WO2003036000A1

WO2003036000A1 - Floor or wall element

Info

Publication number: WO2003036000A1
Application number: PCT/IB2002/005764
Authority: WO
Inventors: Bart Vanhee
Original assignee: Daglau Nv
Priority date: 2001-10-26
Filing date: 2002-10-25
Publication date: 2003-05-01
Also published as: BE1014685A6

Abstract

This invention relates to a floor or wall element for creating a floor or wall covering, characterized in that it comprises a covering unit (1), provided on a support (2), such as, for instance, a floor tile, as well as at least one spacer, extending past an edge of the covering unit (1), which is provided in order to obtain a joint groove, having a predetermined width, between respective covering units (1) of floor or wall elements fitting together, while each covering unit (1) is provided on the support (2) in such a position that its upper surface defines a plane (A), running practically parallel with the supporting surface (B) defined by the lower side of the support (2). When constituting a floor or wall covering, both the width of joint desired between the covering units (1) and the positioning as to height of the covering units (1) is obtained in a simple manner.

Description

Floor or wall elemetve-

This invention relates to a floor or wall element, comprising at least one covering unit, such as, for instance, a floor tile or a wall tile (faience) or another panel shaped entity, the bottom face of which defines a supporting surface:

On the other hand, this invention relates to a method for manufacturing such floor or wall elements.

It is for instance known to position floor tiles on a layer of finishing material made as level as possible and to fix them by means of cement. Because they consist of a burnt ceramic material, floor tiles seldom have an entirely even top surface, they are often not just as thick all over and their shape differs from the ideal square or rectangular form. These defaults must be compensated by the tile-layer, for instance, by laying a tile - which is a somewhat thicker on the one side or, because of its being curved, is raised with respect to the bottom side of the tile than on the other side - a bit deeper on the side first mentioned than on the other side. The differences in dimensions lengthways en widthways are compensated because the tile-layer has the possibility to adapt the width of the joint. This method however requires quite some experience, because of which the average do-it-yourselfer is unable to do a good job.

Ceiling tiles, laminated or veneer finished floor panels, massive parquet floor panels are milled to measure as a whole or, if panels made of synthetic material are used, are moulded in one piece by means of pressure die-casting or extrusion techniques. These panels are quite even as far as their dimensions are concerned and have an almost perfectly even upper surface. Furthermore, they are provided with some groove and tongue or clicking system. In this way they may be laid very easily by do-it-yourselfers. The only condition is that an even subfloor is available. In general, as far as floor coverings are concerned, this even subfloor is obtained by means of a so-called "floor finishing material".

With elements produced by means of other manufacturing processes, such as, among others, by burning elements made from ceramic material or by moulding elements out of stone by means of mechanical means, the dimensions are differing too widely to allow for such a simple method, requiring only limited skills.

In order to remedy these drawbacks, a floor or wall element was developed, comprising at least one covering unit, and the lower surface of which defines a supporting surface, the floor or wall element according to this invention being made in such a manner that at least three points of reference of the upper surface of each covering unit are situated in a plane which runs practically parallel with the supporting surface.

When constituting a floor or wall covering, the floor or wall elements according to this invention are laid next to one another on an even subfloor, the covering units (such as, for instance, a ceramic tile having an irregular thickness and/or a curved upper surface) will immediately take up an ideal position (as to height) to realise an even floor or wall covering, where the upper surfaces of the covering units, lying next to one another, together form a surface as even and flat as possible.

Because of this, the covering unit, notwithstanding its formal deviations, will take up an ideal position with respect to the even subfloor.

Because in this manner, the formal deviations (for instance floor tiles or wall tiles having an uneven thickness and/or a curved upper surface) of the covering unit are compensated for, a person without having the skill of a tile-layer, may also be able to realise an even floor or wall covering.

The parallelism of the said surfaces is obtained, for instance, when manufacturing the element, by positioning the covering unit and a support correctly with respect to one another (for instance, in an apparatus or a machine provided for that purpose) and by providing a layer of glue (or any other binding means) between the covering element and the support thus obtained, so that this support and the covering unit are joined, their positions (as the said parallel surfaces are concerned) with respect to one another being maintained.

It is likewise possible to attach or fix a product directly to the lower surface of the floor or wall tile, so that the position desired of the floor or wall tile, as height is concerned, is obtained. This may be, for instance, a glue or synthetic material, sprayed onto the tile. The said support is then constituted by the product with which the tile material has been provided. Preferably the product is applied locally (for instance, only next to the corners) on the lower side of the tile.

The said characteristic according to this invention may be further obtained by treating its lower side (for instance, by removing material by grinding or milling) after the floor or wall element having been produced (for instance, after it having been burnt) , until the supporting surface being determined by this lower side is practically parallel to the imaginary plane in which the points of reference are situated.

Preferably an imaginary upper surface of the covering unit is determined by means of four points of reference. Preferably, these points of reference are determined in such a manner that these points constitute the corners of a square or a rectangle. These points of reference are best situated next to the corners of the covering unit. During the manufacturing process the covering unit is positioned such, with respect to the support, or after having been manufactured, the lower side of the floor or wall element is treated in such a manner that the imaginary plane through the said points of reference runs parallel with the supporting surface defined by the lower side. So this supporting surface functions as a plane of reference. Positioning the covering unit preferably occurs by a positioning (at the height desired) of the points of reference of the upper surface of the covering unit.

Preferably, the floor or wall element according to this invention is manufactured in such a manner that it comprises at least one spacer, which is provided in order to obtain an air space of a predetermined width between the respective covering elements of floor or wall elements fitting together.

Therefore this invention relates more particularly also to floor tiles, wall tiles, ceiling tiles or any other panel shaped entity, provided for being fixed (by means of cement or glue) to a foundation next to one another, leaving .a certain width of joint. This foundation may be a wall or a subfloor or a ceiling and may be levelled beforehand or not, by evening out, or by applying a layer of material or mixture to that effect (for instance a finishing layer) .

By constituting a floor or wall covering each floor or wall element, with its spacer, is placed against an adjacent floor or wall element, so that the width of joint desired between the covering units is automatically obtained. When producing the element according to this invention, this width of joint is defined by the positioning of the covering unit with respect to the edges of the spacer. Thus a floor or wall covering may be constituted with joints between the different covering units, the width of which is quite equal, without any particular skill being required to that effect.

In a preferred embodiment comprises the floor or wall element, at least one covering element provided on a support, so that the lower side of this support defines the supporting surface mentioned above.

In a particular embodiment, the floor or wall element according to this invention comprises at least two covering units attached next to one another to the same support with intermediate joint spaces, while the points of reference of the upper surfaces of said covering units are situated in a plane which runs practically parallel to the supporting surface. For instance, floor or wall elements are provided comprising four covering units. With such elements a floor or wall covering may be composed very quickly.

In a very simple embodiment a sideways protruding spacer is provided with respect to each edge of the covering unit.

Preferably, each spacer of the floor or wall element according to this invention is an unalterable part of the support. Such an element can be rapidly produced in a simple manner.

The support, for instance, has the shape of a frame, preferably made of synthetic material, at least one straight part of which, is protruding past an edge of the covering unit and functions as a spacer.

The support may be carried out with a hollow space, at least partly filled with a synthetic material, such as, for instance, polyurethane. The support is, for instance a frame with an open central part, which during the production process is filed with a synthetic material, such as, for instance, polyurethane in order to give the element a sufficient bending strength, so that the covering element (for instance the floor tile) will not break under the influence of the normal load applied to a floor.

Preferably the support is also provided with connection means on opposite sides, for instance, with a groove and tongue, in order to connect the floor or wall element with or to position it with respect to other floor or wall elements.

In a particular embodiment, each spacer is a part of the covering unit . These spacers are then moulded to the covering unit, for instance, from ceramic material, and then burnt, after which, most of the time, the spacers have to be subjected to a finishing operation (grinding, milling, ...) in order to obtain the dimensions desired.

To facilitate the work still more, the support may be provided on one or several sides with at least one sideways protruding lip or at least one recess corresponding to such a lip, with which the various elements may be positioned in a straight line one after the other or shifted over half a width with respect to one another. Because of this, it is no longer needed to take measurements or to place a line of reference to that effect.

In a very preferred embodiment of the floor or wall element, each covering unit is made from a ceramic material or from natural stone. Preferably, this applies to floor tiles.

This invention relates also to a set of floor or wall elements comprising a first and a second floor or wall element according to this invention, characterized in that these elements comprise respective connecting means, provided for their being reciprocally connected or positioned at a height, where the surfaces, defined by the upper surfaces of their respective covering units practically coincide.

This invention further also relates to alternative methods for manufacturing a floor or wall element, comprising at least one covering unit and the lower side of which defines the supporting surface.

According to a first method, at least three points of reference are defined on the upper surface of each covering unit, each covering unit being connected to a support and positioned thus, with respect to the supporting surface defined by the lower side of the support, that these points of reference are situated in a same imaginary plane, running practically parallel to the supporting surface, defined by the lower side of the support. According to a second method the floor or wall element is manufactured or moulded first, thereafter at least three points of reference are defined on the upper surface of each covering unit, and the lower side of the floor or wall element is treated, so that this lower side constitutes a supporting surface which runs practically parallel to the imaginary plane in which the said points of reference are situated.

Preferably, the points of reference are defined such that they are the corners of a square or rectangle.

According to a particular method for manufacturing a floor or wall element, an area is defined per covering unit, the dimensions of which practically correspond to the nominal dimensions of the covering unit, increased or not by half a width of joint, of each area the intersection of the centre lines is determined and in a respective area, each covering unit is placed in a position in which its centre line intersection coincides with the centre line intersection of the area concerned.

These and other characteristics and advantages of this invention are now further explained in the following, more detailed description, referring to the attached drawings. This description only aims to be an illustration of a possible embodiment and method according to the invention, and therefore, never may be considered to be a restriction of the scope of protection of this invention as has been set forth in the attached claims.

In the following description, reference is made, by means of reference numbers, to the attached drawings, of which: figure 1 represents a cross section of a first embodiment of an element according to this invention; figure 2 represents a top view of the element according to figure 1; figure 3 represents a top view of a support for an element according to this invention; figure 4 represents a top view of a number of supports for elements according to this invention, joined together by means of positioning lips and corresponding recesses; figure 5 represents a cross section of a second embodiment of an element according to this invention; figures 6 represents a top view of the element according to figure 5; figure 7 represents a top view of a third embodiment of a floor element according to this invention; figure 8 is a partial cross section of two floor elements according to figure 7, fitting together against one another; figure 9 is a cross section of the floor element according to figure 7; figure 10 is a top view of a fourth embodiment of a floor element according to this invention; figure 11 is a cross section of the floor element according to figure 10,

In figure 1 a floor tile (1) is represented to which a frame (2) is attached at the bottom by means of glue (3) . The frame (2) is injection moulded from synthetic material and is attached to the tile in such a manner that the plane through the points of reference (4) on the upper face of the tile runs parallel to the lower side (5) of the frame, while the surface occupied by the tile (1) is situated centrally with respect to the surface occupied by the frame (2) . The aim is, on the one hand to be able to place tiles (1), glued or not, on an equalized surface (= finishing layer) without having to adjust their position, as to height, with respect to one another. On the other hand, the aim is also that, when applying the tiles (1), the width of joint required will be effected automatically, taking into account the various dimensions lengthways and widthways of the tiles.

The frame (2) which is glued at the bottom of the tile (1) is almost perfectly at right angles and its dimensions are exact (machine moulded). Connection means (7), (8) are provided on the edge, such as, for instance, a groove and tongue system, provided or not with means to realize a snap action fastening. These connection means may also be provided for connecting the frames to one another without any differences in height. An additional form (9), (10) may be applied to the frame, in such a manner that a sideways centring in line (or even shifted over half a tile, see figure 4) will occur automatically.

The possibility exists also (not represented in the figures) to apply an (elastic) joint filling material beforehand, which on applying will be a slightly compressed, so that it is no longer required to fill the joints afterwards.

The remaining space inside the frame and under the tile (1) may be filled, if necessary, with a synthetic material (6) or another filling material. Polyurethane is a preferred material.

The element according to this invention represented in figure 6, comprises one support (2) to which nine ceramic floor tiles (1) are attached by means of a synthetic material or a glue (3) .

Each floor tile (1) is positioned with respect to a perfectly square area (11) (indicated by a dashed line), the dimensions of which are corresponding with the nominal dimensions of the floor tiles (1) . These areas (11) are equally distributed over the surface of the support (2), so that the required width of joint between the floor tiles (1) is obtained. Of each area (11) and of each tile (1) the centre lines are determined, and each tile (1) is positioned in an area (11), so that its centre line intersection coincides with the centre line intersection of the area (11) .

Because the dimensions of the tiles (1) are different from the nominal dimensions, their surfaces do not correspond with the surface of their area (11) . The tiles (1) are positioned in such a way that the aspect of the whole (after finishing) is as even as possible.

Four points of reference (4) are chosen on the floor tiles

(1) near the four corners. The floor tiles (1) are, as their position as to height is concerned, attached to the support

(2) in such a manner that their points of reference are situated in a same plane (A) running parallel to the supporting surface (B) of the support (2) .

The distance (Z) between the centre lines of two adjacently situated tiles is equal to the sum of the distance (X) between the one edge of the support (2) and the centre of the floor tiles situated along that edge on the one hand, and the distance (4) between the opposite edge of the support (2) and the centre of the floor tiles (1) situated along that edge on the other hand. Because of this the width of joint desired, corresponding to the width of joint between the floor tiles situated next to one another of a same element, is automatically obtained between the floor tiles lying next to one another of elements according to this invention fitting together.

A tongue (7) and a groove (8) are provided on the opposite sides of the frame (2) .

According to another method according to this invention (see figures 7 to 10) a floor tile is moulded as a whole with spacers (11) protruding sideways and having supporting elements (12) provided at the bottom side.

These spacers (11) are carried out with a greater length than required to obtain the exact width of joint desired, so that there will be an excess of material, allowing them to be finished at the required length afterwards. By means of their lower sides, the supporting elements (12) define a random supporting surface and they are also made thicker than required, so that here also there is an excess of material allowing the supporting surface to be corrected by a finishing operation afterwards.

After the floor tile thus moulded (from ceramic material) has been burnt, the spacers (11) are treated, so that the required length is obtained to define a square or rectangular area inside which the irregularly constituted (13) tile surface is centred. This occurs in such a way that the centre lines (U) , (P) of the tile surface (13) coincide with the centre lines (not represented) of the square or rectangular area defined by the (finished) end faces of the spacers (11) . More particularly, of each side of the tiled surface (13) the centre is taken in order to define the said centre lines (U) , (P) (see figure 7).

The spacers (11) may be provided with a bevelled face.

When two floor elements are fitting together, the bevelled faces of their spacers (11) will be lying against one another (see figure 8) .

In a finishing operation the above-mentioned supporting elements (12) also will be brought to their exact thickness

(by grinding, milling,...) in order to create a supporting surface (B) , running parallel with an imaginary plane through four points of reference (4) of the upper surface of the tile surface (13) . The points of reference (4) are chosen in the same place for each tile, for instance, near the four corners of the tile surface.

According to the same method several floor tiles or wall tiles may be constituted as a whole with spacers (11) and supporting elements (12) . In figure 10 a ceramic floor element is represented comprising four tile surfaces (13) having an irregular form. This element is carried out as one entity having a joint groove (14) between the tile surfaces

(13) . Each tile surface (13) is positioned in such a manner that its centre lines (U) , (P) coincide with the centre lines of the square and rectangular area provided for the tile surface concerned, including half of the width of joint.

In a finishing operation, after the floor elements have been burnt, the spacers (11) according to the principles and methods already described, are brought to the exact length and are bevelled if required (see figure 11) . Then the supporting elements (12) also are brought to the exact thickness in order to obtain a supporting surface (B) , running parallel with the plane through the points of reference on the combined tile surface.

The advantage of the whole being that a do-it-yourselfer will be able to place wall tiles on an equalized surface in a simple manner.

Claims

A floor or wall element comprising at least one covering unit (1) and the lower side of which defines a supporting surface (B) , characterized in that it is made such that at least three points of reference of the upper surface of each covering unit (1) are situated in a plane (A) running practically parallel with the supporting surface (B) .

Floor or wall element, according to claim 1, characterized in that it comprises at least one spacer, which is provided for to obtain a joint groove, having a predetermined width, between respective covering units (1) of floor or wall elements fitting together.

Floor or wall element, according to claim 1 or 2, characterized in that the covering unit (1) is provided on a support (2), and in that the lower side of the support (2) defines the supporting surface (B) .

Floor or wall element, according to anyone of the preceding claims, characterized in that it comprises at least two covering elements (1) which, with intermediate joint grooves, have been attached to the same support (2) next to one another, and in that the points of reference of the upper surfaces of the said covering units (1) are situated in a plane (A), running practically parallel with the supporting surface (B) defined by the lower side (5) of the support (2) .

Floor or wall element, according to anyone of the preceding claims, characterized in that a sideways protruding spacer (11) has been provided with respect to each edge of the covering unit (1) .

Floor or wall element, according to anyone of the claims 3 to 5, characterized in that each spacer (11) is an unalterable part of the support (2) .

Floor or wall element, according to anyone of the claims 3 to 6, characterized in that the support (2) has the form of a frame, at least one straight part of which extends past an edge of each covering unit (1) and functions as a spacer.

Floor or wall element, according to anyone of the claims 3 to 7, characterized in that the support (2) has been provided with connection means (7), (8), on the opposite sides, to connect the floor or wall element to or to position it with respect to other floor or wall elements .

Floor or wall element, according to anyone of the claims 2 to 8, characterized in that each spacer (11) is a part of a covering unit (1) .

Floor or wall element, according to anyone of the preceding claims, characterized in that it is carried out as a whole.

Floor or wall element, according to anyone of the preceding claims, characterized in that it has been provided on one or several sides with at least one protruding lip (9) or with a recess (10) at least corresponding to such a lip (9) in order to position the various elements in a straight line one after the other or shifted over half a width with respect to one another .

12. Floor or wall element, according to anyone of the preceding claims, characterized in that the covering unit is made of a ceramic material or of natural stone.

13. Method for manufacturing a floor or wall element comprising at least one covering unit (1) and the lower side of which defines a supporting surface (B) , characterized in that at least three points of reference (4) are defined on the upper surface of each covering unit (1) and in that each covering unit (1) is connected to a support (2) and moreover is positioned with respect to the supporting surface (B) defined by the lower side of the support (2) in such a manner that the points of reference (4) are situated in an imaginary plane, which runs practically parallel with the said supporting surface (B) .

14. Method for manufacturing a floor or wall element comprising at least one covering unit (1) and the lower side of which defines a supporting surface (B) , characterized in that the floor or wall element is manufactured and mould first, and that subsequently at least three points of reference (4) are defined on the upper surface of each covering unit (1), and in that the lower side of the floor or wall element is treated, so that this lower side constitutes a supporting surface (B) , running practically parallel with an imaginary plane (A) in which the said points of reference (4) are situated. 5. Method according to claim 14, characterized in that these points of reference (4) are defined in such a manner that these points (4) are the corners of a square or a rectangle.

Method according to anyone of the claims 13 to 15, characterized in that per covering unit (1) an area is defined, the dimensions of which practically coincide with the nominal dimensions of the covering unit (1), increased or not by half a width of joint, in that the intersection of the centre lines is defined for each area, in that the intersection of the centre lines of each covering unit is defined, and in that each covering unit in a respective area is provided in a position, in which its centre line intersection coincides with the centre line intersection of the area concerned.