Patent Description:
Interlocking floor tiles are known in the art. Such tiles employ various interlocking mechanisms. Often, the interlocking mechanisms result in a rigid connection between tiles, which prevent the tiles from flexing, at least to some degree. Further, such tiles may also require a prepared surface that is generally even. If the surface has too much variation, the locking mechanisms may not work as intended, or at all.

A prior art floor tile system is known from <CIT>.

It may be desirable to provide an interlocking tile that allows for deformation or shifting in response to forces applied to the tile surface, e.g., from walking or driving on the surface. In some instances, it may be advantageous to permit vertical movement of the tiles and/or provide a variance in height during installation, particularly on uneven surfaces.

The following presents a simplified summary of the invention in order to provide a basic understanding of some aspects of the invention.

According to the invention an interlocking tile as claimed in claim <NUM> is provided. In one embodiment, the interlocking tile i. includes a top surface, a bottom surface, and marginal faces disposed along a perimeter of the top surface. The tile also includes at least one male coupler disposed on a first marginal face and at least one female coupler extending from the bottom surface and disposed on a second marginal face. The at least one female coupler includes an arm, which has a first notch for engaging with a corresponding male coupler of an adjacent tile at a first position, and a second notch for engaging with the corresponding male coupler of the adjacent tile at a second position.

Further, according to the invention an interlocking tile system, as claimed in claim <NUM>, is provided. The interlocking tile system i. includes a first tile comprising a top surface, marginal faces disposed along at least a portion of a perimeter of the top surface, a male coupler disposed on a first marginal face, and a female coupler disposed on a second marginal face. The female coupler includes an arm, the arm comprising a first notch for engaging with a corresponding male coupler of an adjacent tile at a first position, and a second notch for engaging with the corresponding male coupler of the adjacent tile at a second position.

Still further, according to the invention a method of adjoining interlocking floor tiles on an uneven surface, as claimed in claim <NUM>, is provided. The method i. comprises providing a plurality of floor tiles. Each tile has a male coupler extending from a first marginal face of the floor tile that includes an aperture. Each tile further includes a female coupler disposed along a second marginal face of the floor tile. The female coupler includes an arm having a proximal and a distal end and a plurality of notches located generally near the distal end. The method further includes positioning a first tile of the plurality of tiles generally adjacent a second tile of the plurality of tiles such that the male coupler of the first tile is generally adjacent the female coupler of the second tile. The first and second tiles are interlocked by inserting the arm of the female coupler of the second tile into the aperture of the male coupler of the first tile such that one of the plurality of notches of the arm of the female coupler of the second tile engages with the male coupler of the first tile.

<FIG> and <FIG> show an embodiment of a floor tile <NUM> which has a top surface <NUM> (<FIG>), an optional bottom surface <NUM> (<FIG>), and marginal faces <NUM> which may extend at least partially along a perimeter of the top surface <NUM>. Top surface <NUM> may be generally even and regular. In some embodiments, voids <NUM> may defined in the top surface <NUM>, e.g., to allow for drainage, as shown in <FIG>.

Bottom surface <NUM> includes a support structure <NUM>, which supports the tile <NUM> above the surface. The support structure <NUM> may include portions 123b that extend from the bottom surface <NUM> provide strength to the tile top surface <NUM>. Additionally, the support structure <NUM> may include portions 123a that extend beyond the portions 123b. The portions 123a contact the ground surface when the tile <NUM> is in an installed configuration.

Referring also to <FIG>, in some embodiments, passages <NUM> may be defined within the support structure <NUM>. The passages <NUM> may improve the drainage underneath the floor tile <NUM>. Passages <NUM> may also facilitate additional aspects of the tile <NUM>, for example, allowing for tubing or wiring to pass under the floor tile <NUM>. The tubing or wiring may be contained within passages <NUM>. In some embodiments, the passages <NUM> may span the entire width of bottom surface <NUM>, in lieu of any support structure <NUM>, e.g., as is the case with channel tiles <NUM>, described in greater detail below.

As noted above, marginal faces <NUM> extend around the perimeter of the tile <NUM>, and may be generally perpendicular to the top surface <NUM>. In some embodiments the marginal face <NUM> may be offset from top surface <NUM> at a non-perpendicular angle. Marginal faces <NUM> extend past the bottom surface <NUM> of the floor tile <NUM> and may form a part of the support structure <NUM>. In some embodiments, marginal face <NUM> may be of variable height, as shown in <FIG>.

In the illustrated embodiment, tile <NUM> has a generally rectangular shape, although it will be understood by those of skill in the art that tile <NUM> may resemble a variety of shapes, such as generally triangular, trapezoidal, pentagonal, hexagonal, and octagonal.

In some embodiments, the tile <NUM> is configured to couple to other tiles <NUM> and/or tile components. For example, <FIG> illustrates a tile system showing a first tile 100a coupled to a second tile 100b and tile channels 200a and 200b. A tile channel <NUM> is illustrated in <FIG> and <FIG> and is substantially similar to floor tile <NUM>, except as specifically noted and/or shown, or as would be inherent. For uniformity and brevity, reference numbers from <NUM> to <NUM> may be used to indicate elements corresponding to those discussed above numbered from <NUM> to <NUM> (e.g., top surface <NUM> corresponds generally to the top surface <NUM>, faces <NUM> correspond generally to the respective faces <NUM>, et cetera), though with any noted, shown, or inherent deviations.

As illustrated in <FIG>, tile channel <NUM> may have a bottom surface <NUM> which is generally planar. Tile channel <NUM> may vary from tile <NUM> in that tile channel <NUM> may not include a supporting structure or any portion which extends outward from the bottom surface <NUM>. This may be desired in order to create a larger passage underneath the tile channel <NUM> for wiring, piping, drainage, or any other system which may be installed below tile channel <NUM>.

The second tile 100b in <FIG> is coupled to edge pieces 300a, 300b, and 300c. Edge pieces <NUM> are illustrated in <FIG> and <FIG>. As shown in <FIG>, edge piece <NUM> may include a top surface <NUM> which includes a generally planar portion and a portion <NUM> which is angularly offset from horizontal.

To facilitate coupling of floor tiles <NUM>, tile channels <NUM> and/or edge pieces <NUM>, floor tiles <NUM> and tile channels <NUM> may have at least one male coupler <NUM> (<FIG>) and at least one female coupler <NUM> (<FIG>). Preferably, floor tiles <NUM> and tile channels <NUM> may have a plurality of male couplers <NUM> and female couplers <NUM>. Although not necessary, the male couplers <NUM> may be disposed along two adjacent sides <NUM> of a tile <NUM>, with female couplers <NUM> being disposed along the remaining two adjacent sides <NUM>. Alternatively, male couplers <NUM> may be disposed along two opposing sides <NUM> of a tile <NUM>, with female couplers <NUM> being disposed along the remaining two opposing sides <NUM>. Of course, where the tile <NUM> includes more or less than four sides, each side may have male couplers <NUM> or female couplers <NUM>. The tile channels <NUM> may include one or more male couplers <NUM> disposed along a first long edge, with one or more female couplers <NUM> disposed along an opposing second long edge. Short edges of the tile channels <NUM> may or may not include couplers <NUM> and/or <NUM>.

As shown in <FIG>, each edge piece <NUM> may include at least one male coupler <NUM> or at least one female coupler <NUM> along a long edge (or along a straight edge, if it's a corner edge piece). Accordingly, edge pieces <NUM> may be particularly configured to attach to a side of a tile having either a male coupler <NUM> or a female coupler <NUM>. In some embodiments, each short edge of the edge pieces <NUM> may additionally include a male coupler <NUM> or a female coupler <NUM>, and preferably may include a male coupler <NUM> on one short edge and a female coupler <NUM> on the opposing short edge, to facilitate coupling of the edge piece along the perimeter of the tiles <NUM>.

Referring now to <FIG>, a male coupler <NUM> is illustrated with a tile <NUM>. Male couplers <NUM> may extend outward from marginal face <NUM> of tile <NUM>. Preferably, the male couplers <NUM> may extend perpendicularly from the marginal face <NUM>, although it may be advantageous for the couplers <NUM> to extend at a non-perpendicular angle from the marginal face <NUM>. In <FIG>, the male couplers <NUM> do not extend the entire height of the marginal face <NUM>. However, it will be understood by those of skill in the art that the male couplers <NUM> may extend along the entire height of the marginal face <NUM>.

Each male coupler <NUM> may include a central portion and at least one aperture <NUM> for connecting with a corresponding female coupler <NUM>. Preferably, each male coupler <NUM> has a plurality of apertures <NUM>.

It shall be understood that a male coupler <NUM>, <NUM> on a tile channel <NUM> or an edge piece <NUM>, respectively, is substantially similar to the male coupler <NUM> described herein. For example, tile channels <NUM> (<FIG> and <FIG>) may have a male coupler <NUM> which is substantially similar to, and performs substantially the same function, as male coupler <NUM>. Edge pieces <NUM> (<FIG> and <FIG>) may similarly have a male coupler <NUM> which performs substantially the same function as male couplers <NUM>, but includes only the central portion of the male coupler and does not include any apertures.

Referring to <FIG>, a female coupler <NUM> is illustrated with a tile <NUM>. It shall be understood that a female coupler <NUM> on a tile channel <NUM> or an edge piece <NUM> is substantially similar to that described herein. The female couplers <NUM> are configured to be complimentary to the male couplers <NUM>, such that floor tiles <NUM> may be coupled together to form a tile system. Female couplers <NUM> may include at least one arm <NUM> extending from bottom surface <NUM> of the floor tile <NUM>, and preferably two opposing arms 152a and 152b. Each arm <NUM> has a proximal end <NUM>, a distal end <NUM>, and at least one notch <NUM> on an inside face of an elbow <NUM> of the arm <NUM>.

As shown in <FIG>, the arms <NUM> may have two notches 158a and 158b. The notices 158a and 158b may not be colinear. In other words, the first notch 158a may be generally inwardly offset as compared to the second notch 152b. Unlike a single notch, the double notch may allow for floor tiles <NUM> to be installed over an uneven surface so that if a tile <NUM> is slightly elevated compared to an adjacent tile <NUM>, the first notch 158a may engage with a corresponding male coupler <NUM> of the adjacent tile <NUM>. If the neighboring tiles <NUM> are on the same level, the second notch 158b may engage with the corresponding male coupler <NUM> of the adjacent tile <NUM>. Thus, it shall be understood that adjacent tiles <NUM> may be adjoined on different horizontal planes depending on which notch 158a or 158b is engaged between respective male and female couplers <NUM> and <NUM>. Although in the illustrated embodiments, the arms <NUM> have two notches, it will be understood by those of skill in the art that arms <NUM> may have any number of notches <NUM>, and may therefore be able to engage with male coupler <NUM> at a plurality of heights.

The arms <NUM> may be positioned inside of the marginal face <NUM>. Additionally, as shown in <FIG>, the top surface <NUM> may extend over the female coupler <NUM>. This may allow the respective marginal faces <NUM> of adjacent tiles <NUM> to more closely abut.

Moving on, <FIG> illustrates a spring tab <NUM> disposed along the marginal face <NUM> of a floor tile <NUM>. The spring tab <NUM> may have an exterior face <NUM> and a slot <NUM>. Preferably, floor tile <NUM> has a plurality of spring tabs <NUM> disposed along the marginal face <NUM>. Spring tabs <NUM> create a gap between adjacent tiles <NUM>. The creation of a gap between tiles <NUM> may allow for a small amount of deformation during impacts. Furthermore, the gap created by spring tabs <NUM> may allow for expansion or contraction of the floor tiles <NUM> when subject to extreme temperatures, thereby minimizing the likelihood of component failure.

In the illustrated embodiment, the exterior face <NUM> of spring tab <NUM> is generally planar and is substantially parallel to the marginal face <NUM>. However, in some embodiments, the exterior face <NUM> may not be generally planar, and instead may be concave, convex, or angled.

The spring tabs <NUM> may be constructed from the same material as the other components of floor tile <NUM>. However, it may be beneficial to construct the spring tabs <NUM> from a different material than that of the rest of floor tile <NUM>. For example, a more flexible material, in conjunction with various shapes of the spring tabs <NUM>, may provide a more desirable level of impact dispersion and/or temporary deformation.

It shall be understood that tile channels <NUM> may optionally additionally include spring tabs <NUM>.

<FIG> illustrates another embodiment of a floor tile <NUM> that is substantially similar to floor tile <NUM>, except as specifically noted and/or shown, or as would be inherent. Further, those skilled in the art will appreciate that the embodiment <NUM> (and thus the embodiment <NUM>) may be modified in various ways, such as through incorporating all or part of any of the described embodiments, for example. For uniformity and brevity, reference numbers from <NUM> to <NUM> may be used to indicate elements corresponding to those discussed above numbered from <NUM> to <NUM> (e.g., top surface <NUM> corresponds generally to the top surface <NUM>, faces <NUM> correspond generally to the respective faces <NUM>, et cetera), though with any noted, shown, or inherent deviations.

Tile <NUM> may have at least one projection <NUM> having a proximal end <NUM> and a distal end <NUM> and extending from the top surface <NUM>. Preferably, tile <NUM> may have a plurality of projections <NUM> extending from the top surface <NUM>. Projections <NUM> may provide increased resistance against shifting of artificial turf or any other material which may be placed upon the top surface <NUM>. Even without a material atop the tile <NUM>, the projections <NUM> may friction to the top surface <NUM> to prevent slippage, e.g., of a person moving atop the tile <NUM> or a vehicle driving atop the tile <NUM>.

In the illustrated embodiment, projections <NUM> have a general triangular prism shape. However, it will be understood by those of skill in the art that projections <NUM> may be any shape, including rectangular, conical, cylindrical, pyramid, et cetera.

It may be advantageous for the at least one projection <NUM> to form part of a coupling mechanism with any surface material that may be applied to the tile <NUM>. For example, a corresponding recess may be provided in the turf backing or other surface material. In this configuration, the risk of uncontrolled movement of the applied turf may be significantly minimized. However, even with corresponding recesses, the projections <NUM> may greatly reduce unwanted shifting of the material atop the tile <NUM>. Further, the projections <NUM> may reduce or even eliminate the need for adhesives to be applied between the tile <NUM> and any surface material, which may reduce the time required for installing a tile and surface material systema and further allow for easier maintenance of the system.

The projections <NUM> may be molded (e.g., via injection molding, co-injection molding, overmolding, multi-material injection molding, etc.) as part of the floor tile <NUM>. The projections <NUM> may be molded via a removable insert which may be added or removed to the tile mold during the molding process. This may be beneficial, as it allows for a variation in design or functionality of the tiles without the need for bespoke molds.

Many different arrangements of the various components depicted, as well as components not shown, are possible without departing from the scope of the appended claims. Embodiments of the present disclosure have been described with the intent to be illustrative rather than restrictive. Alternative embodiments will become apparent to those skilled in the art that do not depart from its scope. A skilled artisan may develop alternative means of implementing the aforementioned improvements without departing from the scope of the appended claims.

Claim 1:
An interlocking tile (<NUM>; <NUM>), comprising:
a top surface (<NUM>);
marginal faces (<NUM>) disposed along at least a portion of a perimeter of the top surface;
at least one male coupler (<NUM>) disposed on a first marginal face; and
at least one female coupler (<NUM>) disposed on a second marginal face,
wherein the at least one female coupler (<NUM>) comprises two opposing arms (152a, 152b), each arm comprising a first notch (158a or 158b) for engaging with a corresponding male coupler (<NUM>) of an adjacent tile at a first position, and a second notch (158a or 158b) for engaging with the corresponding male coupler (<NUM>) of the adjacent tile at a second position; and the first position is in a different horizontal plane from the second position.