Arch-ribbed tile system

Abstract

A tile for forming a floor covering includes a perimeter support wall, a top surface, interconnecting structure for releasably connecting with adjacent tiles, and intermediate upstanding grid structure. The intermediate upstanding grid structure comprises a repeating pattern of polygonal units, such as hexagons, having sidewalls extending from a bottom of the tile to the underside of the top surface. An arched support structure is disposed within each polygonal unit, connecting an upper portion of the sidewalls of each polygonal unit with the underside of the top surface. The arched configuration reduces stress concentrations at the junction of the arched support structure and the sidewalls.

Description

PRIORITY CLAIM [0001] This application claims priority from U.S. provisional patent application Ser. No. 60 / 482,104, filed on Jun. 24, 2003.BACKGROUND OF THE INVENTION [0002] 1. Field of the Invention [0003] The present invention relates generally to floor tile systems. More particularly, the present invention relates to an interlocking floor tile system having a support system of hexagonal cells and arched support ribs disposed below the top surface of the tile to improve the dispersion of forces applied to the tile and to reduce irregularities in the top surface. [0004] 2. Related Art [0005] Numerous types of flooring have been used to create multi-use surfaces for sports, as well as for other purposes. In recent years, the use of modular flooring assemblies made of synthetic materials has grown in popularity. Modular flooring systems generally comprise a series of interlocking tiles that can be permanently installed over a subfloor, such as concrete or wood, or temporarily laid d...

AI Technical Summary

Benefits of technology

[0010] It has been recognized that it would be advantageous to develop an improved floor tile that provides more even distribution of loads, and eliminates stress concentrations that can lead to premature failure of the tile.

[0011] It would also be advantageous to develop a floor tile design that reduces the risk of warping and other distortions, while at the same time reducing the amount of plastic material needed to produce a single tile.

[0012] The invention advantageously provides a tile for forming a floor covering, comprising a perimeter support wall, a top surface connected atop the perimeter support wall, and intermediate upstanding grid structure. The perimeter support wall defines an outer boundary of the tile, and includes interconnecting structure for releasably connecting with interconnecting structure of adjacent tiles to form a continuous floor surface. The intermediate upstanding grid structure is internally coupled to the perimeter support wall and within the outer boundary, and comprises a repeating pattern of hexagon units extending in parallel orientation substantially across an entire area of the tile within the outer boundary, the hexagon units having sidewalls extending from a bottom of the tile to the underside of the top surface. A support structure, connecting an upper portion of the sidewalls of each hexagon unit with the underside of the top surface, is disposed within each hexagon unit. The support structure has an arched configuration so as to reduce stress concentrations at the junction of the support structure and the sidewalls.

Problems solved by technology

Additionally, these flooring assemblies generally require little maintenance as compared to other flooring, such as wood.

One problem that has plagued modular floor covering systems is uneven point load distribution.

Uneven load distribution can make the floor feel unnatural to those using it, and can result in premature failure of the flooring tiles.

These problems have limited the use of these flooring systems.

If the floor feels unnatural, those using the facility will often object to the flooring tiles and / or return to more conventional floor materials, such as wood or concrete.

Premature failure of the flooring tiles also increases the likelihood that the modular flooring will be replaced by other alternatives.

However, a substantial cost is involved with the quantity of materials needed for the equilateral wall structure of an isogrid tile.

One problem with this hexagon tile is that it experiences stress concentrations at the juncture of each cross rib with the walls of the hexagon.

This is a particular problem when point loads are imposed on a tile.

The stress concentration contributes to cracking and failure of the tile where the cross ribs meet the corresponding hexagon wall.

Warping and dimpling of the top surface are also common problems with injection molded polymer floor tiles.

The prior art has not adequately addressed these problems.

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