches, the connector is dimensioned to extend substantially along the entire length of two tiles, and so on. As another example, for an about 18 by about 18 inch tile, the connector may have a major linear dimension of about 18 inches, about 36 inches, about 54 inches, and so on. Where the major linear dimension is about 18 inches, the connector is dimensioned to extend substantially along the entire length of the edge of one tile. Where the major linear dimension is about 36 inches, the connector is dimensioned to extend substantially along the entire length of two tiles, and so on. 
     The minor linear dimension (e.g., width) W of the tile connector may be selected to ensure sufficient contact with the bottom side of each tile without unnecessarily using excess materials. In general, the minor linear dimension may be less than the length or width of the tile, and in some examples, the minor linear dimension of the tile connector may be from about 2 to about 6 inches, for example, about 4 inches, such that from about 1 to about 3, for example, about 2 inches of the width of the connector underlies each tile. Thus, in one particular example, the tile connector may have a length of 18 inches and a width of about 4 inches such that the tile connector extends substantially along the entire seam between two 18 by 18 inch tiles and such that about 2 inches of the width of the tile connector underlies each tile. However, other suitable dimensions may be used. 
     To use the connector  100  according to one exemplary method, the optional release liner or liners  112 ,  114  (where present) may be separated from the top and/or bottom sides of the connector. The connector  100  then may be positioned along a seam between two adjacent tiles with the tile-engaging layer  108  facing the bottom of the tiles with the lengthwise centerline CL ( FIG. 1A ) of the connector being substantially centered along the seam. Additional connectors may be used as needed, depending on the number of tiles to be joined to one another. 
     By way of example,  FIGS. 1F and 1G  schematically depict an exemplary tile assembly  124  formed using the tile connector  100  of  FIG. 1A . In this example, a first connector  100   a  (shown schematically with dashed lines) is positioned along a seam S between edges E 1 , E 2  of tiles T 1 , T 2  with the tile-engaging layer  108  ( FIG. 1B ) facing the bottom of the tiles T 1 , T 2 . The lengthwise centerline of the connector  100   a  is substantially centered along the seam S between the tiles T 1 , T 2 . Additional connectors  100   b ,  100   c ,  100   d  (shown schematically with dashed lines) may be used in a similar manner to secure additional tiles T 3 , T 4  to one another and to tiles T 1 , T 2 , respectively, to prevent the tiles T 1 , T 2 , T 3 , T 4  from moving relative to one another. 
     In the exemplary installation  124  shown in  FIG. 1F , the tile connectors  100   a ,  100   b ,  100   c ,  100   d  have substantially the same major linear dimension (e.g., length) as tiles T 1 , T 2 , T 3 , T 4 , such that each connector  100   a ,  100   b ,  100   c ,  100   d  extends substantially along the length of the seam S between the respective adjacent tiles. It will be noted that where the tiles are square in shape, the seams generally extend in a first direction D 1  and a second direction D 2  substantially perpendicular to D 1 , such that the seams S are substantially perpendicular to one another, and such that adjacent pairs of connectors  100  are substantially perpendicular to one another underlying the seams, as discussed above. It will also be noted that countless configurations of tiles are contemplated, and the 4 by 4 arrangement of tiles in  FIG. 1F  is provided for purposes of illustration only. 
     As shown in schematic cross-sectional view in  FIG. 1G , the tiles T 1 , T 2 , T 3 , T 4  (only T 1  and T 2  are shown in  FIG. 1G ) are not adhered to the floor F. Instead, the entire collection or assembly of interconnected tiles  124  generally serves as a unitary textile or “rug” that “floats” on the floor, such that the assembly of tiles  124  may be collectively repositioned on the floor F. Further, when needed or desired, one or more individual tiles T 1 , T 2 , T 3 , T 4  may be repositioned, replaced, reconfigured, or otherwise altered without causing damage to the surface of the floor F. 
     While the weight of the tiles T 1 , T 2 , T 3 , T 4  (and any items placed on the tiles) may provide sufficient resistance to undesired movement of the assembly  124 , additional slip resistance may be provided where the connectors  100  include a floor-contacting layer  110  or surface  104  that comprises a non-slip or slip resistant material, as discussed above. 
       FIGS. 2-7  schematically illustrate various other tile assemblies  224 ,  324 ,  424 ,  524 ,  624 ,  724  using tile connectors  200 ,  300 ,  400 ,  500 ,  600 ,  700  (shown schematically with dashed lines). The assemblies and connectors may be similar to the assembly  124  and connector  100  of  FIGS. 1A-1G , except for variations noted and variations that will be apparent to those of skill in the art. It will be noted that any of such connectors may have the same arrangement of layers as described with the connector  100  of  FIG. 1 , or may have an alternate arrangement of layers. 
     In the exemplary installations or assemblies  224 ,  324  shown in  FIGS. 2 and 3 , the tile connectors  200 ,  300  have a major linear dimension (i.e., length) that is about two times the length of the tiles, such that each connector extends substantially along the length of two tiles T. Accordingly, each connector  200 ,  300  may be used to join four tiles to one another along the length of the seam between the respective tiles. 
     It will be noted that in this and other embodiments, it may be sufficient to use a connector  200 ,  300  along fewer seams, for example, as illustrated in  FIGS. 2 and 3 . In such instances, it may be necessary and/or desirable to use one or more connectors to secure tiles to one another along the periphery of the assembly. In such cases, in this and other embodiments, the installer may choose to cut the connector  200  along its lengthwise centerline CL so the connector  200 ′ has a generally trapezoidal shape. In this configuration, the connector  200 ′ can be positioned along the edge fittedly abutting any adjacent connectors, as shown in the exemplary installation or assembly  224  of  FIG. 2 . Alternatively, the installer may cut one or both ends off the connector and install the remainder of the connector  300 ′, which has a generally rectangular shape, along the edge of the tile, as shown in  FIG. 3 . Other possibilities are contemplated. It is also contemplated that the connectors may be provided or available for purchase as a variety of such pre-cut shapes for the installer to use. 
     In the assembly  424  of  FIG. 4 , the connector  400  is generally cross shaped, with four substantially identical arms extending outwardly from a midpoint or center C of the connector, such that the connector is substantially symmetrical along its centerlines CL. Each arm includes an outwardly facing end  418  (only one of which is labeled) having a generally pointed or chamfered shape as described in connection with  FIG. 1D , such that the end of each arm may be substantially right isosceles triangular in shape. In this manner, the ends of the connector  400  may fittedly abut the ends of other similar connectors, as described above in connection with connector  100 . 
     In the illustrated embodiment, the major linear dimension (i.e., length) of each arm may be an integer multiple of the length of the tile T, such that each of the four arms of the connector extends substantially along the length of one tile (only one of which is labeled), while the center C of the connector generally overlies the intersecting seams between the tiles. The major linear dimensions (i.e., length and width) of the connector  400  may be an integer multiple of two times the length of one tile T, such that the connector  400  can extend along the length of two tiles. In this manner, a single connector can secure four tiles to one another. 
     Still other possibilities are contemplated. For example, in the assembly  524  of  FIG. 5 , connector  500  is similar in shape to connector  400  of  FIG. 4 , but in this example, the length of each arm of connector  500  is less than an integer multiple of the length of the tile, so that each arm extends along only a portion of the tile edge. Although this configuration may provide slightly less strength and stability than in the assembly  424  of  FIG. 4 , this configuration may nonetheless be suitable for many applications. It will be appreciated that connectors may be cut or provided with different shapes if needed to connect some tiles along the periphery of the assembly, as shown, for example, with connectors  500 ′. It will also be appreciated that the ends  518  of the connector may be made to be any shape (e.g., square or rectangular), since the connector is not being abutted with another connector. However, as a matter of manufacturing expedience, for example, where it is desirable to make all of the connectors have the same shape and size, and the connectors made for 12 inch square tiles include the chamfered ends, the same connectors may be used on an 18 inch square tile, even where the chamfered ends are not needed. 
     As another example, in the assembly  624  of  FIG. 6 , the connector  600  is generally cross shaped, with four substantially identical arms extending outwardly from a midpoint or center C of the connector, such that the connector  600  is substantially symmetrical along its centerlines (hidden from view, i.e., along the seams S). In this example, however, the ends  618  of the arms are substantially square or rectangular in shape. Also, in this example, the major linear dimensions (i.e., length and width) of the connector may be an integer multiple of the length of one tile T, such that each arm of the connector extends along one-half the length of the tile. In this manner, a single connector  600  can secure four tiles to one another. When additional connectors are used, the arms of the connectors may abut one another along their ends  618  to collectively substantially extend along the entire seam or length of the tile. 
       FIG. 7  schematically illustrates a variation of the assembly  624  of  FIG. 6 . In this exemplary assembly  724 , the connectors  700  are similarly shaped to the connectors  600  of  FIG. 6 , but have a smaller size relative to the size of the tile, such that the major linear dimension of the connector  700  is less than an integer multiple of the length of the tile. While this may not provide as much coverage of the seams S as with the assembly  624  of  FIG. 6 , this configuration may nonetheless be suitable for many applications. Also, as stated previously, the use of a smaller connector may provide a manufacturing efficiency, for example, where it is desirable to make all connectors a single size (e.g., 12 inches in length) for use with both 12 inch square tiles and 18 inch square tiles. 
     Still countless other possibilities are contemplated. For example, while all of the illustrated connectors are symmetrical in shape, connectors having non-symmetrical shapes are contemplated. Also, numerous other regular and irregular shapes are contemplated, including squares, circles, triangles, rectangles, and countless other shapes. 
     It will be readily understood by those persons skilled in the art that the present invention is susceptible of broad utility and application. It will also be recognized by those skilled in the art that various elements discussed with reference to the various embodiments may be interchanged to create entirely new embodiments coming within the scope of the present invention. While the present invention is described herein in detail in relation to specific aspects and embodiments, it is to be understood that this detailed description is only illustrative and exemplary of the present invention and is made merely for purposes of providing a full and enabling disclosure of the present invention and to set forth the best mode of practicing the invention known to the inventors at the time the invention was made. The detailed description set forth herein is illustrative only and is not intended, nor is to be construed, to limit the present invention or otherwise to exclude any such other embodiments, adaptations, variations, modifications, and equivalent arrangements of the present invention. All directional references (e.g., upper, lower, upward, downward, left, right, leftward, rightward, top, bottom, above, below, vertical, horizontal, clockwise, and counterclockwise) are used only for identification purposes to aid the reader&#39;s understanding of the various embodiments of the present invention, and do not create limitations, particularly as to the position, orientation, or use of the invention unless specifically set forth in the claims. Joinder references (e.g., joined, attached, coupled, connected, and the like) are to be construed broadly and may include intermediate members between a connection of elements and relative movement between elements. As such, joinder references do not necessarily imply that two elements are connected directly and in fixed relation to each other. Further, various elements discussed with reference to the various embodiments may be interchanged to create entirely new embodiments coming within the scope of the present invention. Many adaptations of the present invention other than those herein described, as well as many variations, modifications, and equivalent arrangements will be apparent from or reasonably suggested by the present invention and the above detailed description without departing from the substance or scope of the present invention. Accordingly, the detailed description set forth herein is not intended nor is to be construed to limit the present invention or otherwise to exclude any such other embodiments, adaptations, variations, modifications, and equivalent arrangements of the present invention.