WO2000053865A1

WO2000053865A1 - Free lay ceramic tile flooring systems and methods

Info

Publication number: WO2000053865A1
Application number: PCT/US2000/006268
Authority: WO
Inventors: Graham Scott
Original assignee: Interface, Inc.
Priority date: 1999-03-11
Filing date: 2000-03-10
Publication date: 2000-09-14
Also published as: AU3873900A

Abstract

A free lay flooring system including a base matrix (12) for securing a replaceable wear surface (14) to a floor or subfloor. The base matrix includes a plurality of flooring recesses (16) sized to receive the replaceable wear surface. Ceramic tile, carpet, carpet tile, fabric, vinyl flooring and wood are a sample of materials suitable as the replaceable wear surface (14). When viewed from above, the base matrix (12) and replaceable wear surface (14) appear as a 'grout-less' tile flooring structure.

Description

FREE LAY CERAMIC TILE FLOORING SYSTEMS AND METHODS

RELATED APPLICATION

This application claims priority to a U.S. Patent Application serial no.

60/123,884 filed March 11, 1999, entitled, "Free Lay Ceramic Tile Flooring

Systems and Methods," which is incorporated by reference herein.

FIELD OF THE INVENTION

This invention relates in general to the field of caφet and other floor

covering, and in particular to free lay ceramic tile flooring systems and methods.

BACKGROUND OF THE INVENTION

Typical floor coverings include ceramic tile, caφet, wood flooring or other

materials that cover a floor or subfloor. Ceramic tile provides a durable, attractive,

and long lasting floor covering. However, installing ceramic tile requires an

investment in labor and materials, such as, cutting devices, adhesive, grout, and of

course, ceramic tiles. Further, a relatively level floor or subfloor is necessary for

installing a ceramic tile floor covering. An installer must possess skills necessary

to level an unleveled floor or remove an existing floor covering before installing

the new floor.

The investment in time, labor and materials required to install a ceramic tile

floor covering discourages users from changing their installed floor even if they

tire of the design, color, or texture floor covering. An easy, efficient and cost effective system and method of installing ceramic tile floors provide users the

option to change their floor covering at will.

Therefore, a need exists for free lay systems and methods for installing

ceramic tiles and other flooring surfaces.

SUMMARY OF THE INVENTION

This invention relates to the use of a base matrix to secure a replaceable

wear surface to a floor. This invention includes free lay ceramic tile flooring

systems and methods having a base matrix and a replaceable wear surface. The

base matrix includes a plurality of flooring recesses sized to receive the

replaceable wear surface. Divider partitions surround each flooring recess. The

replaceable wear surface may include a variety of flooring surfaces such as

ceramic tile, caφet, caφet tile, fabric, vinyl flooring, wood, and a variety of other

materials.

A plurality of base matrices may be positioned on a floor or subfloor with

the result that the replaceable wear surfaces will be entirely surrounded by divider

partitions thereby providing an attractive flooring that can be efficiently installed.

Objects of this invention include:

To provide systems and methods for a "grout-less" ceramic tile flooring

structure.

To provide systems and methods for a free lay flooring structure that

contours to the floor or subfloor. To provide systems and methods for a flooring structure where the wear

surface is easily replaced.

To provide systems and methods for a flooring structure that provides for

many design options for the replaceable wear surface.

As the following description and accompanying drawings make clear, these

and other objects are achieved by this invention.

BRIEF DESCRIPTION OF THE DRAWINGS

Fig. 1 shows a perspective view of a base matrix and replaceable wear

surface of the free lay ceramic tile system of this invention.

Fig. 2 shows a top plan view of a plurality of base matrices of Fig. 1 with

replaceable wear surfaces disposed thereon arranged to create a floor covering.

Fig. 3 shows a cross-sectional view of a replaceable wear surface disposed

within the base matrix.

Fig. 4 shows a cross-sectional view of an alternative embodiment of the

replaceable wear surface of Fig. 3.

DETAILED DESCRIPTION OF THE INVENTION

Fig. 1 shows a free lay ceramic tile flooring system 10 of this invention.

The free lay ceramic tile flooring system 10 includes a base matrix 12 and a

replaceable wear surface 14. In a preferred embodiment, the replaceable wear

surface 14 is a ceramic tile.

The base matrix 12 includes a plurality of flooring recesses 16 sized to

receive the replaceable wear surface 14. Divider partitions 18 surround each

flooring recess 16. In a preferred embodiments, the divider partitions 18 are arranged such that each partition is joined at substantially a 90° angle forming a

square around the recess 16. A flush fit between the replaceable wear surface 14

positioned in the flooring recess 16 of the base matrix 12 allows the replaceable

wear surface 14 to remain in position in the base matrix 12 when a downward

pressure is exerted on the base matrix 12. When viewing the base matrix 12 from

above, the combination of the divider partitions 18 and the replaceable wear

surface 14 of ceramic tile disposed within the flooring recess 16, appears as a

flooring surface of ceramic tile surrounded by grout. Yet this invention provides

for a "grout-less" ceramic tile flooring structure.

Preferably, the base matrix 12 has a thickness of about 1/8 inch and

constructed of an elastomer. This allows the base matrix 12 to contour with the

floor or subfloor providing for a level flooring surface. In an alternative

embodiment, the base matrix 12 is secured to the floor by an adhesive.

As will be appreciated by reference to Figure 2, a plurality of base matrices

20 may be positioned on a floor or subfloor with the result that replaceable wear

surfaces 14 will be entirely surrounded by divider partitions 18 thereby providing

an attractive flooring that can be efficiently installed.

Fig. 3 is a cross-sectional view taken along lines 3-3 of Fig. 2 showing a

replaceable wear surface 14 disposed within the base matrix 12. The replaceable

wear surface 14 fits in a pocket 22 of the flooring recess 16. Divider partitions 18

surround the replaceable wear surface 14 keeping the replaceable wear surface 14

in position in the base matrix 12. Fig. 4 shows a cross-sectional view of an alternative embodiment of the

replaceable wear surface 14. The replaceable wear surfaces 14 may be a variety of

flooring surfaces such as ceramic tile, caφet, caφet tile, fabric, vinyl flooring,

wood, and a variety of other materials. An example of a wear surface embodied as

a caφet tile 24 is shown in Fig. 4. Fig. 4 shows the caφet tile 24 without a

backing however this invention envisions a backing positioned between the caφet

tile 24 and the base matrix 12. In the embodiment shown in Fig. 4, the caφet tile

24 is flush mounted within the flooring recess 16 at a level even with the divider

partitions 18. In an alternative embodiment, the caφet tile 24 may extend

outwardly from the base matrix 12 above the level of the divider partitions 18.

An advantage of this invention is that it provides systems and methods for a

"grout-less" ceramic tile flooring structure.

Another advantage of this invention is that it provides systems and methods

for a free lay flooring structure that contours to the floor or subfloor.

Yet another advantage of this invention is that it provides systems and

methods for a flooring structure where the wear surface is easily replaced.

Still another advantage of this invention it that it provides systems and

methods for a flooring structure that provides for many design options for the

replaceable wear surface.

While certain embodiments of this invention have been described above,

these descriptions are given for puφoses of illustration and explanation.

Variations, changes, modifications and departures from the systems and methods disclosed above may be adopted without departure from the spirit and scope of this

invention.

Claims

Claims:

1. A free lay flooring system comprising:

a base matrix; and

a replaceable wear surface adapted to fit within the base matrix.

2. The free lay flooring system of claim 1 , further comprising a plurality of

flooring recesses in the base matrix, the flooring recesses sized to receive the

replaceable wear surface.

3. The free lay flooring system of claim 2, further comprising divider

partitions surrounding each flooring recess.

4. The free lay flooring system of claim 3, wherein the divider partitions are

arranged such that each divider partition is joined at a substantially 90° angle

forming a square around the recess.

5. The free lay flooring system of claim 1 , wherein the replaceable wear

surface is selected from the group consisting of:

ceramic tile;

caφet;

caφet tile;

fabric;

vinyl flooring; wood; and

other floor covering materials.

6. The free lay flooring system of claim 3, wherein the base matrix contours

to a floor or subfloor.

7. The free lay flooring system of claim 3, wherein when viewing the base

matrix from above, the combinations of divider partitions and replaceable wear

surface disposed in the flooring recess appear as a flooring surface surrounded by

grout.

8. The free lay flooring system of claim 2, wherein the replaceable wear

surface fits flush within the flooring recess of the base matrix that allows the

replaceable wear surface to remain in position in the base matrix when a

downward pressure is exerted on the base matrix.

9. The free lay flooring system of claim 1 , wherein the base matrix has a

thickness about 1/8 inch.

10. The free lay flooring system of claim 1 , wherein the base matrix is

constructed of a elastomer.

11. The free lay flooring system of claim 1 , wherein the base matrix secures to

a floor by an adhesive.

12. The free lay flooring system of claim 2, further comprising a pocket formed

by the flooring recesses for receiving the replaceable wear surface.

13. The free lay flooring system of claim 3, wherein the replaceable wear

surface comprises a ceramic tile.

14. The free lay flooring system of claim 3, wherein the replaceable wear

surface comprises a caφet tile.

15. The free lay flooring system of claim 14, wherein the caφet tile further

comprises a backing layer positioned between the caφet tile and the base matrix.

16. The free lay flooring system of claim 14, wherein the caφet tile is flush

mounted within the flooring recess at a level even with the divider partitions.

17. The free lay flooring system of claim 14, wherein the caφet tile extends

outwardly from the base matrix above a level of the divider partitions.

18. A method for assembling a free lay system comprising: positioning a plurality of base matrices having divider partitions forming

flooring recesses; and

placing a replaceable wear surface m each flooring recess

19. The method of claim 18, wherein the placing a replaceable wear surface in

each flooring recess is performed with a ceramic tile comprising the replaceable

wear surface.

20. The method of claim 18, wherein the placing a replaceable wear surface m

each flooring recess is performed with a caφet tile comprising the replaceable

wear surface.