HK1202598B - Interlocking floor tile - Google Patents

Description

Interlocking floor tile

Cross-referencing

This international application claims priority from U.S. patent application No. 13/311,979, filed on.12/6/2011 and U.S. patent application No. 13/706,058, filed on.12/5/2012, the entire contents of which are incorporated herein by reference.

Technical Field

The present invention relates generally to floor tiles and, in particular, to a flexible interlocking floor tile made of rubber or the like. More particularly, the present invention relates to interlocking floor tiles that are easily manufactured and installed without the need for professional installers and without the need for glue or other adhesives in the installation of the floor tiles.

Background

Various types of commercial flooring (commercial flooring) are known in the art. Places where commercial floors are used are typically large traffic areas (highrafdicarea) and include office buildings, hospitals, recreation centers, hotels, apartment buildings, and the like. These high traffic areas often require durable but inexpensive flooring, and also have an aesthetically pleasing appearance. Conventional wood flooring is expensive and difficult to maintain and is therefore not optimal for commercial use. Ceramic and stone flooring, laminate tiles (tile), polyethylene tiles/planks and LVT (luxury polyethylene tiles) are all alternatives to wood flooring but are still expensive-these types of flooring and tiles are also rigid, not flexible or cut resistant, and not as slip resistant as rubber-containing flooring. Carpets are generally not ideal in large traffic areas because they wear out very quickly, are difficult to clean and must be replaced often, and can obstruct vehicular traffic passing through them. Even if a carpet of the above type is selected for commercial use, it requires a significant amount of time and effort to properly install. If a new building is built, the building may be delayed due to the time to install any of the above-described floors. In addition, removing and replacing any of the above floor types is also expensive and time consuming, which can result in delays in actual commercial operations in the building. Some of these removal and replacement are done at night or on weekends so as not to impede traffic at the location where the activity is being performed. If the original floor contains asbestos, the demolition is more expensive due to the handling required for the demolition and cleaning.

Based on the multiple landThe above-mentioned disadvantages of the panels, use cheaper and durable floors made of rubber, vinyl or the like in a commercial environment. The flooring typically comprises individual molded tiles, panels, boards, etc. which are interlocked together and are set on the ground. Various types of interlocking mechanisms are known in the art. For example, Johnsonite Inc. of Charglin Fowles, Ohio manufactured toInterlocking tiles are named. TheThe tiles feature interlocking mechanisms in the form of tongue and groove connections on the underside of the tiles that fit together like a puzzle without the need for adhesive between the tiles, or between the tiles and the floor or ground. TheThe tiles are easy to install and remove and can be done without the use of specialized installers.

One disadvantage of most molded products is the flash left on the product after the molding process. Flash is a thin layer of excess material that exceeds the conventional part geometry of the product. The flash extends from the molded product and must typically be removed. Flash is typically caused by molding material between two surfaces of a form or mold leaking out of the mold. This leakage is typically due to excess material in the mold beyond conventional part geometries. With regard to interlocking flooring assemblies, flashing must be removed to ensure a precise interlocking fit between the tiles. Any excess flashing that is not removed from the interlocking tiles can compromise the integrity of the mating of the tiles, which can result in uneven floors, warping, corners, etc., and also add difficulty to the installation of the tiles. A tool knife or other tool is typically used during the manufacturing process to cut or remove excess flash, thereby removing the flash. Since removal of the flash is another time consuming and costly step, it is desirable to have a quick and easy method for this removal. Flash removal is particularly time consuming for tiles having non-linear intersecting edges. Therefore, the flash removal must be performed along a curved edge or a non-linear edge, so that the cumbersome process requires additional time and expense. Consequently, flash removal is a serious obstacle for molded tile installers.

In addition, some tiles feature a local backing (studded particulate backing) with particles to keep the tile above the ground while providing air spaces between the particles. The particles allow less contact with the sub-floor in the presence of contaminants and liquids. However, the granules (stud) only extend over the tongue and groove arrangement or interlocking mechanism and do not cover the entire bottom of this type of brick. This tongue and groove arrangement is often an important feature of this type of brick.

U.S. patent publication No. 2005/0183370 to cripts discloses floor tiles with interlocking edge elements that allow tiles to be assembled side-by-side by a vertical snap or press-in assembly method to secure the tiles together. The first and second pairs of adjacent transversely extending walls of the tile are configured to meet at a right angle of about 90 degrees and are located at the opposite edge of the tile from the first set of two transversely extending walls. The second set of transversely extending walls meet at a common corner diagonally opposite the other corner. The tiles have two channels due to the first and second laterally extending walls forming part of the interlocking mechanism. The side walls forming the channel include undercuts (undercuts) as part of the interlocking mechanism. The tile does not include a member extending downwardly therefrom at the corners of the tile for additional support at the corners of the tile. The floor tiles are made of one material rather than a dual structure made of two materials. Additionally, cripts' tiles are two-piece constructions that also include a separate, compressible seal.

U.S. patent publication No. 2007/0011980 to Stegner et al discloses an integral interlocking floor tile having interlocks on adjacent sides of the tile with a gap at the midpoint of the interlock along each side of the tile forming a discontinuous interlocking structure on the sides of the tile. The interlocking structures do not extend completely to the corners of the tile. Stegner et al do not disclose a continuous interlocking structure on adjacent sides of the tile that extends to the corners of the tile. This discontinuous interlocking configuration of Stegner et al results in the formation of multiple joints when joining the tiles to each other, which results in a loose fit between the tiles, creating functional and aesthetic problems. If the discontinuous interlocking structure is not a perfectly straight line between the gaps, realignment problems can occur when fitting multiple tiles together, particularly if the tiles are staggered and not side-by-side. This discontinuous interlocking arrangement also results in excessive time being required to remove the flash from the interlocking arrangement, as the direction of movement of the tool blade must be interrupted on different sides of the tile, as well as requiring additional time for the installer to remove the flash. This is due to the gap at the mid-point of the interlocking structure along each side of the tile so the installer cannot use a tool knife to remove the flashing in a single action. The interlocking floor tiles are made of one material.

U.S. patent publication No. 2003/0093964 to Bushey et al discloses a floor grid system comprising a plurality of interconnectable tiles made from a single material. The tiles are interconnected to each other by the use of locking assemblies extending between the tiles. The locking assembly uses a half dovetail as an interlocking configuration. The upper surface of the tile comprises two locking elements on two adjacent sides on the upper surface of the tile. The bottom surface of the tile comprises two locking elements on opposite adjacent sides on the bottom surface of the tile. Each locking element includes a base projecting outwardly from the tile and an upwardly extending upright member having an inner surface spaced from a respective side of the tile to define a wall-receiving channel therebetween. The locking elements on adjacent sides of the tile extend beyond the corners of the tile, with vertical projections at the intersection of the locking elements. Bushey et al do not include downwardly extending elements at the corners of the tile. Furthermore, the locking element has a plurality of edges in different directions, resulting in a large amount of time required for flash removal.

U.S. patent publication No. 2010/0319282 to Ruland discloses a polyethylene flooring made from a mixture of polymer and cork particles. The tiles may be interconnected to each other by a locking system between the tiles. Similar to the Bushey et al description above, the locking elements on adjacent sides of the tile extend beyond the corners of the tile, with vertical projections at the intersection of the locking elements. Ruland does not disclose downwardly extending elements at the corners of the tiles.

Accordingly, there is a need for tiles having interlocking mechanisms that are spaced from the ground or sub-floor portion when installed, and may be spaced from contaminants on the ground or sub-floor. The tile should be easy to manufacture and allow some intentional misalignment of the seams of the tile to allow various layout designs for fitting a variety of different sized tiles together, which does not affect the aesthetics of the tile arranged or its function. The tile should be inexpensive and meet the objectives of being easy to install, durable, having a long life, and capable of withstanding a predetermined load. The tile also has the need to reduce the amount of flash removed and it is easier to install and reinstall than existing tiles, saving installation time. Desirably, the tile may allow for continuous connection along all sides of the tile, and include sufficient support at the corners of the tile. This latter feature prevents sagging, denting, bending or warping of the corners of the overlapping, installed tile sections when the heel of the high-heeled shoe is pressed on. The desired tile will have a single interlocking structure or groove to maintain a tight engagement of the entire tile with other tile joints, rather than an interlocking structure that can cause disruption of functional and aesthetic defects in the entire floor. This single continuous interlocking structure will allow any excess material or flash to be easily removed from the tile in one step after the molding process. The tile will advantageously include shallow particles distributed randomly or continuously uniformly over the entire bottom of the tile to allow for less contact with the sub-floor when it has contaminants. The structure with the granules also makes the tile lighter, easier to install, and easier to lift when it is necessary to inspect the floor beneath it or to replace the tile. The lighter weight is also more environmentally friendly as it allows less fossil fuel to be used in transporting the brick to its final destination. Most desirably, the unit maintains a strong, structurally sound installation of the tile on the ground, which allows for easy installation. Time saving is very important in multi-room facilities where floor installation needs to be fast and cost effective, such as apartment buildings, hospitals, hotels, etc., where new building construction and renovation is common. The tile can be removed and reused or repurposed in other areas, avoiding expensive landfills, making it also more environmentally friendly. The problem underlying the present invention is therefore to provide a tile having the above-mentioned features.

Many floor tiles are made of expensive composite polyethylene, linoleum or rubber, and do not contain inexpensive recycled materials. This can be expensive, especially for commercial buildings with a large amount of floor space that requires tile coverage. By using inexpensive recycled polyethylene, rubber, etc., in portions on the underside of the tile, in locations not visible after laying, it may be advantageous to use less expensive tiles that also meet their intended purpose and have all the necessary structural features.

Disclosure of Invention

The present invention provides a flooring solution to the above-mentioned problems of producing and installing interlocking floor tiles. Applications of interlocking floor tiles according to the present invention may include covering aisle floors, temporary office areas, exercise areas, sub-floors with high humidity or even areas where show floor (tradeshowfolor) performance and flexibility are equally important. Other uses include areas where only temporary solutions are needed. The interlocking floor tiles are designed to fit together, and the locking structure under each tile is not easily visible and remains aesthetically pleasing if visible. As explained hereinafter, the damaged tile according to the preferred embodiment of the present invention can be easily removed even at the middle of the floor, and the replacement does not require any special tools; removal and replacement is accomplished by simply lifting the damaged brick and replacing it, as described below. This preferred embodiment is inexpensive compared to existing interlocking floor tiles because it is bi-structural, partially made of inexpensive materials, such as inexpensive recycled materials, particularly without affecting the function and appearance of the more expensive components of the tiles.

It is an object of the present invention to provide interlocking floor tiles that have a dual construction and partially include invisible reclaimed rubber or other materials that are less costly than the visible portion of the tile.

It is another object of the present invention to provide interlocking floor tiles that are easily installed and reinstalled without the need for skilled installers.

It is another object of the present invention to provide interlocking floor tiles that can be installed by a stitch roller or a manual stitch roller to lock the tiles together.

It is another object of the present invention to provide interlocking floor tiles with a continuous connection along all sides to keep the entire joint between the tiles tight.

It is still another object of the present invention to provide tiles that have adequate support at the corners of the installed set of tiles.

It is another object of the present invention to provide interlocking floor tiles having an interlocking mechanism that is not completely and directly exposed to the sub-floor and any contaminants thereon.

It is another object of the present invention to provide interlocking floor tiles that do not require installed adhesive between tiles or between tiles and the floor or subfloor.

It is still another object of the present invention to provide interlocking floor tiles that are portable and can be used for both temporary and permanent installation.

It is another object of the present invention to provide interlocking floor tiles that can be placed directly on an uncured concrete slab.

It is still another object to provide an improved interlocking floor tile system that can be installed on a sub-floor having high humidity.

Another object of the present invention is to significantly reduce installation time and associated costs with floor installation techniques, to make it easier to lay the tiles of the present invention than to lay existing tiles, and to reduce the overall time required for installation by reducing flashing that must be removed.

It is an object of the present invention to provide improved, interlocking floor tiles that are easy to remove if they have flash.

It is another object of the present invention to provide interlocking floor tiles that are easily removable in the event of damage or other problems and replaceable without any special tools.

Still another object of the present invention is to reduce the weight of the tile by incorporating shallow particles throughout the bottom of the tile without affecting the functionality of the tile or the footprint of each tile, which may additionally make the improved tile easier to install, remove and transport.

It is another object of the present invention to provide interlocking floor tiles that are non-slip.

It is another object of the present invention to provide improved interlocking floor tiles that can be easily maintained.

It is another object of the present invention to provide interlocking floor tiles that are fire resistant and have a primary flame retardant property (Class1 FlameRating).

It is another object of the present invention to provide interlocking floor tiles that allow for a unique and aesthetically pleasing pattern to be created from tiles of various sizes.

It is an object of the present invention to provide improved interlocking floor tiles having the above-mentioned advantages that can be laid in a conventional corner-to-corner pattern or offset over any length to create a staggered appearance.

It is a general object of the present invention to provide an improved tile which is efficient in production, installation and use, and which can be manufactured efficiently and economically.

Drawings

Further features and advantages of the invention will appear from a reading of the following detailed description of non-limiting embodiments of the invention and from a review of the attached drawings:

fig. 1A is a top perspective view of an interlocking floor tile according to the present invention.

FIG. 1B is a top perspective view of the tile of FIG. 1 shown from another angle of the tile.

Fig. 2A-2C are enlarged partial top perspective views of several corners of the tile of fig. 1.

Figure 3A is a partial side view of a corner of one side of the tile of figure 1.

Figure 3B is a partial side view of a corner of the other side of the tile of figure 1.

Figure 3C is a partial side view of a corner of another embodiment of the tile.

Figure 4A is a bottom perspective view of the tile of figure 1.

Figure 4B is a bottom perspective view of the tile of figure 1 shown from the other side of the tile.

Fig. 5A-5D are enlarged partial bottom perspective views of several corners of the tile of fig. 1.

Fig. 5E-5F are enlarged partial bottom perspective views of several corners of other embodiments of the tile shown in fig. 3C.

Figure 6A is another enlarged partial bottom perspective view of another corner of the tile of figure 1.

Figure 6B is a partial side view of a corner of still another side of the tile of figure 1.

Figure 6C is a partial side view of a corner of still another side of the additional embodiment of the tile shown in figure 3C.

Fig. 7A is a top partial perspective view of two adjacent tiles prior to assembly.

Fig. 7B is a top partial perspective view of two adjacent tiles after assembly.

Fig. 7C is a top partial perspective view of three adjacent tiles prior to assembly.

Fig. 8A is a bottom partial perspective view of three adjacent tiles prior to assembly.

Figure 8B is a bottom partial perspective view of three adjacent tiles after assembly.

FIG. 9 is a top perspective view of a plurality of staggered tiles after assembly.

FIG. 10 is a perspective view of a large stitch roller for interlocking tiles.

FIG. 11 is a perspective view of a manual stitch roller for interlocking tiles.

Detailed Description

The preferred embodiment of the present invention is directed to an improved floor tile having an interlocking mechanism that is easy to install for installation in high quality. The surface of the installed floor tile of the present invention is not fully and directly exposed to the sub-floor and any contaminants thereof. The interlocking tiles may be made of any suitable flexible material, such as natural and synthetic rubber, and the like. The tile is not limited to a particular size, but can be designed to any size to fit the size of the subfloor (subfloor) or floor (floor) and space to be covered. The tile is preferably constructed of a beautiful material that is exposed when installed, and a low cost and inexpensive effective material that is not exposed when the tile is installed. Tiles of the present invention can be placed on the ground or sub-floor, slid into the desired position relative to adjacent tiles, and pressed together with adjacent tiles to interlock them together. According to a preferred embodiment of the invention, no adhesive is required or recommended for mounting the tiles.

Turning to fig. 1A, 1B and 4A, 4B, an exemplary interlocking floor tile 210 is shown according to a preferred embodiment of the present invention. Each tile 210 is preferably made of a double construction, meaning that each tile 210 includes a top portion 212 and a bottom portion 214, the top portion 212 being made of one material and the bottom portion 214 being made of another material except for its edge portions. One material is preferably virgin or new, while the other material is preferably recycled or waste (any one or any combination of which is referred to herein as "recycled"). The edge portions of tile 210 may be made of only one material, the other material, or a combination of the two materials. Both materials preferably have a rubber composition. It is of course also possible to use more than two different materials and also any combination of these different materials. In a preferred embodiment, the flexible interlocking floor tile 10 comprises 73% reclaimed rubber and 27% virgin rubber. Preferably, both parts comprise a rubber component. The edge portion of tile 210 will be described in more detail later in this application.

The top portion 212 includes a large top layer 312, which is a surface layer (finishlayer) for aesthetics and performance, and may be made of any number of materials known in the art, which is flexible and resilient to absorb shock and return or intend to return to an original shape if temporarily bent. For example, the top layer 312 may be made of rubber, which has a greater elastic effect. The top layer 312 may include a variety of compositions with different properties, such as SBR rubber and clay. SBR (styrene-butadiene-rubber) is a synthetic rubber copolymer composed of styrene and butadiene. The term "rubber" as used herein includes natural rubber and any rubber-like compound of synthetic materials, including synthetic rubbers made from polymerized unsaturated hydrocarbons, such as isoprene and butadiene. In addition to rubber, interlocking tiles may also include other materials, such as fillers. Thus, interlocking tiles are made of a homogeneous composition (composition) comprising, for example, rubber, natural fillers, kaolin or CaCO₃Curing agents and natural colorants such as iron oxide and titanium dioxide. The top layer 312 may also include coloring and/or design for aesthetic purposes. As described below, the harder material of the top layer 312 may also be used for the edges of the top portion 212 (FIGS. 1A-3B, 7A-7C) and a portion of the edges of the bottom portion 214 (FIGS. 3A-6B, 8A-8B). According to a preferred embodiment, the height of the bottom portion 14 is 7.5mm and the height of the top portion 12 is 2.0 mm.

The base 214 includes a relatively inexpensive large base layer 300, preferably a softer material such as reclaimed rubber, as described below. The large base layer 300 extends to true edges (veryedge)302 on both sides of the tile 210, up to (upto) only a pair of channels at edges 304 and 306 of the large base layer 300 as will be described below, all as shown in fig. 4A, 4B. Base layer 300 provides padding and absorbs some of the impact from the load on tile 210. The base layer 300 may be made of a less expensive material than the top layer 312. For example, the base layer 300 may be made of industrial rubber waste or reclaimed rubber including reclaimed SBR (synthetic butadiene rubber) rubber. New SBR rubbers, natural rubbers and vulcanized recycled rubber powders may also be used.

The top 212 and bottom 214 combine to form a dual construction brick by curing, which is known in the art. The top portion 212 includes a rubber sheet, as described above, while the bottom portion 214 includes a reclaimed rubber sheet, as described above. Next, the two sheets are bonded by a vulcanization process without using an adhesive. After the vulcanization of the dual structure is complete, the material is placed into a mold in a press. During the curing process, the two different sheets of material may overflow into the top portion 212 or the bottom portion 214 in the mold. This also results in the edge portion having a combination of new rubber and reclaimed rubber as will be further explained below.

For the 3/8 inch version, the entire brick included about 53% recycled or remanufactured material. The top portion 212 is 100% virgin or new material and the bottom portion 214 is approximately 73% recycled or remanufactured material. Thus, the bottom portion 214 is approximately 27% virgin or new material. For the 1/4 inch version, the entire brick includes substantially 34% recycled or remanufactured material. The top portion 212 also includes 100% virgin or new material, and the bottom portion is about 73% recycled or remanufactured material and about 27% virgin or new material.

In order to meet various performance criteria, such as slip resistance, wear or wear resistance, etc., top portion 212 must have a minimum thickness to meet the criteria. The thickness of the bottom portion 214 may vary depending on the desired properties of the tile. For example, if a more flexible and soft tile is desired, the bottom portion 214 will have a greater thickness than a tile that requires less flexibility and more rigidity. Change the performance criteria of the tile 210Another way of not changing the thickness of bottom portion 214 requires the use of a different material in top portion 212. The table shown below indicates the differences obtained with different materials. For example, for ordinary use to carry conventional walking traffic floors, referred to herein as "ordinary floors" (as opposed to floors where there is substantial wear (referred to herein as "sports floors"), such as floors that receive impact and cutting when engaged, such as sporting equipment, where there may be free weight to fall, stepped on by a person wearing skates, baseball spikes, golf spikes, soccer cleats, etc.), a thickness of 3/8 inches has been found to be suitable. Sports flooring requires an optimal formulation with respect to the amount of rubber included and requires a more flexible composition to cushion the impact of such objects. Specifically, the top portion 212 of the sports floor includes approximately 35% -45% rubber, while the ordinary floor includes approximately 25% -27% rubber. The additional rubber in the top portion 212 of the sports floor provides more flexibility and more cushioning as described above. "Flexible" as used herein refers to engineering science and technology dictionary 10 th edition (ASTM) according to ASTM engineering science and technology dictionary 10^thEdition) is defined as any one of the following:

"flexible-capable of being bent, bent or twisted without cracking, breaking or exhibiting other permanent damage and returning to or not returning to its previous shape. F141(flexibility-the adaptability based element, turned, ortwistedWithoutlying, broakgorshorworthermermamage and without the output of the transmission for the shape of the device F141)'.

"flexibility-the property of a material to withstand repeated flexing, bending or bowing without splitting. D123, D4850 (flexibility-property of amorphous material energy requirement flexibility, bonding, orbowangwithout output. D123, D4850) "

One criterion is penetration resistance, indicated by the shore hardness value (shore avalaue), as measured by ASTM standard test method D2240, where the higher the value the harder the material. Another criterion is sound insulation, which is not very important for floors in normal foot traffic, but which is important for sports floors and is measured by the value for the Impact Insulation Class (IIC), which is an integer value related to the degree to which the building floor reduces impact sounds such as footsteps, dropped weight, etc. The IIC is logarithmic and is obtained from ASTM method E989 using a ceiling sampler (tappingmachine) as described in ASTM method E492.

This 3/8 inch thickness is effective for interlocking tiles for both ordinary and sports flooring according to a preferred embodiment of the present invention. This 3/8 inch thickness has been found to make the seams between interlocking tiles as described above less noticeable. This 3/8 inch thickness has been found to be more effective in protecting flooring in some cases, but 1/4 inch thickness is less expensive and can adequately protect ordinary flooring.

The following table shows comparative values of interlocking floor tiles for general flooring and sports flooring, respectively, according to a preferred embodiment of the present invention:

3/8 inch interlocking floor tile of the present invention

1/4 inch interlocking floor tile of the present invention

Common floor

The total thickness of the 3/8 inch version of floor tile 210 is about 0.375 inch (3/8 ") or about 9.5 mm. Top portion 212 has a thickness in the range of 0.070-0.110 inches or approximately 1.7mm-2.8 mm. Preferably, the thickness of the top portion 212 is 0.090 inches or 2.3 mm. The bottom portion 214 has a thickness in the range of 0.265-0.305 inches or about 6.7-7.7 mm. Preferably, bottom portion 214 has a thickness of 0.285 inches or 7.2 mm. In other words, the total thickness of the 1/4 inch version of floor tile 210 is about 0.250 inch (1/4 ") or about 6.3 mm. However, in order to meet various performance criteria, such as slip resistance, abrasion or wear resistance, etc., as described above with respect to the 1/4 inch version of floor tile 210, top portion 212 must also have a minimum thickness to meet the criteria, which is the same as the minimum thickness of the 3/8 inch version of floor tile 210. That is, for the 1/4 inch version of floor tile 210, top portion 212 has a thickness in the range of 0.070-0.110 inches, or in the range of about 1.7mm-2.8 mm. Preferably, top portion 212 has a thickness of 0.090 inches or 2.3 mm. Thus, bottom portion 214 will have a smaller thickness than bottom portion 214 of tile 210. Specifically, the bottom portion 214 has a thickness in the range of 0.140-0.180 inches or about 3.5mm-4.5 mm. Preferably, bottom portion 214 has a thickness of 0.160 inches or 4.0 mm.

Each tile 210 may have any desired polygonal shape, but is preferably generally rectangular to more easily interlock. For tiles having any polygonal shape, a side portion of a first tile will have a particular shape and a side portion of another tile adjacent to the side portion of the first tile will have a corresponding matching shape. It is also possible for a single tile to have one side of a particular shape, while the side opposite the first side of the tile has a corresponding mating shape, so that the two tiles interlock in firm but releasable engagement. For example, if the tile is crescent shaped, one side of the tile will have a convex shape, while the side of another crescent shaped tile adjacent to the side of the tile will be concave in shape. Thus, each side has a corresponding mating shape.

As shown in fig. 1A, 1B, the top layer 312 includes an outward top planar sidewall 215 on each of two adjacent sides 211A, 211B of the tile 210. Bottom interlocking element set 216 is included in top portion 212, spaced from top layer 312 and disposed adjacent to an outwardly facing top planar sidewall 215 on each of two adjacent sides 211a, 211b of tile 210. Referring to fig. 2A-3C, the bottom interlocking element set 216 includes a bottom base 218 and a bottom upwardly extending raised locking tab 220. The protrusion locking protrusion 220 includes a parting line 221 (the parting line 221 and a parting line 231 described below constitute parts of a single parting line), the parting line 221 being located on an outer surface thereof along the side portions 211a, 211 b. The parting line 221 is a small line of material protruding from the outer surface of the protrusion locking protrusion 220 along the side portion 211 b. Parting line 221 is formed at a location where the top and bottom molds of tile 210 come into contact when tile 210 is pressed together, with any excess material or flash escaping between the top and bottom molds. Although excess flash is removed by a tool knife or similar tool, a small line of material remains and the line is a parting line. The position of the parting line 221 depends on the dimensions (i.e., thickness) of the top and bottom molds. For example, if the top mold is the same thickness as the bottom mold, parting line 221 will occur at a mid-point of sides 211a, 211b of tile 210, since the top mold will contact the bottom mold at that mid-point when pressed together. If the top mold has a thicker thickness than the bottom mold, the parting line 221 where the top and bottom molds contact when pressed together will occur below the midpoint of the tile 210. Similarly, if the bottom mold has a thicker thickness than the top mold, a parting line where the top and bottom molds contact when pressed together will occur above the midpoint of the tile 210. Parting line 221, as will be described later in this application, facilitates interlocking of tiles 210. A bottom base 218 extends outwardly from an outwardly facing top planar sidewall 215 of tile 210 proximate bottom portion 214. The bottom upwardly extending raised locking tab 220 has an inward bottom planar wall 222 spaced from the outward top planar side wall 215 of the respective side 211a, 211b of tile 210, defining a bottom channel 224 therebetween. Bottom interlocking element set 216 is made of a dual construction, i.e., it is composed of virgin material of top portion 212 and recycled or remanufactured material of bottom portion 214.

The bottom interlocking element sets 216 on each adjacent side 211a, 211b are connected at corners 227 of the tile 210 by bottom base elements 225. The bottom base member 225 is an extension of the bottom base 218, but does not have any protruding locking portion protruding therefrom. Bottom base element 225 provides support for corner posts of adjacent interlocking tiles 210 when joined, as will be further described below.

When viewed from the bottom, as shown in fig. 4A, 4B, base layer 300 includes outward bottom planar sidewalls 217 on two other adjacent side portions 211c, 211d opposite side portions 211a, 211B on the top portion of tile 210. Each adjacent side portion 211c, 211d includes a top interlocking element set 226. Referring to fig. 5A-6B, top interlocking element set 226 includes a top base 228 and a top projection extending downward (when bottom portion 214 is facing downward) locking tab 230. The top male locking projection 230 also includes a parting line 231 located on the outer surface along the side portions 211c, 211 d. As described above, the parting line 231 is a small line of material protruding from the outer surface of the protrusion locking convex part 230 along the side portions 211c, 211 d. As described above, parting line 231 and parting line 221 together form a single parting line. When tile 210 is pressed together between the top and bottom molds, parting line 231 is formed where the top and bottom molds of tile 210 contact. The location of the parting line 231 also depends on the dimensions (i.e., thickness) of the top and bottom molds. That is, if the top mold is the same thickness as the bottom mold, parting lines 231 will be formed at the mid-positions of the side portions 211c, 211d of tile 210 when pressed together as the top mold will contact the bottom mold at the mid-positions. If the top mold is thicker than the bottom mold, parting line 221 will occur below the center of tile 210 where the top and bottom molds meet when pressed together. Similarly, if the bottom mold is thicker than the top mold, parting line 231 will occur above the middle of tile 210 where the top and bottom molds contact. Parting line 231 facilitates interlocking of tiles 210, as will be explained in this application. A top base 228 projects outwardly from each outer bottom flat sidewall 217 of each side portion 211c, 211d near the top of the tile 210, and a top downwardly extending projecting locking tab 230 extends downwardly from the top base 228. Top male locking tab 230 has an inner or inward top sidewall 232 (fig. 5A) spaced from sidewall 217 of respective side 211c, 211d of tile 210, thereby defining a top channel 234 therebetween.

As shown in fig. 5C-5D, each top interlocking element group 226 on each adjacent side portion 211C, 211D is connected by a top base element 235 at an upper corner 237 of tile 210, top base element 235 can be considered an extension of top base 228. The top base member 235 is substantially the same thickness as the top base 228 (i.e., the top base member 235 is level with the top base 228) and includes support posts 238. When tile 210 is installed, support post 238 depends downwardly from top base element 235 toward the sub-floor. Support posts 238, which together with bottom base element 225 provide support, are located near the corners of adjacent tiles 210 when joined together, resting on bottom base element 225, as shown in the bottom of the joined together tiles 210 in fig. 8A. Fig. 8B shows the tiles 210 joined together from fig. 8A, but with the support posts 238 hidden from view. Bottom base member 225 on top portion 212 does not have any protruding tabs to allow space for top protruding locking element set 226 to pass therethrough when joining multiple tiles 210 together. When multiple tiles 210 are joined and respective top locking element sets 226 and respective bottom locking element sets 216 are connected, a cavity is formed if support post 238 is not present. Since the top base member 235 is unsupported at its upper corners 237 when the tile 210 is installed, the cavity will pose a tripping hazard and will be pressed or deformed by tall heels, spikes, cleats, skates, or other shoes having a pointed structure at the bottom of the shoe. However, support posts 238 (fig. 8A) fill the cavity and fully support the corners of tile 210. It is advantageous for the support posts 238 to extend downwardly from the top base member 235 rather than resting on and extending upwardly from the bottom base member 235. The support post 238 effectively prevents any movement of the upper corner 237 (e.g., sliding or shearing) with the bottom base member 225 of another tile 210 when pressed downward by a shoe (or a portion of a shoe, such as a tall thin heel, etc.). However, if the support post 238 is located on the bottom base element 225, it is believed that since the support post 238 is not connected to the upper corner 237 when pressed by a shoe (or a portion of a shoe, such as a tall thin heel, etc.), it is likely that the upper corner 237 will slide or shear on the support post 238. This can cause a person walking (or running) on tile 210 to trip and can injure him.

In a preferred embodiment, the raised locking tabs 220 and 230 on the respective interlocking element sets 216 and 226, respectively, have a generally rectangular cross-section, as shown in fig. 3A, 3B and 6B, for reasons that will be explained below. However, the cross-section may also include some dove-tail shaped (dove-cut) type of design.

Considering fig. 2A-2C and 3A-3B, the upper edge of each tile 210 is slightly curved or sloped (e.g., has a flat surface), as indicated by reference numeral 229. Since the upper surfaces of the tiles 210 may not be in the same plane when installed, one does not want any tiles to project upwardly to disrupt a smooth surface, even if the projection is not high enough to cause tripping over it. Thus, the bend or inclination 229 can be seen, but not unsightly, which adds to the aesthetics of the floor as shown in FIGS. 7A-7C. The appearance may be noticeable when light strikes the ground at a small angle, early or late in the day, but not unsightly.

Because the present invention is made by molding methods known in the art, flashing may be left in some areas of tile 210 as described above. Flashing is formed during the molding process, wherein rubber or other material leaks along the edges of the mold, which leaves excess material (i.e., flashing) after the tile cures. Flashing is typically formed at multiple edges of tile 210, including respective sets of interlocking elements 216 and 226. This excess flashing must typically be removed to allow tiles 210 to be locked together. A tool knife or other suitable tool is used to trim the excess flash. Since interlocking element sets 216 and 226 run the entire length of tile 210 without interruption, excess flashing can be easily removed with a single continuous action using a tool knife. There are no curved or sharp corner edges (i.e., as in a jigsaw puzzle) that need to be tracked by the tool knife and trimmed in succession. This saves considerable installation time.

A further advantage of the present invention is the continuous connection along all sides of tile 210, since there are no breaks in the respective interlocking element sets 216 and 226. The tiles may be locked together using a large stitch roller or a manual stitch roller as is commonly used. A conventional large stitch roller 310 is shown in fig. 10. Large seam rollers are heavy and can be pushed from behind by a person to roll over and level interlocking tiles. The weight of the roller 310 itself pushes the bricks downward to fully engage each other. Alternatively, as shown in fig. 11, a manual roller press 311 may be used by the installer to physically push the locking member into place. This allows the joint or joint where the two tiles 210 are in contact to remain tight, which provides a better appearance and prevents dirt and other impurities and even moisture from entering the joint. Another advantage of this continuous connection or joint is that it prevents realignment problems with tile 210. As previously explained with respect to the prior art, a separate locking tab or a discontinuous locking connection would lead to possible realignment problems. Finally, since interlocking element sets 216 and 226 run along the entire length of tile 210 without interruption, tiles 210 may be staggered to form any type of pattern or design (i.e., tiles 210 do not require diagonal corners). For example, FIG. 9 shows a plurality of tiles in a staggered pattern.

To maintain the tight engagement as described above, the interlocking element sets 216 and 226 have a generally square cross-section, as shown in fig. 3A, 3B, and 6B. Each raised locking tab 220 and 230 is press fit into a corresponding bottom and top channel 224 and 234, respectively, easily accomplished by a stitch roller 310 or a manual stitch roller 311. Because tile 210 is flexible, there is some elasticity when male locking projections 220 and 230 are fitted into top and bottom channels 224 and 234. However, the initial force must be overcome to begin press fitting tiles 210 together. To help overcome this initial force, interlocking element sets 216 and 226 include rounded and/or chamfered edges and corners to provide a small space or relief (relief) to overcome this initial force. The top downwardly extending raised locking tab 230 includes rounded corners 240 as shown in fig. 5A. For the 3/8 inch version of tile 210, the top locking element set 226 in the bottom portion 214 additionally has a chamfered edge 242 that extends along an inside edge 244 of the top protruding locking tab 230, as shown in fig. 5A-5D and 6A, 6B. Support post 238 also includes a rounded edge 246. Support post 238 also includes a rounded edge 246. The rounded corners 240, chamfered edges 242 and rounded edges 246 provide a small space or relief when the top downwardly extending male locking projections 230 are initially press-fit into the corresponding bottom channels 224. This space or relief is particularly necessary in the event that any excess flash remains on interlocking element sets 216 and 226. For example, if a small piece of flashing remains on the bottom upwardly extending male locking projection 220 (fig. 2A-3B), the chamfered edge 242 of the top male locking projection 230 will provide space or relief for the flashing and will allow the top male locking projection 230 to be fitted into the bottom channel 224. Even if there is no excess flashing, chamfered edge 242 will allow top male locking tab 230 to enter bottom channel 224 and overcome the initial force of mating and locking tiles 210 together.

In the 1/4 inch version of tiles 210, the chamfered edge is not included on the inside edge 244 of the top protruding locking tab 230, as shown in fig. 3C, 5E-5F, and 6C, since less material is engaged between the interlocking tiles 210. Having chamfered edges will result in less engagement between the protruding locking projections 220 of the thinner tiles 210. In other words, because the 1/4 inch version of tile 210 is thinner than the 3/8 inch version of tile 210, and thus the raised locking tabs 220 and 230 of the 1/4 inch version of tile are smaller, the chamfered edges will form less engagement between the respective raised locking tabs 220 and 230. Thus, the 1/4 inch version of tile 210 has no chamfered edges at the inboard edge 244.

Parting lines 221 and 231 also assist in interlocking tiles 210. In particular, parting lines 221 and 231 help to keep tiles 210 locked together. As described above, the parting lines 221 and 231 are small lines of material that protrude from the protrusion locking projections 220 and 230, respectively. When the male locking projections 220 and 230 are press-fit into the respective bottom channels 224 and 234, the parting lines 221 and 231 ensure that the press-fit is tight and does not loosen (i.e., the parting lines 221 and 231 are pressed into the inner wall 232 and the outer wall 215, and the inner wall 232 and the outer wall 215 apply respective mutual forces to the parting lines 221 and 231 of the male projections 220 and 230 to form the press-fit). The close fit also prevents any lateral or vertical sliding of the male locking projections 220 and 230 in the bottom channels 224 and 234. Specifically, the friction created between the walls 211a, 211b, 22 and the walls 211c, 211d, 32 of the respective male locking tabs 220 and 230 (i.e., the vertical walls of the male locking tabs 220 and 230) prevents any lateral or vertical sliding of the tile 210. When engaged as shown just prior to engagement in fig. 7A, additional friction is created between the horizontal surfaces 223, 233 of the respective protruding locking tabs 220 and 230 and the horizontal surfaces 239, 241 of the bottom channels 224 and 234. The tab locking projections 220 and 230 are fully engaged with the bottom channels 224 and 234, i.e., the horizontal surfaces 223, 233 of the tab locking projections 220 and 230 and the horizontal surfaces 239, 241 of the bottom channels 224 and 234 are coplanar and in contact with each other, thus creating friction therebetween. Since tile 210 is preferably made of rubber as described above, and rubber is more slip resistant to displacement and difficult to lift or slide than other materials that do not include rubber, the friction between raised locking projections 220 and 230 engaging bottom channels 224 and 234 is greater than other materials that do not include rubber. Tiles made of polyethylene type material are loosely held together by an interlocking arrangement and are more easily displaced and slid, and can be more easily lifted on themselves. Thus, there is no gap or space or loose fit between the raised locking tabs 220 and 230 and the bottom channel 224 when engaged. This friction ensures that tiles 210 do not displace (i.e., loosen) from each other during use. This is in contrast to the gaps or spaces required in prior art interlocking mechanisms to ensure natural expansion of materials such as wood.

To lock tiles 210 together, a pair of tiles 210 are disposed adjacent to one another, as shown in FIG. 7A, but may also be staggered as described above and shown in FIG. 9. Top male locking projections 230 of top male interlocking element set 16 are inserted into bottom channels 224 of adjacent tiles 210. The rounded corners 240, chamfered edges 242, and rounded edges 246 provide a small space or relief when the top male locking projection 230 is initially press-fit into each bottom channel 224. The bottom upwardly extending raised locking tabs 220 are then inserted into the top channels 234 of the top locking element set 226. The square cross-sectional configuration of raised locking tabs 220 and 230, including parting lines 221 and 231, maintains the connection between adjacent tiles 210 and prevents lateral movement of tiles 210 when disposed on top of a subfloor as shown in fig. 7B. Because tile 210 is flexible, the respective sets of interlocking elements 216 and 226 can deform slightly when engaged with one another to secure the tiles together and provide a tight connection. Figure 7C shows a plurality of tiles 210 connected together.

Bottom portion 214 includes a continuous grid of shallow flat rounded particles (stud)250 that allow for uninterrupted extension to adjacent tiles 210 when installed, as shown in fig. 8B. The particles 250 can provide moisture flow while the uncured cement (or wet sub-floor) is still dry and provide a better cushioning effect for the tile 210 when a load is applied thereto (e.g., when walking on the tile 210, a vehicle is passing, cleaning and repair equipment is disposed thereon). The use of particles 250 provides less contact with the sub-floor. If the subfloor has old adhesive or impurities it will be easy to pull up if needed. Thus, the particles 250 are easily detached from the ground or subfloor, facilitating installation and removal of a particular tile 210. The bonded particles also reduce the weight of the tile. This is more ergonomic for the installer and more eco-friendly as less fossil fuel is required to transport the tiles.

Interlocking floor tiles 210 have many applications and are designed for use in many types of sports floors or other multi-functional floors. Interlocking tiles 210 of the 3/8 inch version, which are thicker than the 1/4 inch version, are more durable, spike resistant, skate resistant, and non-slip. Previous interlocking tiles 210 have been subject to constant foot traffic on the floor, athletic activity, heavy rolling impacts, and objects such as sporting equipment. Further, the 3/8 inch version of interlocking tiles 210 may absorb more noise generated in these types of environments and may be ideal for use in areas where extreme sports involving spikes, skates, and free weight do not exist. The 1/4 inch version is durable and is used for regular or non-extreme sports. Each thickness helps to cover the seams in the floor while allowing access to the underlying floor for repair or reconfiguration. As mentioned above, this 1/4 inch version is satisfactory in protecting the floor on which the tile is installed in these situations.

Interlocking floor tiles 210 are easy to install and do not require adhesives for quick installation and quick service times. Interlocking tiles 210 may be easily removed and reinstalled as needed and easily replaced if needed. For example, for sub-floors with foreign objects or moisture issues, the interlocking floor tiles 210 allow for periodic inspection or disassembly for maintenance. Interlocking floor tiles 210 may be a temporary or permanent solution for applications where access to the floor is required or where the sub-floor is not suitable for tile attachment. Finally, interlocking tiles 210 may be reused elsewhere.

The interlocking floor tiles 210 may be aligned diagonally by corners, or staggered (i.e., staggered) at any location along the edges of the tiles to form a unique pattern. The design is not limited as the edges of tile 210 may lock and align at any other location on the continuous edge of another tile, and may form, for example, a checkerboard, zigzag, or other pattern.

The tile according to the invention can be easily maintained by using a wet wipe or a microfiber pad, and small amounts of water and cleaning solution. This maintenance technique avoids water from soaking into the sub-floor via the hidden locking mechanism.

Although the present invention has been described with reference to certain preferred embodiments, it is to be understood that the present disclosure is by way of example only and that various changes, modifications and variations in the details of construction and the combination and arrangement of parts may be resorted to without departing from the spirit and scope of the invention. Improvements, modifications and changes within the purview of those skilled in the art are intended to be covered by the scope of the invention.

Claims (8)

1. A flexible interlocking floor tile having a rectangular shape for placement on a floor or subfloor for locking together with an identical flexible interlocking floor tile to cover all or a portion of the floor or subfloor, said floor tile comprising:

a dual structure comprising a top portion and a bottom portion, the top portion being made of a new rubber, the new rubber being a resilient material and facing away from a ground or sub-floor when disposed thereon, the bottom portion being made of a reclaimed or reconstituted rubber, the reclaimed or reconstituted rubber being resilient and elastic, facing the ground or sub-floor, the top portion and the bottom portion being bonded together by vulcanization to form the dual structure;

the bottom portion is made of a relatively softer rubber than the new rubber of the top portion;

the top portion and the bottom portion have edge portions with a combination of virgin rubber and reclaimed or reconstituted rubber

The top portion includes:

a top layer made of virgin rubber and being a relatively hard material, the top layer being a surface layer for beauty and performance, and being flexible and elastic to absorb impact and return to an original shape if the top layer is bent;

an outward top sidewall on both first adjacent side portions of the tile;

a bottom interlocking element set including a bottom base extending outwardly from each of said outwardly directed top side walls and a bottom upwardly extending raised locking tab having an inwardly directed bottom side wall spaced from each of said outwardly directed top side walls defining a bottom channel therebetween; and

a bottom base element connecting respective sets of bottom interlocking elements on the respective two adjacent side portions, the bottom base element defining an outer corner of the tile and being devoid of any protruding locking portion projecting therefrom;

the bottom portion includes:

a base layer that is a relatively softer material than the top layer, the base layer providing padding and absorbing some impact from the load on the flexible interlocking floor tile, the base layer comprising:

an outward bottom side wall on two other adjacent side portions of the tile opposite the respective two first adjacent side portions;

the other two adjacent side portions meet at an upper corner; and

a top interlocking element set comprising a top base extending outwardly from each of said outwardly directed bottom side walls and a top projecting downwardly extending locking lug having an inwardly directed top side wall spaced from each of said outwardly directed bottom side walls defining a top channel therebetween;

a top base element connecting respective sets of top interlocking elements on said two second adjacent side portions of said tiles and forming said upper corner of said floor tile, said top base element including downwardly depending support posts for providing support in cooperation with said bottom base element when a plurality of said tiles are connected together, said support posts being seated on said top base element.

2. A flexible interlocking floor tile according to claim 1 wherein said top layer further comprises upper edges on each side portion of said tile, said respective upper edges being curved or beveled to provide an aesthetic appearance even when sunlight strikes said flexible interlocking floor tile at a slight angle.

3. A flexible interlocking floor tile according to claim 1 wherein said tile comprises about 73% reclaimed rubber and about 27% virgin rubber.

4. A flexible interlocking floor tile according to claim 1 wherein the height of said bottom portion is 7.5mm and the height of said top portion is 2.0 mm.

5. A flexible interlocking floor tile according to claim 1 wherein said top raised downwardly extending locking tab includes a chamfer along its inner edge to facilitate press fitting of said top raised downwardly extending locking tab into said bottom channel of said bottom interlocking group.

6. A flexible interlocking floor tile according to claim 1 wherein said base layer of said bottom portion comprises a continuous network of shallow, flat particles for engaging a ground or sub-floor when said flexible interlocking floor tile is disposed thereon, thereby providing moisture flow along said ground or sub-floor and providing a cushioning effect to said flexible ground or sub-floor.

7. A flexible interlocking floor tile according to claim 1 wherein said bottom interlocking element set and said top interlocking element set each extend along the entire length of said flexible interlocking floor tile thereby enabling any excess flashing to be easily removed with one continuous action using a tool knife, facilitating the locking of two flexible interlocking floor tiles together using a manual stitch roller press thereby preventing realignment problems of said flexible interlocking floor tiles, and for enabling said flexible interlocking floor tiles to be laid in a staggered fashion rather than arranged at angular diagonals.

8. A flexible interlocking floor tile according to claim 1 wherein said bottom interlocking element set and said top interlocking element set have components that are perpendicular to each other for remaining tightly connected when said interlocking tiles are interlocked together, and said outer sidewalls on said top portion and said inner walls of said bottom interlocking element set engage respective side portions and said inner walls of said bottom interlocking element set and said inner walls of said top interlocking element set and said side walls of said bottom portion engage respective bottom inner walls and sides of said bottom interlocking element set.