Resilient ceramic tile flooring

• US 4,567,704 A
• Filed: 11/02/1977
• Issued: 02/04/1986
• Est. Priority Date: 05/03/1977
• Status: Expired due to Term

• Current Assignee: Tile Council of America Incorporated
• Original Assignee: Tile Council of America Incorporated
• Inventors: Burley, David R., Bernett, Frank E.
• Primary Examiner(s): Murtagh, John E.
• Application Number:
  US05/847,795
• Time in Patent Office: 3,016 Days
• Field of Search: 428/49, 428/48, 428/310, 428/166, 428/137, 428/311, 428/77, 428/325, 52/384, 52/390, 52/385, 52/389, 52/309.3
• US Class Current: 52/309.3
• CPC Class Codes: E04F 13/0862 composed of a number of elements which are identical or not, e.g. carried by a common web, support plate or grid
• CPC Class Codes: E04F 15/02194 Flooring consisting of a number of elements carried by a non-rollable common support plate or grid E04F15/022 takes precedence
• CPC Class Codes: E04F 15/087 The lower layer being of organic plastic with or without reinforcements or filling materials
• CPC Class Codes: Y10T 428/166 Glass, ceramic, or metal sections [e.g., floor or wall tile, etc.]

Abstract

A composite floor covering comprising a rubbery backing strip or layer in intimate contact with the floor, ceramic tiles placed over the backing layer and flexible grouting between the tiles.

Claims

1. A method for improving the resiliency yet maintaining and improving the wearability of a ceramic tile floor covering which comprises ceramic tile arranged in an edge-to-edge, spaced apart relationship, said method comprising the steps of

arranging said ceramic tiles in said relationship to overlay but not to be secured directly to a resilient rubbery backing of a flexible foamed or cellular plastic material having a thickness of greater than 1/32nd inch and up to one inch, the resiliency of said backing layer as measured on a Shore A Durometer is between 0 and 40 and wherein the compression deflection of said resilient backing is from 1 to 40 psi as defined in ASTM Test D-1056;

and

bonding said ceramic tiles to each other along their respective edges with a flexible grouting having resiliency characteristics, said grouting forming an interlocking lattice of flexible adhesive between and separating each of said ceramic tiles and bonding adjacent tile pieces at their edges wherein the top and bottom faces of the ceramic tiles are free of the grouting material and the edges of said tile pieces are substantially vertical.

2. The method of claim 1 wherein the resilient rubbery backing is selected from the group consisting of foamed vinyls and urethane foam.

3. The method of claim 1 wherein the flexible grouting material is a natural or synthetic rubber or polymer selected from the group consisting of polymers of urethanes, vinyls, acrylics, epoxies, silicones and combinations thereof.

4. The method of claim 1 wherein the ceramic tiles are adhered to the backing layer by an adhesive.

5. A method for rendering a floor resilient with a surface covering composed substantially of rigid materials, said method comprising the steps of

arranging in an edge-to-edge, spaced apart relationship rigid floor covering pieces selected from the group consisting of ceramic tiles, marble, slate and glass having overall dimensions less than 12"×

12";

placing said floor covering pieces in said relationship to overlay but not to be directly secured to a resilient rubbery backing layer composed of open-celled flexible foamed plastic materials, wherein said rubbery backing is greater than 1/32nd inch and up to one inch thickness and has a resiliency as measured on a Shore A Durometer of between 0 and 40 and a compression deflection from 1 to 40 psi as defined in ASTM Test D-1056; and

bonding said floor covering pieces to each other along their respective edges with a flexible grouting having resiliency characteristics, said grouting forming an interlocking lattice of flexible adhesive between and separating each of said floor covering pieces and bonding adjacent pieces at their edges wherein the top and bottom faces of the ceramic tiles are free of the grouting material and the edges of said tile pieces are substantially vertical.

6. The method of claim 5 wherein said backing layer is a open-celled foamed neoprene rubber.

7. A floor covering characterized as having a hard tiled surface but having resilient characteristics and capable of withstanding normal floor use, said floor covering comprising

a resilient backing of a flexible foamed or cellular material having a thickness of greater than 1/32nd inch and up to one inch, said backing arranged in intimate contact with the floor, the resiliency of said backing layer as measured on a Shore A Durometer is between 10 and 40 and wherein the compression deflection of said resilient backing is from 3 to 40 psi as defined in ASTM Test D-1056;

a plurality of ceramic tiles spaced edge-to-edge to overlay but not to be secured directly to the resilient backing, said tiles being spaced sufficiently from each other so as to form a groove between adjacent tiles; and

flexible grouting in the area between the ceramic tiles, said grout having resiliency characteristics and forming an interlocking lattice of flexible material between and separating each of said tiles, bonding adjacent tile pieces at their edges wherein the top and bottom faces of the ceramic pieces are free of the grouting materials and the edges of said tile pieces are substantially vertical.

8. The floor covering as described in claim 7 wherein the ceramic tiles are adhered to the backing layer by an adhesive.

9. The floor covering as described in claim 7 wherein the resilient backing is composed of a closed-celled flexible foamed plastic material.

10. The floor covering as described in claim 7 wherein the backing layer is comprised of a flexible foamed plastic selected from the group consisting of foamed vinyls and urethane foam.

11. The floor covering as described in claim 7 wherein the foamed material is a closed-celled foamed neoprene rubber.

12. The floor covering as described in claim 7 wherein the flexible grouting material is a natural or synthetic rubber or polymer selected from the group consisting of polymers of urethanes, vinyls, acrylics, epoxies, and silicones and combinations thereof.

13. The floor covering as described in claim 7 wherein the grouting material has a resiliency as measured on a Shore A Durometer of from 30 to 80.