SYSTEM AND PROCESS FOR INSTALLING A TEMPORARY TILE FLOOR SURFACE

Abstract

A process for installing a temporary tile floor surface includes identifying a substrate surface requiring installation of the temporary tile floor surface. The process further includes installing a dampened tile system including a dampening material between a bottom surface of tiles of the dampened tile system and the substrate surface.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This disclosure is a continuation-in part of U.S. application Ser. No. 28/658,996 filed on Mar. 17, 2017, and this disclosure is a continuation-in-part application of U.S. application Ser. No. 14/695,203 filed on Apr. 24, 2015 which claims the benefit of U.S. Provisional Application No. 61/984,105 filed on Apr. 25, 2014, all of which are hereby incorporated by reference.

TECHNICAL FIELD

This disclosure is related to use of a floor tile for use in new construction or renovation. In particular, this disclosure is related to a tile with beneficial properties in applications wherein a substrate can be unstable and/or noise dampening or thermal insulation is desirable. Additionally, the disclosure is related to a tile for use when a temporary flooring material might be desired or a floor with the ability renew and replace easily with no messy or common construction processes would be associated with the replacement process. Additionally, the disclosure is related to a tile for use with a simple installation in which almost no prior experience would be required to complete a satisfactory installation in a floor application.

BACKGROUND

The statements in this section merely provide background information related to the present disclosure. Accordingly, such statements are not intended to constitute an admission of prior art.

Tile is widely used as a decorative and functional material for use in residential and commercial buildings. Tile provides a finished look, and it also is easier to clean in some applications than other types of covering materials. Tile construction typically includes a porcelain or ceramic tile adhered to a substrate surface with an adhesive, and borders surrounding the tile are filled with grout. Such typical tile construction is rigid and durable when it is stable. However, a substrate can be less than perfectly stable. If a substrate flexes or shifts or people or objects move across the floor, grout and/or the adhesive binding the tile to the floor can crack and break, leading to loose or broken tiles.

Standard tile configurations include rigid grout adhering tile to substrate. Such rigid grout easily transmits sound waves from the tile to the substrate and vice versa. Similarly, rigid grout rigidly holds the tile in place. In the event the substrate is uneven or flexible, both the tile and the grout itself are subject to breakage and accelerated wear when weight is applied to the tile.

SUMMARY

A process for installing a temporary tile floor surface includes identifying a substrate surface requiring installation of the temporary tile floor surface. The process further includes installing a dampened tile system including a dampening material between a bottom surface of tiles of the dampened tile system and the substrate surface.

BRIEF DESCRIPTION OF THE DRAWINGS

One or more embodiments will now be described, by way of example, with reference to the accompanying drawings, in which:

FIG. 1 illustrates a bottom side of an exemplary encapsulated tile, in accordance with the present disclosure;

FIG. 2 illustrates a top side of the encapsulated tile of FIG. 1, in accordance with the present disclosure;

FIG. 3 illustrates an alternative exemplary embodiment of tile utilizing a coating of closed-cell foam on a bottom surface of the tile, in accordance with the present disclosure;

FIG. 4 illustrates an alternative exemplary embodiment of tile utilizing a coating of closed-cell foam to create a border around the tile, in accordance with the present disclosure;

FIG. 5 illustrates an alternative exemplary embodiment of tile utilizing a closed-cell foam appliqué to dampen the tile, in accordance with the present disclosure;

FIG. 6 illustrates an alternative exemplary embodiment of tile utilizing the bordered tile of FIG. 4 in combination with a sheet of dampening material between the tile and the substrate, in accordance with the present disclosure;

FIG. 7 illustrates exemplary removal of a first set of dampened tiles and simultaneous installation of a second set of dampened tiles, in accordance with the present disclosure;

FIG. 8 illustrates an exemplary tile configuration including transitions to another floor surface and a wall surface, in accordance with the present disclosure;

FIG. 9 illustrates through a flow chart an exemplary process for installing a temporary tile floor with dampened tiles, in accordance with the present disclosure;

FIG. 10 illustrates through a flow chart an exemplary process for installing a temporary tile floor with a layer of dampening material installed under the tiles, in accordance with the present disclosure;

FIG. 11 illustrates through a flow chart an exemplary process for installing a temporary tile floor with dampened tiles and a layer of dampening material installed under the tiles, in accordance with the present disclosure;

FIG. 12 illustrates a prior art tile placed upon a substrate including a bump upon the substrate, the tile placed upon the substrate without any grout, in accordance with the present disclosure;

FIG. 13 illustrates the prior art tile of FIG. 12, with a crack forming in the tile, in accordance with the present disclosure; and

FIG. 14 illustrates the dampened tile of FIG. 2 placed upon a substrate including a bump upon the substrate, with the dampening material of the tile deforming to permit the tile to lay flat upon the substrate in spite of the bump, in accordance with the present disclosure.

DETAILED DESCRIPTION

Porcelain tile and ceramic tile are a rigid materials. When stably supported, the tile can be strong and durable. If the floor or slab under the tile moves, shifts, or is otherwise unstable, movement between the tile and the floor can damage the tile, the adhesive between the tile and the floor, and the grout surrounding the tile.

A dampened tile is provided utilizing a dampening material applied to lower surfaces if the tile. In one embodiment, the dampened tile is an encapsulated tile, with all sides of the tile coated in the dampening material except the visible surface of the tile. The dampening material can be provided upon the tile at a manufacturing location and shipped and sold to the consumer with the dampening material pre-applied. In other embodiments, the dampening material can cover only the sides or only the bottom of the tile. In other embodiments, the dampening material can be applied away from the manufacturing site or by the consumer. In other embodiments a dampening layer of material can be used in place of or in addition to dampening material applied to the tile.

Exemplary dampened or encapsulated tiles of the disclosure, once installed, resist breakage due to non structural slab movement, they feel softer under foot, they feel warmer than hard set tile floors, less sound is transferred to below living spaces and in the same room. The dampened tiles are easy to install and care for. Using the tiles creates a forgiving system, if an installation error is made or an event ever takes place that would require removal of the tiles this can be done easily and tiles can be replaced once the issue has been corrected.

The disclosed tiles are suitable for residential or light commercial installations, defined as areas where the system is subject to foot traffic or light pneumatic wheeled carts. However, flex and dampening properties provided by the disclosed system can cause force that would normally be distributed across an entire tile or a plurality of tiles to be concentrated on a portion or point of a tile. Care should be taken to avoid using the tile where hard metal or plastic solid wheel carts are utilized. Similarly, heavy point loads exceeding the tiles expected breaking strength requirements should be avoided. The disclosed tile system is not suitable for forklift, pallet jacks, or wheeled traffic of heavy loads or other areas whereby the tiles will be subject to extra heavy load requirements. Care should be taken not to exceed load requirements specified by manufacturers of tiles used or coated as disclosed.

In some embodiments, tiles utilized should be of the highest quality impervious porcelain body, less than 0.5% absorption tested under ASTM test methods. In one embodiment, tiles must be a thickness of 9.5 mm (⅜″) or greater. In one embodiment, tile thickness between 10 and 12 mm is recommended. Under some conditions, tile with small or no deviation in thickness within the tile provide best results. Exemplary tiles for use with the disclosed system should be flat in all aspects, across the face and edges with no wedging or warpage. Such exemplary tiles should be first quality under ANSI A137.1-2008. Under some conditions, all edges should be rectified to provide strait 90 degree edges and a single calibration per lot size.

A floor substrate must be clean and free of debris in preparation for installation. Any floor suitable for a standard thinset application of tile are acceptable with the following restrictions. Floors must be flat and not have deflection greater than ⅛″ in 10 feet. There must be no transitional heights or structural defects to be bridged which would allow upward or other unstable movement under the tiles. The tiles must be tight fit within the field of tiles and at all edges to restrict movement. Use of high quality silicone can be utilized at the outside edges of the tiles to restrict movement of the tiles where there is no wall structure or other edge surface containing the outside tiles. One can use metal or other tile edging transitions known in the art to transition from the tiles. One may bond transitions to the floor to hold tiles firm on their edges. Glue transitions to the floor to hold tiles firm on edges are recommended, with double stick carpet tape or epoxy bond transition strips.

Tiles may be cut to size. One may use scoring tools or a wet saw according to normal tile cutting practice.

Cutting, with scoring tools or wet saw, can be used as are known in the art to cut tiles.

Care of the tiles can be performed according to a number of envisioned processes. Edges may be heat sealed to enhance water perm performance. Mop tiles with light mopping is recommended, as flooding surface should be avoided. If flooding has taken place, and water or cleaner removal is desired pick-up tiles, clean or dry then reset. If heavy cleaning is required to remove contaminants from below the surface of the tiles, pick-up those affected tiles and clean and replace. For care of the specific tiles, one may follow manufacturers recommended instructions.

FIG. 1 illustrates a bottom side of an exemplary encapsulated tile. Dampened and encapsulated tile 10 is illustrated. As disclosed herein, an encapsulated tile is coated on five of the six surfaces of a tile, with the bottom and the four thin side surfaces coated. Coating 20 is illustrate applied to the named sides of tile 30. Coating 20 is illustrated as a thick coating in FIG. 1 and throughout the disclosure, for example, visually comparable to the thickness of the tile. This thickness is for illustration and clarity purposes. In many circumstances, the layer will actually be thin, for example between 1 mm and 5 mm, depending upon the particular dampening material used and the desired application for the tiles.

Dampening materials or coatings as disclosed herein can take any of a number of embodiments. Closed-cell foam, such as exemplary ethylene propylene diene terpolymer (EPDM), is one exemplary product that can be utilized. Open-cell foam is another exemplary product that can be utilized. A rubberized layer or polymerized spray on coating can additionally be utilized. A desirable dampening material is durable and can accept the loading and temperature ranges seen in normal flooring applications. Such a material meets all regulations and codes for safe use around persons. Such a material tends to be flexible, providing elasticity even after the tile is installed to a surface and abutted to other neighboring tiles. Such a material holds up to light cleaning and mopping without absorbing water or other liquids.

According to one exemplary embodiment of dampening materials, Nitto provides 5790S-series dampening tapes, which are single coated foam tapes These dampening tapes are based on a cross linked polyolefin foam, coated with pressure sensitive adhesive, and having excellent bonding properties, especially on low energy surfaces. In one embodiment, the tape includes a polyolefin foam carrier top layer, a modified acrylic adhesive middle layer, and a paper release liner bottom layer. Nitto 5790S-series are single-coated foam tapes known in the art with excellent adhesion properties on a wide range of materials such as plastic, steel, and glass. The flexible foam carrier conforms easy to the irregularities of the substrate and provides impact resistance, thermal insulation, sound dampening and sealing properties. Nitto 5790S-series tapes are used in other applications as a gap filler to absorb sound and to seal against dust and humidity. Exemplary tape thicknesses include 0.6 mm and 1.1 mm.

FIG. 2 illustrates a top side of the encapsulated tile of FIG. 1. Encapsulated tile 10 is illustrated including dampening material 20 and top surface 12 of tile 30 being visible without any dampening coating.

FIG. 3 illustrates an alternative exemplary embodiment of tile utilizing a coating of closed-cell foam on a bottom surface of the tile. Dampened tile 100 is illustrated including tile 30 and dampening coating 40 applied to a bottom side 35 of tile 30. Coating 40 dampens contact between tile 30 and the substrate surface. Once applied to a floor surface, any suitable flexible caulking material can be used to fill gaps between tile 30 and adjacent tiles.

FIG. 4 illustrates in cross-section an alternative exemplary embodiment of tile utilizing a coating of closed-cell foam to create a border around the tile. Bordered tile 200 is illustrated including tile 30 bounded on all four thin sides 38 of tile 30 by dampening coating 50. In one embodiment, such a bordered tile would be beneficial as being easier to ship than an encapsulated tile. Any dampening material could be later applied to the tile or to the substrate to enable bordered tile 200 to perform according to the disclosed tile system.

FIG. 5 illustrates an alternative exemplary embodiment of tile utilizing a closed-cell foam appliqué to dampen the tile. Tile 30 is illustrated, initially provided as an unmodified tile. Appliqué 250 is illustrated, constructed of a dampening material and ready to apply to a bottom side of tile 30. Appliqué 250 is envisioned to take any number of forms, including a layer of closed cell foam applied to a thin sheet of adhesive paper. In another embodiment, appliqué 250 can take the form of a sprayed on rubberized material.

One exemplary particular appliqué can include a particular version of the Nitto 5790S-series dampening tape, disclosed herein. Nitto 5790S10 foam is provided in an exemplary 1300 mm width. In accordance with the present disclosure, this material can be provided as a flat foam product with adhesive pre-applied to the foam with pull-away paper backing preserving the adhesive prior to attachment to the tile. The 1300 mm wide product can be easily cut to size for application to the tile. This particular tape is exemplary of foam tape that can be utilized according to the disclosure, although a number of different foam tapes and other materials can be similarly used. The disclosure is not intended to be limited to the particular examples provided

FIG. 6 illustrates an alternative exemplary embodiment of tile utilizing the bordered tile of FIG. 4 in combination with a sheet of dampening material between the tile and the substrate. Embodiments are disclosed herein wherein dampening material is applied to individual tiles. FIG. 6 illustrates and exemplary separate layer 300 of dampening material that does not need to be applied to each individual tile. Layer 300 can be applied to substrate 310 before bordered tile 200 is installed Tiles without any dampening material can be utilized with layer 300, for example, with a flexible caulking material applied after the tiles are placed upon layer 300. Encapsulated tiles can be used, installed above layer 300. In FIG. 6, a bordered tile 200 including tile 30 surrounded in all four thin sides with dampening material is illustrated.

FIG. 7 illustrates exemplary removal of a first set of dampened tiles and simultaneous installation of a second set of dampened tiles. Tiles 30a illustrate a first color of tile. Tiles 30b illustrate a second color of tile. Tiles 30a and 30b can be coated or encapsulated with the disclosed materials to dampen the tiles. Alternatively or additionally, a layer or sheet of dampening material may be installed upon substrate 310 prior to the installation of the tiles. Due to the ease of installation and removal of the tiles, for example, utilizing a suction handle device 350 to selectively adhere to the top surfaces of the tiles, one may conveniently remove tiles 30a and replace them with tiles 30b. Without having to tear away grout and adhesive from the substrate, a user can easily change one set of tiles for another set. A temporary display at a trade show or in a mall kiosk can conveniently include an seemingly permanent tile floor which can easily be removed when the event is over. A hotel can change tile patterns on the lobby floor based upon a season or a particular event being held at the hotel. A home owner could easily set down different tile in a bathroom or kitchen based upon dinner company or houseguests. The dampened tile disclosed herein provide for easy installation and removal of the tile. The flexible dampening material on the tile or sheet under the tile provide stability and durability to the tiles in use without the use of traditional grout and adhesives.

FIG. 8 illustrates an exemplary tile configuration including transitions to another floor surface and a wall surface. Tiles 30 including coatings 20 are illustrated applied to exemplary rubberized dampening sheet 300 upon substrate 310. Coatings 20 are illustrated on the bottoms and left and right sides of tiles 30, as illustrated. A coating 20 could additionally be included on the visible thin front sides of tiles 30. A neighboring floor surface 360 is illustrated. Floor surface 360 is in this example inadequate to contain tiles 30 bordering floor surface 360. In order to keep tiles directly bordering surface 360 stationary and stable, adhesive 380 can be applied at the transition between tile 30 and substrate 310. Additionally, a neighboring wall surface 372 is illustrated. Exemplary border trim 370 is illustrated mounted above tile 30 at the transition with wall surface 372. As a result of the stabilizing effect of trim 370, no adhesive 380 may be necessary at the transition between tiles 30 and wall surface 372. Adhesive 380 can include silicone or a similar substance preventing water intrusion at the transition. Similar transitions and use of stabilizing adhesive or silicone are envisioned, and the disclosure is not intended to be limited to the particular examples provided herein.

The disclosed tile system enables use of a temporary display construction method in accordance with the disclosure. Any merchant may quickly and inexpensively set up a temporary tile floor that seems to be a permanent construction. Exemplary show booths can be set up for exhibitions, outdoor markets, and fairs. The result is an easy to clean, durable, hygienic temporary surface. An exemplary restaurant, coffee shop, or bar could set up flooring on a sidewalk or parking lot for a one day summer fair or sporting event, providing customers with a professionally crafted tile floor, and then the temporary floor can be easily removed after the event. An exemplary bar could set up a tile surface on an outside wooden deck. A restaurant with a damaged floor could place the disclosed tile system over the damaged floor until the repairs can be arranged in order to remain open in the meantime. A number of exemplary uses of the disclosed system are envisioned, and the disclosure is not intended to be limited to the examples provided.

An exemplary process for installing a temporary floor for a booth or a temporary kiosk includes selecting a sufficiently flat substrate surface; thoroughly cleaning the flat surface; applying a rubberized or polymerized sheet (if one is being used in addition to or in the alternative to a tile with dampening material applied to the bottom of the tile;) laying down untreated tile upon the sheet or laying down treated dampened tile according to the disclosure; securing side tiles of the floor pattern (using an adhesive such as silicone or using a transition bracket or transition strip;) using and cleaning the surface for the commercial event or activity; removing the tile and associated transition materials; removing the sheet from the substrate if applied; and cleaning the substrate surface according to methods known in the art.

In addition to commercial uses, the disclosed tile system can be used in temporary, permanent, or semi-permanent residential flooring applications. For example, the disclosed tile system could be used on outdoor and backyard to cover a cement patio or a wood deck or even a grass area (meeting the flatness requirements) around pools and gazebos. If a wedding reception were being held at a house, an outside patio could be turned into a tent area with a fine tile floor which could be removed the next day. If a kitchen floor includes a fairly flexible wooden surface that would cause normal grout to crack and fail under normal use, the disclosed tile could be used to provide a tile surface over the wooden surface. A number of exemplary uses of the disclosed system are envisioned, and the disclosure is not intended to be limited to the examples provided.

The disclosed tile system, in several exemplary embodiments, is easy to install, temporary, reusable, or reusable flooring that may be removed shortly after being installed or may not ever be removed. Unlike anything else on the market, people may want the floating floor for their permanent flooring because it is easy to install, but knowing they can later remove for fashion change, in a water event like a flood, etc. . . . it allows removal, drying and replacement of the flooring, sell the house take your flooring with you. No adhesive, grout, side groves or click system is required. The user can lay the tile as disclosed and allow damping material to provide movement and edge stability between the tiles and the subfloor.

Whereas undampened tile laid upon a substrate such as a flat concrete surface, due to small inconsistencies in the tile or the substrate, would be prone to movement, rocking, and cracking, use of a dampened tile or a sheet of dampening material permits the improved tile to lay flat upon the substrate in spite of the inconsistencies. FIG. 12 illustrates a prior art tile placed upon a substrate including a bump upon the substrate, the tile placed upon the substrate without any grout. Tile 700 is laid upon substrate 710. Substrate 710 is illustrated including bump 705 representing an inconsistency that prevents a bottom surface of tile 700 from laying flat upon substrate 710. Because tile 700 of FIG. 12 does not lay flat upon substrate 710, the tile is prone to movement, rocking, and/or cracking as weight is applied to a top surface of the tile. FIG. 13 illustrates the prior art tile of FIG. 12, with a crack forming in the tile. Tile 700 is illustrated laid upon substrate 710 including bump 705. Crack 715 has formed in tile 700, as pedestrian traffic or other weight applied to a top of tile 700 broke the tile.

FIG. 14 illustrates the dampened tile of FIG. 2 placed upon a substrate including a bump upon the substrate, with the dampening material of the tile deforming to permit the tile to lay flat upon the substrate in spite of the bump. Tile 30 is illustrated including dampening material 20 applied to the thin sides and a bottom surface of tile 30. Tile 30 is laid upon substrate 810 including bump 805. The illustration includes magnified portion 802, illustrating bump 805 displacing a portion of dampening material 20. Because the dampening material can deform and displace away from bump 805, tile 30 lays flat upon substrate 810 in spite of bump 805.

FIG. 9 illustrates through a flow chart an exemplary process for installing a temporary tile floor with dampened tiles. Process 400 starts at step 402. At step 404, a conforming sub-surface or substrate area, for example, meeting criteria for flatness, is identified requiring tile installation. At step 406, the sub-surface area is cleaned to remove excess inconsistencies. At step 408, a tile with a dampening coating upon a bottom side of the tile is installed over the sub-surface area. Step 408 is repeated over and over again until the area is covered with dampened tiles. At step 410, an exemplary event which prompted installation of the tile is held. At step 412, the dampened tiles are picked up one by one until the sub-surface area is exposed. At step 414, the process ends.

FIG. 10 illustrates through a flow chart an exemplary process for installing a temporary tile floor with a layer of dampening material installed under the tiles. Process 500 starts at step 502. At step 504, a conforming sub-surface or substrate area, for example, meeting criteria for flatness, is identified requiring tile installation. At step 506, the sub-surface area is cleaned to remove excess inconsistencies. At step 508, a sheet of dampening material, for example, including foam sheet according to the disclosure, is laid upon the sub-surface. At step 510, an unimproved tile is installed over the dampened sheet. Step 510 is repeated over and over again until the area is covered with tiles. At step 512, an exemplary event which prompted installation of the tile is held. At step 514, the tiles are picked up one by one until the sheet is exposed. At step 516, the sheet of dampening material is picked up. At step 518, the process ends.

FIG. 11 illustrates through a flow chart an exemplary process for installing a temporary tile floor with dampened tiles and a layer of dampening material installed under the tiles. Process 600 starts at step 602. At step 604, a conforming sub-surface or substrate area, for example, meeting criteria for flatness, is identified requiring tile installation. At step 606, the sub-surface area is cleaned to remove excess inconsistencies. At step 608, a sheet of dampening material, for example, including foam sheet according to the disclosure, is laid upon the sub-surface. At step 610, a tile with a dampening coating upon a bottom side of the tile is installed over the sub-surface area. Step 610 is repeated over and over again until the area is covered with dampened tiles. At step 612, an exemplary event which prompted installation of the tile is held. At step 614, the dampened tiles are picked up one by one until the sub-surface area is exposed. At step 616, the sheet of dampening material is picked up. At step 618, the process ends.

The disclosure has described certain preferred embodiments and modifications of those embodiments. Further modifications and alterations may occur to others upon reading and understanding the specification. Therefore, it is intended that the disclosure not be limited to the particular embodiment(s) disclosed as the best mode contemplated for carrying out this disclosure, but that the disclosure will include all embodiments falling within the scope of the appended claims.

Claims

1. A process for installing a temporary tile floor surface, comprising:

identifying a substrate surface requiring installation of the temporary tile floor surface; and

installing a dampened tile system comprising a dampening material between a bottom surface of tiles of the dampened tile system and the substrate surface.

2. The process of claim 1, wherein installing the dampened tile system comprises installing the tiles comprising a dampening material adhered to the bottom surface of the tiles.

3. The process of claim 1, wherein installing the dampened tile system comprises installing a sheet of dampening material between the tiles and the substrate surface.

4. The process of claim 3, wherein installing the dampened tile system further comprises installing the tiles, each tile comprising a dampening material adhered to at least one surface of the tile.

5. A process for installing a temporary tile floor surface, comprising:

identifying a substrate surface requiring installation of the temporary tile floor surface; and

laying dampened tiles comprising a ceramic tile and a dampening material adhered to a bottom surface of the ceramic tile upon the substrate surface.

6. A process for installing a temporary tile floor surface, comprising:

identifying a substrate surface requiring installation of the temporary tile floor surface; and

laying dampened tiles comprising a ceramic tile and a dampening material adhered to a bottom surface and at least one thin side surface of the ceramic tile upon the substrate surface.