TILE SYSTEMS AND METHOD OF ASSEMBLING A TILE SYSTEM

DESCRIPTION Technical field

The invention relates to interlocking tiles for covering a surface of a building, structure or outdoor area. The surface is typically a floor and the tiles may be used as an easy way to change its appearance or its physical characteristics such as the surface material. The use of the tiles may be temporary, e.g. in a display area, or of unlimited duration, e.g. around a swimming pool or in a garage.

Background of the invention

Interlocking modular panels are well known as temporary ground coverings, for example to create temporary dance floors or routes for vehicles to travel across soft ground. They can also be put to more permanent use, e.g. to install wood flooring or to create a raised floor with a void underneath, which can be used for routing electrical or telecommunications cables. When used on a floor, such systems generally do not need to be fixed down: they can “float” and their own weight combined with engagement with the adjoining panels is sufficient to hold them on the substrate. Modular panel systems have the advantage of being relatively quick to install as a way of changing the appearance or physical characteristics of the floor, without the need to remove and replace the existing ground surface. They are also generally quick to remove when a temporary installation comes to an end or if access is needed to the ground below a permanent installation.

There has been little use of such interlocking modular technology in applications for which ceramic or stone tiles are more traditionally used, for example in swimming pool surrounds. One reason may be that if the individual tiles are smaller, more of them are required, so the installation becomes more time-consuming and, with a greater number of connections each offering a small amount of play, the stability of the final construction is reduced. While larger tiles or panels could be used in these situations, their uniform appearance gives little scope for the creation of interesting designs and may detract from the appearance of the finished floor surface.

Summary of the invention

The invention provides a tile system according to claim 1.

The ability to lay cables under the tiles provides advantages: for example, to provide power or networking to equipment that may be placed on the tile assembly without creating a trip hazard. Because there are two sets of channels, which are typically orthogonal and intersecting, cables can be guided through the tile along many different paths. Special cables can be used to add lighting or to heat the tile assembly itself from below. In embodiments of the invention where a lighting cable under the tiles lights the floor surface through translucent inserts, it will be understood that this can be a cost-effective way to provide floor-level lighting for use in emergency situations.

The invention further provides an alternative tile system according to claim 12.

The tiles according to the invention may be made large enough to be quick and easy to install and to form a robust and stable structure, while retaining the freedom to create an enormous variety of decorative patterns, depending on how the inserts are arranged in the recesses. For example, if the recesses are arranged in a grid pattern over substantially the whole surface of the tile, the inserts can be arranged in the manner of a mosaic.

It will be understood that the patterns formed by the inserts need not be purely decorative: for example, in some situations they could be used to define a route, form a directional indicator or highlight a hazard.

The invention additionally provides a method of assembling a tile system according to claim 27. The dependent claims define features of the invention that are preferred but not essential.

The specification also discloses a tile system that comprises a plurality of tiles, wherein the underside of each tile comprises a plurality of cells and wherein at least one side edge of the tile comprises engagement means suitable for securing the tile to an adjacent, similar tile, each engagement means comprising a flexure that extends from the side edge of the tile and terminates in a boss, the flexure extending into an opening in a side edge of the adjacent tile, and the boss fitting into a cell on the underside of the adjacent tile.

In this specification, words such as “lower” and “under” refer to the direction towards the substrate on which the tile is mounted, while words such as “upper” and “over” refer to the opposite direction. These words therefore have their natural meaning when the substrate is a floor but the invention does not exclude mounting the tiles on substrates with other orientations, e.g. on a wall. Naturally, the tiles and other components of the invention may be manufactured, transported and stored in any orientation prior to use, without departing from the scope of the invention defined by the claims.

The drawings

Figure 1 is a perspective view showing the components of a tile assembly in accordance with the invention.

Figure 2 is a perspective view of part of the underside of a tile that may be used with the present invention, illustrating a cable clip in accordance with the invention.

Figure 3 is a perspective view of part of the underside of a tile in accordance with the invention, illustrating engagement means for connecting adjacent tiles.

Figure 4 is a cross-section through part of the tile assembly of Fig. 1, showing an insert located in a recess of the tile.

Figure 5 is a cross-section through part of the tile assembly of Fig. 1, showing the use of a cable clip to secure a lighting cable. Figure 6 is a perspective view of the underside of a tile in accordance with the invention, showing its use with a heating cable.

Figure 7 is a plan view of two tile parts in accordance with the invention, which have been secured together by junction clips.

Figure 8 is a partial cross-section of Fig. 7, taken along the length of one of the junction clips.

Figure 1 illustrates 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 tiles 2. In this embodiment the tiles 2 are 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 tile 2 is 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 tiles 2 are designed to interlock with one another so that they can cover an indefinite area of the substrate in modular fashion. As shown in Figure 1, the main tiles 2 may also interlock with edge pieces 4 and corner pieces 6 at the edges of the desired area of floor.

Each tile 2 is formed as a single moulding, structured as a grid of square cells 8, which in the illustrated embodiment form a 14 x 14 array. In accordance with the invention, at least some of the cells 8 provide recesses 10 in the upper surface of the tile 2, into which inserts 12 can be pressed to form a desired pattern, as will be described in more detail below. In the illustrated embodiment of the invention, every cell 8 has such a recess 10, although Figure 1 shows only one representative cell 8 that is occupied by an insert 12. Alternatively, smaller numbers of recesses 10 could be provided: for example, spread more sparsely over the whole area of the tile 2, confined to particular areas of the tile or arranged in pre-defmed 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 tile 3 is shown in Figure 2. Apart from the absence of recesses 10, the structure of the plain tile 3 is substantially the same as that of the tiles 2 according to the invention so Figure 2 is useful for understanding both kinds of tile.

As seen in Figure 2, the underside of each cell 8 is substantially hollow. The walls between adjacent cells 8 take the form of arches 14, which spring from pillars 16 located at each intersection of the grid. The array of pillars 16 supports the floor above the substrate on which it rests. The lines of arches 14 along each row and column of the grid of cells 8 create first and second sets of channels 18 that open to the underside of the tile 2. The channels 18 extend parallel to the upper surface of the tile and at least some of the channels 18 emerge at openings 20 in the side edges of the tile. For a square or rectangular tile 2, as illustrated, the first and second sets of channels 18 are orthogonal to one another and each cell 8 is located at the intersection of two channels 18. 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 tiles 2,3, 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 in Figure 3, the engagement means typically comprise projections 22 that extend from edges of the tile 2. In the embodiment of the invention illustrated in Figure 1, each projection 22 has a substantially square boss 21 that fits into the hollow underside of a cell 8 of the adjacent tile. The boss 21 is connected to the tile 2 by a narrow flexure 23, which will fit through one of the arched openings 20 at the end of a channel in the side edge of the adjacent tile. The illustrated projections 22 are in adjacent pairs, spaced at intervals along two neighbouring side edges of the tile 2. The bosses 21 of the adjacent projections 22 are joined to one another such that, in the assembled floor, the two bosses 21 will fit respectively in two adjacent cells 8 and the part joining them will pass through the arch 14 between the two cells 8. Seen in plan view, the flexures 23 of the adjacent projections 22 are configured as mirror-image S-shapes. This permits some movement of the projections 22 parallel 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 flexures 23 can also move to accommodate thermal expansion of the tiles 2.

During assembly of a floor, the edge of each new tile is lowered over the engagement means 22 that project from a tile 2 already in place. The boss 21 is a push-fit into the cell 8 and assembly does not require a hammer or any other tool. In order that the new tile cannot simply be lifted off again, small retaining hooks 25 may be provided on the two side edges of each tile 2 that do not carry the engagement means 22. When the new tile is pushed fully into place, its retaining hooks 25 catch under channel openings 20 of the existing tile 2 to hold the new tile down in a releasable manner. The bosses 21 of the engagement means 22 may be provided with countersunk screw-holes 26, through which the tiles 2 can 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 projection 22 is matched by a complementary opening 20 in the corresponding position in the opposite edge of the tile 2. It is preferred that some of the channels 18 are kept clear of engagement means, in order that each such channel can provide a straight path through the underside of the tile 2 between the openings 20 at its ends. Because of the repeating pattern of cells 8 on the underside of the tiles 2,3, a tile may be cut along certain lines parallel to its side edges so as to leave a whole number of cells 8 remaining. The line of arches 14 exposed by the cut form new end openings 20 of the channels 18, which can receive the engagement means 22 of an adjacent tile and thus secure the cut tile to the floor in the same way as a whole tile.

Figure 4 is a cross-section through part of a tile 2, which shows how an insert 12 can be received and retained by one of the recesses 10. At the base of each recess 10 is a hole 24 through to the underside of the tile 2. The shape of each insert 12 complements the shape of the recess 10. At the bottom of the insert is a pair of downwardly projecting arms 27, which engage the hole 24 in snap-fit connection. The arms 27 end in a pair of hooks 28 that face away from one another. In the relaxed state of the arms 27, the hooks 28 are too wide to fit through the hole 24 but the leading faces of the hooks 28 are tapered to guide them into the hole 24 and to urge the arms 27 to bend towards one another. When the insert 12 is fully inserted into the recess 10, the hooks 28 clear the bottom of the hole 24, allowing the arms 27 to spring resiliently apart. The hooks 28 then catch behind the bottom wall of the recess 10 to prevent the insert 12 being accidentally removed again. The arms 27 and the hole 24 may 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 tile 2 to get access to the underside.

The inserts 12 may be formed from the same material as the tile 2 or from a different material to provide different characteristics. They will generally be of one or more colours that are different from the tile 2 and it will readily be understood from Figure 1 how an arrangement of multiple inserts 12 over the array of recesses 10 can be used to build up a mosaic in any desired pattern. The inserts 12 are normally shaped so that their upper face 30 is flush with the upper surface 32 of the tile 2 but, as seen in Figure 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 recess 10 - either through the body of the insert or around its outside - to provide drainage from the upper face of the tile 2. In many cases, it will be acceptable to leave some of the recesses 10 unfilled by inserts 12 so that the holes 24 provide drainage from the upper face of the tile and air circulation to the substrate below the tile.

Reverting to Figure 2, this illustrates how a cable 34 may be ducted under the tile 2 through the channels 18 formed by rows or columns of cells 8 interconnected by arches 14. 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 cable 34 to 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 cable 34 can be held in place by a removable clip 36, which bridges across the channel 18 in which the cable 34 has been laid. Each end of the clip 36 comprises a foot 38, which is shaped to be a push- fit into the adjacent hollow cell 8 on each side of the channel 18.

Figure 5 is a partial cross-section showing the same arrangement, in which a cable is held in a channel 18 by a clip 36 that is anchored in adjacent cells 8 on each side. The cable in Figure 5 is a particular instance, namely a lighting cable 40, which has lighting elements 42 such as LEDs spaced at intervals along its length. Preferably, the lighting elements 42 are spaced at intervals that are a multiple of the spacing between cells 8 of the grid, whereby it can be arranged that successive lighting elements 42 are aligned with recesses 10. Those recesses 10 can be left open or filled with translucent inserts 12 - either clear or coloured - to allow light from the lighting elements 42 to reach the upper surface 32 of the tile for decorative and/or practical purposes. In plain tiles 3 or in regions of a normal tile 2 that lack recesses, the floor surface itself may be made sufficiently thin above some or all of the cells 8 that it becomes translucent to light emitted by a lighting cable 40 below the tile.

Figure 6 illustrates another type of cable that may be ducted beneath a tile 2 according to the invention, namely a heating cable 44. The cable 44 carries 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 cable 44 in the serpentine manner shown ensures that the heat is evenly distributed across the area of the tile 2. Cable clips 36 (not shown in Figure 6) could again be used to secure the heating cable in position.

Figures 7 and 8 show 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 parts 50,52 may be parts of plain tiles 3 or of normal tiles 2 that have recesses 10. In this example, a single tile is replaced by two complementary parts 50,52 of tiles according to the invention, which have been cut along a curved line 54. The two parts 50,52 are secured together by a series of junction clips 56, which bridge the cut line 54. The junction clips 56 are very similar to the cable clips 36, having a foot 58 at each end that is a push-fit into a cell 8 on the underside of the respective tile part 50,52. However, in this case the junction clip 56 preferably bridges across two intermediate cells 8 to allow room for an oblique cut line 54 that crosses two cells (as seen near the bottom of Figure 7). When joined together, the tile parts 50,52 form the same overall shape as a whole tile 2,3 and 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 means 22 for securing adjacent tiles together does not depend in any way on the tiles having recesses 10 and inserts 12 in 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 inserts 12 and the recesses 10, 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.