Flooring system

[0002] This invention relates to tile and supporting structure flooring systems wherein the tile is supported in a frame of elements surrounding each tile and interconnected with each other by shared terminating ends.

[0003] There are numerous methods and mechanisms for laying tile in a flooring system for homes and businesses. Many of these systems are difficult for the consumer to use and as such require special expertise to install.

[0004] Strong adhesives are commonly employed to secure the tile to the subflooring. This adds to the difficulty of installation, since the tiles must be aligned and held in place until the adhesive sets. Also, should the consumer ever desire to remove the flooring, the permanency of the adhesive makes this task very difficult. Alternatively, fasteners, such as nails, can be used in order to anchor the tiles to the subfloor; however, these means are unsightly if left exposed and possibly a hazard if they loosen. Concealing the fastening means adds even greater complexity to the flooring project.

[0005] Further, should a consumer wish to install a heterogeneous floor, such as one combining wood and ceramic tile elements, to present an intricate and appealing visual pattern, the degree of installation complexity increases multifold.

[0006] It would be desirable to have a flooring system that was easy to install in a home or business by the ordinary consumer, using subfloor fasteners that were both easily concealed and removed, and aesthetically appealing through the employment of complex patterns and varied construction materials.

[0007] It is an object of the present invention to provide an aesthetically appealing flooring system comprised of a frame of connected unitary elements supporting a tile within.

[0008] It is a further object of the present invention to provide a frame and tile flooring system that is easy to assemble and install by the consumer.

[0009] More particularly, the present invention is directed to a flooring frame for ceramic or other types of tiles. The frame is comprised of uniform frame elements, preferably made of a unitary piece of material, each element having the shape of an elongated hexagon. The four short sides are equal in length with the angle between the short sides being 90°.

[0010] Each short side of the frame element is also fashioned with a dowel pin on one side of the angled face and a mated recess on the other angled face. The placement of pin and recess is reversed at the opposite end of the frame element. The recess and pin placement permit the locking together of adjoining frame elements and prevents the pieces from slipping relative to each other. An extension or blind nailer is located along the base of each of the long sides of the elongated hexagonal-shaped frame element, with the end edges of the nailer being cut to match the taper of the short ends.

[0011] Thus, the elements fit together to form a frame of interlocking squares having nailers forming a tile supporting ledge upon which the tile rests. The top face of the rectangular section is exposed and becomes an aesthetic component of the flooring system. The elements are dimensioned to match the proportions of the tile to be supported. Each piece of tile will be surrounded by frame material, eliminating the use of grout. A sealer is applied to the gaps between the edges of the frame and tile in order to prevent dirt and liquids from getting under the flooring.

[0012] The present invention also relates to a method of installing the flooring system described herein.

[0013] FIG. 1 is a perspective view of several sectional units of the completed flooring system showing a uniform frame element separated from the remainder of the floor.

[0014] FIG. 2 is a perspective view of one of the uniform frame elements.

[0015] FIG. 3 is a perspective view of an exploded frame system unit.

[0016] FIG. 4 is a plan view of several sectional units of the completed flooring system.

[0017] FIG. 5 is a sectional view of a uniform frame element and associated tile and subsupport.

[0018] As shown in FIGS. 1, 3 and 4, frame unit 10 is composed of four hexagonal-shaped elongated uniform frame elements 20 of identical shape. As best shown in FIG. 1, each elongated frame element 20 is attached at opposing first or second terminating ends 26 or 27 to another identical frame element 20.

[0019] As best shown in FIGS. 1 and 3, each first terminating end 26 of element 20 is connectable to a second terminating end 27 of an adjacent element 20 within the same frame unit 10. As best shown in FIG. 2, one side of the first terminating end 26 defines a mated recess 25 that is sized to accept a dowel pin 24 into the mated recess 25. The dowel pin 24 is located on and affixed to one side of the second terminating end 27. Both first 26 and second 27 terminating ends each have a dowel pin 24 on one side 28bof the end and a mated recess 25 on the adjacent side 28aof the same end. The difference between the first 26 and second 27 terminating ends is only that the dowel pins 24 and mated recesses 25 are on opposite sides 28a&bof each end. This permits the elements 20 to fit together into a unit 10 on one side of each element 20 and permits connection of the element 20 in one unit 10 to another element 20 in an adjacent unit 10, as shown in FIGS. 1 and 4. The angle of the sides 28a&bof each terminating end 26 or 27 in relation to each other is 90°. This angle a results in the frame unit 10 forming a perfect square of connected elements 20. Other means for attaching the terminating ends can be used as may be appropriate, but the dowel pin and mated recess type fitting is preferred.

[0020] As shown in FIG. 4, the individual elements 20 fit together to form a frame unit 10 and then each frame unit 10 further fits together with another frame unit 10, each unit sharing one of its sides with the adjacent unit. The units 10 combine to form a continuous frame lattice over the entire surface to be covered. The junction of each group of four units creates a distinctive “X” pattern 40 that repeats across the entire surface and further adds to the aesthetic appeal of the completed floor.

[0021] The ease in which assembly of the flooring system is achieved is now described. The installer begins in the corner of the room and connects two frame elements 20 together to form a right angle, and aligns these elements 20 with the corner of the room. The remaining two frame elements 20 are connected to the right angle to form the first complete frame unit 10. More frame elements 20 are added to the first unit 10 in order to create adjoining frame units 10 until the surface to be tiled is covered with a lattice of interconnected frame units 10. The elements 20 are affixed to the subfloor as each unit 10 is completed, or as each element 20 is added to the growing lattice.

[0022] As seen in FIG. 2, each element 20 has on both of the vertical surfaces 29 of its elongated sides an extension 21 along the bottom portion of the vertical surface it 29 referred to hereinafter as a blind nailer. The extension or blind nailer 21 terminates at both ends in a taper cut 22 that aligns with the angle of the first end 26 and second end 27. The blind nailer 21 functions as a hidden means of affixing the frame unit 10 to the subflooring. Flooring nails are hammered through the blind nailer 21 and into the subfloor thus securely fixing the unit 10 to the subfloor and preventing slippage of the floor as a whole (not shown). Further, as shown in FIG. 3, the blind nailers 21 of the completed frame unit together form a tile supporting ledge 41 upon which the tile rests when properly positioned. Therefore, when a tile 11 is positioned in the frame 10, the nails and the nailer 21 are hidden from view, thus presenting a more appealing surface.

[0023] As shown in FIG. 3, a subsupport square 12, having dimensions slightly smaller than the perimeter created by the four blind nailers 21 of the surrounding elements 20 that make up a particular unit 10, is placed within the unit 10 and in direct contact with the subfloor. As best shown in FIG. 5, the height of the subsupport square 12 is equal to the height of the blind nailers 21. Thus, the subsupport square 12 acts as a further support for the tile 11, which is positioned on top of the blind nailers 21 and the subsupport square 12 and between the elements 20 of a unit 10. A sealant may then be applied to the slight gap between the edges of the tile 11 and the edges of the elements 20 in order to prevent particulate matter and liquids from falling into the gap. After the complete lattice is assembled and the tile installed, the finished product appears as best shown in FIG. 4. Only the top surface 23 of each element 20 and the top surface of the tiles 13 are visible to the eye after the floor is completely assembled. None of the subfloor anchoring means is visible. This gives a uniform appearance and alternating pattern of tile and frame elements that is aesthetically pleasing to behold.

[0024] One preferred composition of the frame elements 20 is wood. Any type of wood that is strong enough to be used as flooring is acceptable. For example, oak, cherry, pine or veneers of wood are preferred materials for the elements 20. The wood may be chosen to match existing décor and fixtures. The wood may be stained or painted as appropriate to further its aesthetic appeal. The frame elements 20 may also be composed of different metals, as well as stone, such as marble, or composite resins. A preferred tile 11 is ceramic. However, it may also be composed of stone, such as marble, granite or slate, wood or other substances commonly available as tiling material.

[0025] The dimensions of the frame elements 20 may be as large as needed to produce a unit 10 of size required to support the desired tile 11. One preferred embodiment is an element 20 having a length of between six and thirty-six inches and a width of one to five inches, not including the blind nailers 21.

[0026] It will be realized by one skilled in the art that various changes may be made to the specific embodiments disclosed and described without departing from the principals and spirit of the present invention.