Tiles, floors, and methods and processes related thereto

Abstract

Two-piece tiles and/or floors comprised of a plurality of such two-piece tiles. In other embodiments, methods and/or processes for manufacturing or assembling such two-piece tiles, and/or to methods of assembling floors comprised of such tiles.

Claims

1. A two-piece tile comprising: a base tile portion having a plurality of structurally supportive skeletal members distributed between walls of a frame, said plurality of structurally supportive skeletal members and said frame collectively comprising a skeletal base structure; a plurality of male interlocking members extending from at least one edge of said frame of said skeletal base structure; a plurality of female interlocking receptacles located along at least one edge of said frame of said skeletal base structure for receiving male interlocking members of a different, adjacently located two-piece tile; a plurality of tread elements located and distributed atop one or more surfaces of said skeletal base structure; a top generally planar tile portion having a plurality of apertures which are so sized and spaced so as to match the respective size and spacing pattern of said plurality of tread elements of said base tile portion, such that said top generally planar tile portion assembles to, and is assembled to, said base tile portion with said plurality of tread elements nested in said plurality of apertures; and wherein, when said top generally planar tile portion is assembled to said base tile portion, said plurality of tread elements at least partially extend above a planar surface of said top generally planar tile portion thereby providing an anti-slip surface.

2. The two-piece tile according to claim 1 wherein said base tile portion is formed from a material having a first color, and said top generally planar tile portion is formed from a material having a second color which is different from said first color.

3. The two-piece tile according to claim 2 wherein said plurality of tread elements are formed from a material having the same color as said first color of said material forming said base tile portion.

4. The two-piece tile according to claim 3 wherein said base tile portion and said top generally planar tile portion are each formed from an injection molding procedure.

5. The two-piece tile according to claim 3 wherein said top generally planar tile portion is removably connected to said base tile portion.

6. The two-piece tile according to claim 5 wherein because said top generally planar tile portion is removably connected to said base tile portion, said top generally planar tile portion can be replaced independently of said base tile portion to repair said two-piece tile or to change the color appearance of said two-piece tile.

7. The two-piece tile according to claim 1 wherein said base tile portion is formed from a first material, and said top generally planar tile portion is formed from a second material which is different from said first material.

8. The two-piece tile according to claim 1 wherein said top generally planar tile portion is formed from a first material, and wherein said plurality of tread elements are formed from a second material which is different from said first material.

9. The two-piece tile according to claim 8 wherein said base portion is formed from a material which is different than said second material from which said plurality of tread elements are formed.

10. The two-piece tile according to claim 1 wherein said skeletal base structure comprises a plurality of ribs and rings having empty spaces therebetween.

11. The two-piece tile according to claim 10 wherein said plurality of tread elements are located atop said plurality of ribs and rings.

12. The two-piece tile according to claim 1, wherein said two-piece tile includes at least one substantially linear edge for abutting with an adjacent two-piece tile, when assembled together to said adjacent two-piece tile, said substantially linear edge including at least one beveled edge, for aligning with an adjacent beveled edge, to form an interstitial space between assembled together adjoining two-piece tiles such that assembly and disassembly of adjoining two-piece tiles to one another is aided by permitting improved angular manipulation of said adjoining two-piece tiles, one with respect to the other.

13. The two-piece tile according to claim 1 wherein said base tile portion includes at least one channel configured to align with at least one channel of an adjacent two-piece tile, when assembled together to said adjacent two-piece tile, said aligned channels being useful to allow routing of one or more wires underneath said top generally planar tile portion.

14. A two-piece tile comprising: a base tile portion having a plurality of structurally supportive skeletal members distributed between walls of a frame, said plurality of structurally supportive skeletal members and said frame collectively comprising a skeletal base structure; a plurality of male interlocking members extending from at least one edge of said frame of said skeletal base structure; a plurality of female interlocking receptacles located along at least one edge of said frame of said skeletal base structure for receiving male interlocking members of a different, adjacently located two-piece tile; a plurality of tread elements located and distributed atop one or more surfaces of said skeletal base structure; a top generally planar tile portion having a plurality of apertures which are so sized and spaced so as to match the respective size and spacing pattern of said plurality of tread elements of said base tile portion, such that said top generally planar tile portion assembles to, and is assembled to, said base tile portion with said plurality of tread elements nested in said plurality of apertures; wherein said plurality of male interlocking members comprise substantially U-shaped structures; and wherein said plurality of female interlocking receptacles comprise substantially U-shaped channels configured in shape and size to fit said substantially U-shaped structures, of adjacent two-piece tiles, nested therein; and further including a plurality of deformable riser members located proximal openings of said plurality of substantially U-shaped channels, each said deformable riser member being configured to lock a said substantially U-shaped structure within a said substantially U-shaped channel by friction or physical interference engagement with a surface of an adjacent two-piece tile; wherein said base tile portion has a configuration which is generally rectangular in outline and is also generally planar; and wherein said plurality of tread elements are configured to have anti-slip properties and wherein, when said top generally planar tile portion is assembled to said base tile portion, said plurality of tread elements at least partially extend above a planar surface of said top generally planar tile portion.

15. A modular plastic floor comprising a plurality of two-piece tiles assembled to one another, each said two-piece tile comprising: a base tile portion having a plurality of structurally supportive skeletal members distributed between walls of a frame, said plurality of structurally supportive skeletal members and said frame collectively comprising a skeletal base structure; a plurality of male interlocking members extending from at least one edge of said frame of said skeletal base structure; a plurality of female interlocking receptacles located along at least one edge of said frame of said skeletal base structure for receiving male interlocking members of a different, adjacently located two-piece tile; a plurality of tread elements located and distributed atop one or more surfaces of said skeletal base structure; and a top generally planar tile portion having a plurality of apertures which are so sized and spaced so as to match the respective size and spacing pattern of said plurality of tread elements of said base tile portion, such that said top generally planar tile portion assembles to, and is assembled to, said base tile portion with said plurality of tread elements nested in said plurality of apertures; and wherein, when said top generally planar tile portion is assembled to said base tile portion, said plurality of tread elements at least partially extend above a planar surface of said top generally planar tile portion thereby providing an anti-slip surface.

16. A method of making a two-piece tile comprising: forming a base tile portion having a plurality of structurally supportive skeletal members distributed between walls of a frame, said plurality of structurally supportive skeletal members and said frame collectively comprising a skeletal base structure; forming a plurality of male interlocking members extending from at least one edge of said frame of said skeletal base structure; forming a plurality of female interlocking receptacles located along at least one edge of said frame of said skeletal base structure for receiving male interlocking members of a different, adjacently located two-piece tile; forming a plurality of tread elements and locating said plurality of tread elements atop one or more surfaces of said skeletal base structure; forming a top generally planar tile portion having a plurality of apertures which are so sized and spaced so as to match the respective size and spacing pattern of said plurality of tread elements of said base tile portion, such that said top generally planar tile portion assembles to, and is assembled to, to said base tile portion with said plurality of tread elements nested in said plurality of apertures; connecting said top generally planar tile portion to said base tile portion; and wherein, when said top generally planar tile portion is assembled to said base tile portion, said plurality of tread elements at least partially extend above a planar surface of said top generally planar tile portion thereby providing an anti-slip surface.

17. The method of making a two-piece tile according to claim 16, further comprising: forming said base tile portion to have a first color; and forming said top generally planar tile portion to have a second color different than said first color.

18. The method of making a two-piece tile according to claim 17, further comprising: forming a plurality of said base tile portions having said first color, and storing said formed base tile portions pending customer orders for a customer specified two-piece tile color; upon receipt of said customer orders, forming one or more of said top generally planar tile portions to have a second color which matches said customer specified two-piece tile color; and connecting said one or more top generally planar tile portions to one or more of said base tile portions, to form a tile having the color specifications of said customer specified two-piece tile color.

19. The method of making a two-piece tile according to claim 16, further comprising: forming said base tile portion to have a first color; forming said top generally planar tile portion to have a second color; temporarily, removeable connecting said top generally planar tile portion to said base tile portion such that said top generally planar tile portion can be replaced independently of said base tile portion to change the color appearance of said two-piece tile by replacing the original said top generally planar tile portion with a replacement top generally planar tile portion having a third color which is different from said second color.

20. The method of making a two-piece tile according to claim 16, further comprising: forming said base tile portion out of a first material; and forming said top generally planar tile portion out of a second material which is different than said first material.

21. The method of making a two-piece tile according to claim 20, further comprising: forming a plurality of said base tile portions from said first material, and storing said formed base tile portions pending customer orders for a customer specified two-piece tile material configuration; upon receipt of said customer orders, forming one or more of said top generally planar tile portions to have a second material which matches said customer specified two-piece tile material configuration; and connecting said one or more top generally planar tile portions to one or more of said base tile portions, to form a tile having the material configuration of said customer specified two-piece tile material configuration.

22. The method of making a two-piece tile according to claim 16, further comprising: determining a weight bearing strength parameter; and forming said base tile portions to meet or exceed said weight bearing strength parameter by configuring said skeletal base structure to meet or exceed said weight bearing strength parameter.

23. The method of making a two-piece tile according to claim 16, further comprising: determining a two-piece tile height parameter; and configuring a height of said base tile portion such that said two-piece tile height meets said two-piece tile height parameter, when said top generally planar tile portion is connected to said base tile portion.

24. The method of making a two-piece tile according to claim 16 wherein said top generally planar tile portion and said base tile portion are each injection molded.

25. The method of making a two-piece tile according to claim 24 wherein said top generally planar tile portion and said base tile portion are integrally formed utilizing a two-color injection molding step.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The drawings submitted herewith, and which form a part of this patent application, each illustrate an embodiment, or one or more components of an embodiment, of a non-limiting example of Applicant's inventive lids. While these drawings depict certain preferred embodiments of Applicant's invention, as well as certain particularly desirable features thereof, they are intended to be examples only and should not be construed to limit the scope of applicants' invention.

(2) FIG. 1 is a perspective view of one embodiment of a tile according to the subject invention.

(3) FIG. 2 is an exploded view of the tile depicted in FIG. 1.

(4) FIG. 3 is a cross-sectional view of the tile depicted in FIG. 1.

(5) FIG. 4 is a call-out view of an edge of the tile depicted in FIG. 1.

(6) FIGS. 5 and 6 are schematic views showing the assembly of one example tile to another example tile according to one embodiment of the subject invention.

(7) FIG. 7 is a schematic view showing the tiles depicted in FIGS. 5 and 6 being disassembled.

(8) FIG. 8 is an alternative perspective view of the tile depicted in FIG. 1.

(9) FIG. 9 is an alternative bottom plan view of the tile depicted in FIG. 1.

(10) FIG. 10 is an alternative bottom perspective view of the tile depicted in FIG. 1.

(11) FIG. 11 is an alternative bottom view of the tile depicted in FIG. 1 with a single channel.

(12) FIG. 12 is an alternative bottom view of the tile depicted in FIG. 1 with intersecting channels.

DETAILED DESCRIPTION OF CERTAIN EXAMPLE EMBODIMENTS OF THE INVENTION

(13) For a more complete understanding of the present invention, reference is now made to the following description of various illustrative and non-limiting embodiments thereof, taken in conjunction with the accompanying drawings in which like reference numbers indicate like features. These example embodiments, disclosed and discussed below, will assist in a further understanding of the inventions described and claimed herein, but they are not intended to limit the scope of the invention in any way. Although dimensions may be discussed in connection with some embodiments, not all embodiments are intended to be limited to such dimensions, and variants from such dimensions are of course contemplated.

(14) Referring initially to FIGS. 1-3, one example embodiment of a two-piece tile 1, exhibiting improvements over the prior art, is disclosed therein. The two-piece tile 1, in this example configuration, comprises a base board 11 and a stepping portion 12. Moreover, in this embodiment, the stepping portion 12 is comprised of a generally planar surface 122 having a plurality of spaced apart apertures 121. Planar surface 122 is configured as a walking or driving surface, in this example, but may have different configurations in different embodiments where the tile is intended for a different end use. Exemplar base board 11, in turn, is configured to pair with stepping portion 12, and includes a plurality of ribs 112 and a plurality of ring ribs 113 longitudinally and latitudinally spaced and distributed between the walls of rectangular frame 111. Such ribs and rings are supplied to provide structural strength and rigidity to the tile in this embodiment, and may be modified, in other embodiments, to provide different structural characteristics as determined by the planned end use.

(15) For enabling assembly of a plurality of tiles to each other to form a floor surface, a plurality of U-shaped engaging rings 114 are provided at two adjacent border edges of rectangular frame 111, each ring serving as a male mating member for engaging with a female mating member (or surface) of an adjacent tile. On the remaining two border edges of example tile 1, a plurality of U-shaped channels 117 are provided as female mating surfaces, each preferably including a riser structure 115 located proximal thereto. Although configured as U-shaped in this embodiment, other configurations of male and female mating members 114 and 117 are of course contemplated. For example, D-shaped or C-shaped structures could be employed, as could structures having additional angles, e.g. square or rectangular shaped members/structures. U-shaped structures have been utilized in this embodiment, however, because the continuous curve, at the terminal ends of the structures, aids in engagement and disengagement of one tile from another. When construing the term U-shaped herein, however, U-shaped should be construed broadly to also include D-shaped and C-shaped, because a D-shape includes a U-shaped member with an additional linear surface, and a C-shaped structure is generally similar to a U-shaped structure but with modestly different proportions.

(16) More specifically, in the embodiment illustrated in FIGS. 1-3, the plurality of engaging rings 114 and plurality of U-shaped channels 117 are configured to have complementary shapes and dimensions so that the “male” engaging ring 114 of one tile will assemble structurally to the female U-shaped channel 117 of an adjacent tile (i.e., having the same configuration), and nest therewithin. When tiles are connected as such, such as depicted in FIGS. 5-6, they form a floor surface which can be expanded in size by simply adding additional tiles.

(17) In the example embodiment shown in FIG. 2, the base board 11 also includes a plurality of raised tread elements 116 that are connected to the top surface of the plurality of ribs 112, the plurality of ring ribs 113, and the rectangular frame 111. Such tread elements can be formed as part of base board 11, such as in an injection molding process, or they may be added as additional elements, such as by mechanical connection, adhesive, or material fusion or welding (or similarly suitable) methods. Apertures 121 in stepping portion 12 (i.e., formed in the generally planar surface 122 thereof) are preferably configured spatially and in shape and number to receive, in a nested relation, the plurality of raised tread elements 116 so that when the stepping portion 12 is placed on top of base board 11, stepping portion 12 is held (at least “loosely”) in place thereby, because of the mechanical interconnection.

(18) In certain embodiments, stepping board 12 and base board 11 are effectively permanently connected to one another. In such embodiments, although tread elements 116 serve as a mechanical interconnections of such bottom and top tile portions to each other (which can be aided by configuring the treads to have locking structures for locking to stepping board 12), supplemental connection structures and/or methods may be utilized to aid in establishing a more permanent connection. For example, mechanical interlocks can be provided (e.g., at tile border edges or on the provide ribs and rings) and/or adhesives may be used and/or the top and bottom surfaces can be fused together such as with heat welding.

(19) In alternative embodiments, where stepping board 12 and base board 11 are merely temporarily connected, certain functional advantages are provided. For example, if a customer desires a color change of their already installed flooring, such customer can order tile top portion replacements in a different color. By way of more specific example, if a customer already owns an installed red tile floor, such customer can 1) order green tile top portion replacements, 2) remove the existing red top tile portions, 3) and install the green tile top portions to change the color of the floor from blue to yellow. Similarly, if a customer desires a surface texture change of their already installed flooring, such customer can order tile top portion replacements having a different surface texture (e.g., stepping surface). Examples of alternative surface textures grain (e.g., wood grain), treads, channels, cross-hatching, concave or convex regions, surface ornamentation, apertures, drain holes, etc. Still further, if a customer is satisfied with the color and/or surface characteristics of their tile floor, but desire a different base portion, 1) new base tile portions may also be ordered, 2) the existing base tile portions disassembled from the desirable top tile portion, and 3) the replacement base portions installed to the retained desirable top tile portions. Reasons for replacing the bottom/base tile portion could optionally include a need (or desire) for a taller height tile (e.g., by selecting a thicker/taller tile base portion) or a need (or desire) for a stronger or more durable bottom/base tile portion (e.g., such as if moving the tile floor to an automotive garage where the tiles will need to carry thousands of pounds). In yet another example, the bottom tile portion could be replaced because of a need (or desire) for a bottom/base tile portion which has different mechanical characteristics than the existing base tile portion. For example, replacement bases could be ordered which have greater elasticity (e.g., “cushioning”) to provide improved walking comfort characteristics to the two-piece tile. In such embodiments, the top tile portion may be selected to be a rigid material—such as a rigid plastic—while the base material is selected to have elastic properties (e.g., thereby obtaining a hybrid two-piece tile configuration). In still other examples, tile base configurations can be selected which include spacing or channels for permitting liquid flow (e.g., while the top tile portion remains raised above the liquid surface), such as for if the tile floor will be installed in areas subject to potential flooding, or other water exposure areas such as showers or bar areas. In these embodiments where stepping board 12 and base board 11 are temporarily connected, the connection of the tile portions is preferably mechanical and can rely on the tread/aperture interconnection alone, or the tread/aperture mechanical connections can be supplemented with additional mechanical connections, such as retaining clips, or locking pins or snap together connectors, formed in one or more of the tile portions.

(20) In the embodiment illustrated, when base board 11 and stepping portion 12 are in an assembled relation, the top surface of one or more of the plurality of raised tread elements 116 extends above the generally planar surface 122 to provide traction for walking or riding or driving. For this purposed, tread elements can be configured to have desirable traction characteristics, in addition to desired ornamental characteristics. Conversely, in other embodiments, tread elements can be positioned flush (e.g., co-planar), or below plane, with (or in relation to) generally planar surface 122, such as in embodiments where the treads are primarily serving an ornamental function.

(21) In at least one example method of manufacturing the tiles described herein, a two-color injection molding machine may be used to form base board 11. In such an embodiment, base board 11 is positioned on a turntable within an injection molding machine, and the turntable of the injection molding machine is rotated, such that the base board 11 and the plurality of raised tread elements 116 are held in position proximal a mold for forming stepping portion 12. Thereafter, while the stepping portion 12 is being molded, the plurality of apertures 121 are formed directly around the structures of the plurality of raised tread elements 116 situated proximal the mold of stepping portion 12. Injection molded using this method, it is ensured that the size, spatial relation, number, and shape of the plurality of apertures 121 substantially matches the tread elements of base board 11, so that the top and bottom tile pieces may be easily assembled and disassembled in matching relation. Alternatively, in other example embodiments, it is also contemplated that this injection molding process can be used to make a two-piece tile 1 wherein the base board 11 and the stepping portion 12 are permanently connected to one another (e.g., such as using the mechanisms or techniques described elsewhere herein).

(22) Referring now to FIGS. 4 and 7, an enlarged view (i.e., call-out view) of an edge (or border portion) of tile 1 is illustrated therein. In this embodiment, the edge of tile 1 is manufactured to have a beveled (i.e., sloped or angled) planar configuration, shown as beveled surface 1112 in the figure (left side, FIG. 7). A mirror image of tile 1, depicted as tile 1′, is also shown in FIG. 4, also having a beveled surface 1112′ (right side, FIG. 7, having substantially the same beveled, planar configuration as surface 1112). Utilizing this configuration, when two tiles having the configuration of tile 1 are placed adjacent one another, a gap A is formed between the slopes of beveled surfaces 1112 and 1112′ of the respective tiles 1 and 1′ (see FIG. 7). Gap A, in this embodiment, is provided for facilitating disassembly of tiles 1 and 1′ from one another, by allowing each individual tile to effectively rotate about the tile intersection point towards one another, as indicated by the arrows in FIG. 7. Manipulating the tiles directionally and angularly as such aids in disengaging the connection between the plurality of engaging rings 114 and U-shaped channels 117 on each respective tile. This is particularly useful in embodiments which utilize riser structures 115. For example, because in certain embodiments, such as shown in FIGS. 9-10, riser structure 115 is a two-piece structure comprising an outer riser portion 115′ and an inner riser portion 115″ each of which is preferably plastically deformable and together having a relative outer diameter (or outer dimension) which slightly exceeds the inner diameter of U-shaped engaging rings 114. Sized and configured as such, and with riser structure 115 located in a central region of U-shaped channels 117, when a U-shaped engaging ring is inserted into a U-shaped channel, riser structure 115 is force fit into the center aperture of the U-shaped engaging ring, slightly temporarily biasing riser portion 115′ and 115″ towards each other (effectively deforming riser structure 115 by pushing its two component parts closer together). Increased bias is supplied at the beginning of the engagement by providing a tip extension 1113 on at least one portion of the riser structure, so that the tip has an effective diameter greater than the diameter of the body 1111 of the riser structure. Consequently, once a U-shaped engaging ring 114 is force fit over a riser structure tip, riser portions 115′ and 115″ return to their static positions (prior to deformation) but while frictionally engaging at least one interior surface of the U-shaped engaging ring. Further aiding retaining the tile-to-tile connection, tip extension 1113 (see FIG. 4) structurally blocks U-shaped engaging ring 114 from being accidentally disengaged from U-shaped channel 117 (within which it has nested). In short, because of the unique mechanical tile-to-tile connection described herein, beveled surfaces 1112 and 1112′, and the gap A therebetween, greatly aid in disassembling one tile from another once connected. Similarly, in the reverse operation, the supplying of structural gap A assists in manipulating and orienting U-shaped engaging rings and U-shaped channels, of adjacent tiles 1 and 1′, sufficiently close and in proper relation to each other, so that they can be snapped together to form a tile-to-tile connection.

(23) In embodiments where tiles 1 (and/or 1′) are comprised of fragile materials, the force required to assemble or disassemble tiles to and from each other could cause cracking, thereby ruining one or more of the tiles for repeated use. In the (optional) embodiment disclosed in FIGS. 4 and 7, however, these issues are overcome by providing the gap A, which reduces the amount of force required for assembling or disassembling the two-piece tiles. Further, this configuration can even prevent cracking of the engaging rings 114 (or other tile parts), thus allowing each two-piece tile 1 to be used repeatedly.

(24) In an alternative (optional) embodiment the base board 11 and the stepping portion 12 can be made of the same material or different materials, or the same color or different colors, so that the plastic floor provides different functions or different visual effects. For example, the material used to form the base board 11, or the plurality of raised tread elements 116, may be one color and the material used to form the stepping portion 12, may be formed from another color. In this fashion when the two-piece tile 1 is assembled, a color contrast is supplied between the rectangular frame 111 and the stepping portion 12, or between the stepping portion 12 and the plurality of raised tread elements 116. Or, as shown in FIG. 8, the base board 11 and the stepping portion 12 can be made of different materials. FIG. 8 provides a two-piece tile 1 wherein the plurality of raised tread elements 116 of the base board 11 are made of an anti-slip material which is different than the material used to form the stepping portion 12.

(25) Referring now to FIGS. 11-12, in yet another alternative embodiment there is provided a two-piece tile 9 that includes at least one channel 901. In this configuration when one or more two-piece tiles 9 are assembled the channel 901 in one tile may be aligned with the channel 901 in an adjacent tile to provide a continuous channel, which will be useful for the routing of wires or other utilities underneath the modular floor. Although it is contemplated that the two-piece tile could include one or more channels in various configurations, FIG. 11 depicts one embodiment with a single channel. FIG. 12 illustrates an alternative view configured with intersecting channels so that adjoining mats will have a matching channel to align with no matter the orientation of the adjacent tiles.

(26) Once given the above disclosure, many other features, modifications, and improvements will become apparent to the skilled artisan. Such features, modifications, and improvements are therefore considered to be part of this invention, without limitation imposed by the example embodiments described herein. Moreover, any word, term, phrase, feature, example, embodiment, or part or combination thereof, as used to describe or exemplify embodiments herein, unless unequivocally set forth as expressly uniquely defined or otherwise unequivocally set forth as limiting, is not intended to impart a narrowing scope to the invention in contravention of the ordinary meaning of the claim terms by which the scope of the patent property rights shall otherwise be determined.