Patent ID: 12188229

DETAILED DESCRIPTION

FIG.1illustrates various components of a modular tile assembly according to a first embodiment of the present invention. The assembly is intended to be laid on a flat substrate, such as a cement screed, to form a floor just above the substrate.

The main area of the floor is constructed from a plurality of interlocking tiles2. In this embodiment the tiles2are square in plan, though other tessellating shapes such as rectangles, hexagons or a combination of two or more different shapes could be used. The design of the illustrated tile2is such that it can be moulded as a single component in a two-part mould. The tiles are preferably formed from a plastic material, such as polypropylene, that is strong enough to carry the weight that is expected to be placed on the floor and hard enough to resist the wear of the activities that are expected to be carried out on it. For example, if vehicles are to be driven over the floor, it may need to be of a more robust material and/or design than for purely pedestrian use. Naturally, other considerations such as colour, grip, weather-resistance, sustainability, etc. may affect the choice of material.

The tiles2are designed to interlock with one another so that they can cover an indefinite area of the substrate in modular fashion. As shown inFIG.1, the main tiles2may also interlock with edge pieces4and corner pieces6at the edges of the desired area of floor.

Each tile2is formed as a single moulding, structured as a grid of square cells8, which in the illustrated embodiment form a 14×14 array. In accordance with the invention, at least some of the cells8provide recesses10in the upper surface of the tile2, into which inserts12can be pressed to form a desired pattern, as will be described in more detail below. In the illustrated embodiment of the invention, every cell8has such a recess10, althoughFIG.1shows only one representative cell8that is occupied by an insert12. Alternatively, smaller numbers of recesses10could be provided: for example, spread more sparsely over the whole area of the tile2, confined to particular areas of the tile or arranged in pre-defined patterns. In regions of the flooring where no surface pattern is required, plain tiles with no recesses may be used alongside tiles according to the invention. The underside of such a plain tile3is shown inFIG.2. Apart from the absence of recesses10, the structure of the plain tile3is substantially the same as that of the tiles2according to the invention soFIG.2is useful for understanding both kinds of tile.

As seen inFIG.2, the underside of each cell8is substantially hollow. The walls between adjacent cells8take the form of arches14, which spring from pillars16located at each intersection of the grid. The array of pillars16supports the floor above the substrate on which it rests. The lines of arches14along each row and column of the grid of cells8create first and second sets of channels18that open to the underside of the tile2. The channels18extend parallel to the upper surface of the tile and at least some of the channels18emerge at openings20in the side edges of the tile. For a square or rectangular tile2, as illustrated, the first and second sets of channels18are orthogonal to one another and each cell8is located at the intersection of two channels18. A system with hexagonal tiles (not illustrated) might comprise three sets of channels and each cell would be located at the intersection of three channels angled at 60° to one another.

Around the edges of the tiles2,3, engagement means are provided for securing each tile to adjacent, similar tiles. The engagement means may take various forms but a mechanical interlock between adjacent tiles is preferred. As seen inFIG.3, the engagement means typically comprise projections22that extend from edges of the tile2. In the embodiment of the invention illustrated inFIG.1, each projection22has a substantially square boss21that fits into the hollow underside of a cell8of the adjacent tile. The boss21is connected to the tile2by a narrow flexure23, which will fit through one of the arched openings20at the end of a channel in the side edge of the adjacent tile. The illustrated projections22are in adjacent pairs, spaced at intervals along two neighbouring side edges of the tile2. The bosses21of the adjacent projections22are joined to one another such that, in the assembled floor, the two bosses21will fit respectively in two adjacent cells8and the part joining them will pass through the arch14between the two cells8. Seen in plan view, the flexures23of the adjacent projections22are configured as mirror-image S-shapes. This permits some movement of the projections22parallel to the plane of the tile and reduces the likelihood of damage in the event that the tile is subjected to torsion, for example by a vehicle turning on it. The flexures23can also move to accommodate thermal expansion of the tiles2.

During assembly of a floor, the edge of each new tile is lowered over the engagement means22that project from a tile2already in place. The boss21is a push-fit into the cell8and assembly does not require a hammer or any other tool. In order that the new tile cannot simply be lifted off again, small retaining hooks25may be provided on the two side edges of each tile2that do not carry the engagement means22. When the new tile is pushed fully into place, its retaining hooks25catch under channel openings20of the existing tile2to hold the new tile down in a releasable manner. The bosses21of the engagement means22may be provided with countersunk screw-holes26, through which the tiles2can be secured to the substrate if required. This may be appropriate if the tiling system is installed on a vertical surface or if there is concern that in some areas it might lift from the substrate.

Many alternative arrangements of the engagement means are possible, provided that each projection22is matched by a complementary opening20in the corresponding position in the opposite edge of the tile2. It is preferred that some of the channels18are kept clear of engagement means, in order that each such channel can provide a straight path through the underside of the tile2between the openings20at its ends.

Because of the repeating pattern of cells8on the underside of the tiles2,3, a tile may be cut along certain lines parallel to its side edges so as to leave a whole number of cells8remaining. The line of arches14exposed by the cut form new end openings20of the channels18, which can receive the engagement means22of an adjacent tile and thus secure the cut tile to the floor in the same way as a whole tile.

FIG.4is a cross-section through part of a tile2, which shows how an insert12can be received and retained by one of the recesses10. At the base of each recess10is a hole24through to the underside of the tile2. The shape of each insert12complements the shape of the recess10. At the bottom of the insert is a pair of downwardly projecting arms27, which engage the hole24in snap-fit connection. The arms27end in a pair of hooks28that face away from one another. In the relaxed state of the arms27, the hooks28are too wide to fit through the hole24but the leading faces of the hooks28are tapered to guide them into the hole24and to urge the arms27to bend towards one another. When the insert12is fully inserted into the recess10, the hooks28clear the bottom of the hole24, allowing the arms27to spring resiliently apart. The hooks28then catch behind the bottom wall of the recess10to prevent the insert12being accidentally removed again. The arms27and the hole24may be configured so that it is possible to remove the inserts, for example using a special tool, or so that it is impossible to remove them without lifting the tile2to get access to the underside.

The inserts12may be formed from the same material as the tile2or from a different material to provide different characteristics. They will generally be of one or more colours that are different from the tile2and it will readily be understood fromFIG.1how an arrangement of multiple inserts12over the array of recesses10can be used to build up a mosaic in any desired pattern. The inserts12are normally shaped so that their upper face30is flush with the upper surface32of the tile2but, as seen inFIG.4, there may be circumstances in which a shallow domed profile is desirable, e.g. to provide increased grip on the floor surface. The upper face of at least some inserts could be textured for the same purpose. Some inserts could be shaped such that after insertion they create a fluid passage through the recess10—either through the body of the insert or around its outside—to provide drainage from the upper face of the tile2. In many cases, it will be acceptable to leave some of the recesses10unfilled by inserts12so that the holes24provide drainage from the upper face of the tile and air circulation to the substrate below the tile.

Reverting toFIG.2, this illustrates how a cable34may be ducted under the tile2through the channels18formed by rows or columns of cells8interconnected by arches14. This is a convenient way to deliver electric power, networking or telecommunications services to apparatus that may be provided on the floor or on adjacent walls; or simply as a way for the cable34to cross the floor without creating a trip hazard. As shown, if the cable is sufficiently flexible, it can change direction through 90° from one channel to a crossing channel and, with careful design of the layout, multiple cables may be accommodated. The cable34can be held in place by a removable clip36, which bridges across the channel18in which the cable34has been laid. Each end of the clip36comprises a foot38, which is shaped to be a push-fit into the adjacent hollow cell8on each side of the channel18.

FIG.5is a partial cross-section showing the same arrangement, in which a cable is held in a channel18by a clip36that is anchored in adjacent cells8on each side. The cable inFIG.5is a particular instance, namely a lighting cable40, which has lighting elements42such as LEDs spaced at intervals along its length. Preferably, the lighting elements42are spaced at intervals that are a multiple of the spacing between cells8of the grid, whereby it can be arranged that successive lighting elements42are aligned with recesses10. Those recesses10can be left open or filled with translucent inserts12—either clear or coloured—to allow light from the lighting elements42to reach the upper surface32of the tile for decorative and/or practical purposes. In plain tiles3or in regions of a normal tile2that lack recesses, the floor surface itself may be made sufficiently thin above some or all of the cells8that it becomes translucent to light emitted by a lighting cable40below the tile.

FIG.6illustrates another type of cable that may be ducted beneath a tile2according to the invention, namely a heating cable44. The cable44carries electrically resistive heating elements (not shown), either continuously or at intervals along its length, from which heat can be conducted through the tile to warm the surface of the floor. Arranging the cable44in the serpentine manner shown ensures that the heat is evenly distributed across the area of the tile2. Cable clips36(not shown inFIG.6) could again be used to secure the heating cable in position.

FIGS.7and8show an example of how the tiling system can be made to provide still more flexible designs by combining cut tile parts of different colours. The tile parts50,52may be parts of plain tiles3or of normal tiles2that have recesses10. In this example, a single tile is replaced by two complementary parts50,52of tiles according to the invention, which have been cut along a curved line54. The two parts50,52are secured together by a series of junction clips56, which bridge the cut line54. The junction clips56are very similar to the cable clips36, having a foot58at each end that is a push-fit into a cell8on the underside of the respective tile part50,52. However, in this case the junction clip56preferably bridges across two intermediate cells8to allow room for an oblique cut line54that crosses two cells (as seen near the bottom ofFIG.7). When joined together, the tile parts50,52form the same overall shape as a whole tile2,3and they can be used in the same manner as a whole tile when assembling a floor.

The reader will understand that various features of the described embodiment of the invention could be used independently of one another. In particular, the operation of the engagement means22for securing adjacent tiles together does not depend in any way on the tiles having recesses10and inserts12in the upper surface (or vice versa).

The reader will also understand that the inventive concept set out in this specification encompasses numerous variants of the particular embodiments described. For example, instead of the described snap-fit connection between the inserts12and the recesses10, there could be a simple push fit or interference fit connection. Alternatively, a second component could be attached to the insert from the underside of the tile to prevent the insert being withdrawn from the recess.

All references, including publications, patent applications, and patents cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.

The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) is to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.

Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.