INTERLOCKING CUSHIONED TILES FROM CRUMB RUBBER

Abstract

Improvements in interlocking cushioned tiles from crumb rubber for the bulk of the tile to be made from recycled tire rubber with virgin material at interlocking areas of the tiles is disclosed. The use of recycled rubber reduces the amount of material in landfills. The density and size of the crumbs is variable to alter the amount of cushion for the tiles. Virgin material bonds easily together and the bonded virgin material has high integrity to keep the interlocking keyed elements together. The interconnection exists on all sides of the tiles and allows for a nearly infinite amount of tiles that can be connected to cover small and large areas. The connection details are essentially lollipop type interconnection male and female members. The interlocking cushioned tiles further include a drain and area for wiring to run under the tiles.

Claims

1. Interlocking cushioned tiles made from virgin and crumb rubber comprising: a plurality of cushioned tiles made from a combination of virgin rubber and crumb rubber; said virgin rubber and said crumb rubber being utilized in at least two different areas of each of said plurality of cushioned tiles; said plurality of tiles having interlocking features wherein a first tile interconnected with at least a second tile in a parallel relationship along elongated sides of said cushioned tile; said interlocking features comprising at least one male lollipop cross-sectional detail and at least one female lollipop cross-sectional detail; said virgin rubber being inserted into said at least one lollipop cross-sectional detail of a cushioned tile mold and into said at least one female lollipop cross-sectional detail of said cushioned tile mold interlocking features; filling a remainder of said cushioned tile mold with said crumb rubber, and vulcanizing said virgin rubber to said crumb rubber whereby creating an integrated said cushioned tile.

2. (canceled)

3. The interlocking cushioned tiles made from virgin and crumb rubber according to claim 1 wherein said vulcanization bonds said crumb rubber with said virgin rubber together at interconnection of said crumb rubber and said virgin rubber communal area.

4. The interlocking cushioned tiles made from virgin and crumb rubber according to claim 1 wherein opposing elongated sides of said plurality of cushioned tiles have opposing elongated said male lollipop cross-sectional detail and said at least one female lollipop cross-sectional detail.

5. The interlocking cushioned tiles made from virgin and crumb rubber according to claim 1 that further includes an integrated drain that runs along at least one edge of said tile.

6. The interlocking cushioned tiles made from virgin and crumb rubber according to claim 1 further includes a bottom with at least one foot pad and at least one recessed area at an underside of said tile.

7. The interlocking cushioned tiles made from virgin and crumb rubber according to claim 6 wherein said at least one foot pad provides clearance for routing electrical wiring and communications cables.

8-24.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

[0021] FIG. 1 shows a top perspective view of a number of cushioning tiles with an edge strip.

[0022] FIG. 2 shows a detailed perspective view of a corner of a cushioning tile.

[0023] FIG. 3 shows top view of a cushioning tile.

[0024] FIG. 4 shows a side view of a cushioning tile.

[0025] FIG. 5 shows view of the bottom of a cushioning tile.

[0026] FIG. 6 shows a cross-sectional view of a cushioning tile taken from section 6-6 from FIG. 5.

DETAILED DESCRIPTION OF THE INVENTION

[0027] FIG. 1 shows a top perspective view of a number of cushioning tiles with an edge strip. Each cushioned tile 20, 21, 22 and 23 weigh anywhere from 20 lbs to 40 lbs. depending on the thickness. Standard sizes include but are not limited to 24241 up to 2 in intervals. The cushioned tiles are made from crumb rubber (recycled tire rubber) binder and sparingly utilize natural rubber at the interconnection areas. The design is such that the tiles will have a 1 over and under sides with a lollipop type fastener made from natural rubber (male and female) which provide the interlocking. The lollipop type fastening. This figure further shows a trim or edge piece 24. The trim or edge piece 24 also engages onto the lollipop type fastener and provide a beveled transition from the cushioning tile to a ground surface.

[0028] Current production cushioning tiles are being fabricated as flat tiles with this system at 1 thick and weigh approximately 20 lbs. each. This product will be used as flooring mainly. Using this method of fabrication thicker and thinner versions are contemplated and the next production version is planned with an overall thickness of 1 thick. This cushioning tile will further have integrated drainage underneath for roofing and decking applications. The underside of the cushioning tile can include voids to both reduce the weight and increase the cushioning effect.

[0029] FIG. 2 shows a detailed perspective view of a corner of a cushioning tile 21. This detail is for a single tile 21 with a top surface 30. The tile 21 shows transitions 31 and 32 from the top surface 30 to the sides of the tile. The transitions 31 and 32 are on the edges and reduce the overall thickness from 1 to along with the inside 90 and outside 35 corners. This figure shows the male 40 lollipop detail and the female 41 lollipop detail. The male lollipop 40 shows a section of the virgin material 51 in the protrusion of the lollipop 40 on the extended side 53 of the cushioning tile 21. The female lollipop 41 shows a section of the virgin material 50 in the protrusion of the lollipop 41. The balance of the material is recycled rubber that is typically called crumb rubber.

[0030] The virgin material 50 and 51 easily bonds to the crumb rubber to make a secure connection. If the crumb rubber is used in the lollipop sections of the tile the crumb rubber does not provide a sufficient bond between the crumb elements and fails in the narrow areas of the lollipop where the lollipop bonds to the tile. The underside of the cushioning tile 21 shows a portion of an optional foot pad 60. The foot pad 60 provides both elevation for the cushioning tile 21 for drainage and for routing 70 of electrical and communication wiring under the cushioning tile 21.

[0031] FIG. 3 shows top view of a cushioning tile 21. The top surface of the cushioning tile 21 is shown as a flat surface, but could also be fabricated with a pattern that provides a wave or other structured surface to simulate wood grain or other appearance. The four sides 31, 32, 33 and 34 of the cushioning tile 21 are essentially perpendicular with the top surface of the cushioning tile 21. A slight taper or draft from the top surface provides a transition area. Two sides of the cushioning tile 21 have male lollipop details 40 and 42. The opposing sides of the cushioning tile 21 have female details that are not visible in this figure.

[0032] FIG. 4 shows a side view of a cushioning tile 21. The top surface 30 is shown as a planar surface with the side tapered surfaces extending from the flat top surface 30. The male lollipop 40 and the female lollipop 41 details are visible in this figure. The bottom surface shows raises foot pads 60 with clearance 61 for drainage and or for routing 70 wiring under the cushioning tile 21.

[0033] FIG. 5 shows view of the bottom of a cushioning tile 21. From this figure the female lollipop features 41 and 42 are visible. This underside view shows multiple foot pads 60. These pads are approximately 1-inch in diameter and provide an elevation of about inch that allows the planar surface of the cushioning tile 21 to be elevated above the surrounding bottom ground. While a diameter of 1-inch and an elevation of inch is identified these dimensions can be larger or smaller. The pads 60 are shown arraigned in rows and columns to provide clearance for wiring to run 70 under the cushioning tile 21.

[0034] This figure further shows several recess areas 62. These are another contemplated embodiment that reduces the amount of crumb rubber that is used to result in a lower weight and increased softness to the cushioning tile 21. A cross-sectional cut 6-6 is shown to provide a better understanding of the cushioning tile 21.

[0035] FIG. 6 shows a cross-sectional view of a cushioning tile taken from section 6-6 from FIG. 5. Because this cross-section cuts through the elevated pads 60 the raised and lowered areas on the bottom of the pad is visible. The clearance channels 63 are shown as a rectangular area, but this area could also be an ellipse 64 that provides clearance for round cables.

[0036] Thus, specific embodiments of interlocking cushioned tiles from crumb rubber have been disclosed. It should be apparent, however, to those skilled in the art that many more modifications besides those described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims.

SEQUENCE LISTING

[0037] Not Applicable.