GB2451514A - Tongue and groove tile - Google Patents

Abstract

An interlocking, resin/mineral composite tile 10 with four sides; two adjacent sides having a female recess 11 and two adjacent sides having a complementary male projection 12 to form a tongue and groove fitting. The projection preferably engages but does not reach the base of the recess, so as to provide a drainage channel and or space for a water seal. The tile is preferably rectangular or square and has a 45 degree chamfer 13 along each edge. The seal may be mastic.

Description

INTERLOCKING TILE

This invention relates to an interlocking tile, and particularly to a wall tile suitable for use in wet areas.

Typically a wet area, such as a shower room, has a wall surface of ceramic tiles. Such tiles are durable, attractive and easy to clean. Ceramic tiles are fixed one by one, generally in straight lines, and the inevitable gaps between adjacent tiles are filled with waterproof grout. Gaps are necessary to accommodate slight imperfections as a result of the manufacturing process, and to allow the tiled surface to be easily adapted to variations in the shape of the substrate to which the tiles are fixed.

Several problems are known with conventional tiling. Firstly a degree of skill is required not only to fix the tiles in a visually straight line, but also to maintain the front face of the tiles in a common plane. The gaps between adjacent tiles must be kept constant, for which separate spacers may be used. Lower tiles must be allowed to become fast before upper tiles are added, in order to prevent the lower tiles dropping. Wet trades are required for grouting, which is a time consuming and messy operation often impeded by tile spacers.

In use grout may become discoloured, may fall out, and especially in public areas may harbour bacterial contamination.

After conventional tiling is fixed, access to the substrate behind the tiling is generally impossible without destruction of the tiled surface, and it is almost impossible to replace a portion of tiling which has been removed in a manner which is unnoticeable.

For this reason even slight damage may require a large area to be re-tiled in order to give a satisfactory visual appearance. Lastly conventional tiles are relatively fragile and cannot be removed intact, once affixed; they are thus single use.

What is required is a solution to the aforementioned problems.

According to the invention there is provided an interlocking tile of resin/mineral composite, and comprising regular planar member having four sides, two adjacent sides having a female recess and two adjacent sides having a complementary male projection so as to permit side to side interlocking to form a planar multi-tile surface.

The term side to side' refers to the each of the four sides of a tile, and thus encompasses both lateral and upright interlocking, typically horizontal and vertical for a conventional tile grid.

Square tiles are preferred, but oblong or diamond shaped tiles also fall within the scope of the invention.

In a preferred embodiment, the male projection is sufficient to mechanically engage the corresponding female recess, but does not reach the base of the recess when fully engaged. Such a recess provides a drainage channel, and may also accommodate a seal, or a sealing material such as silicone mastic.

Preferably the front edge of the tile has a continuous chamfer, for example at 450* In this way adjacent abutting tiles simulate a grout groove, and thus preserve an aesthetically pleasing appearance whilst avoiding discolouration, deterioration and bacterial contamination.

Where the tile material has a surface coating, forming of the chamfer by removal of material may expose a different colour.

Other features of the invention will be apparent from the following description of a preferred embodiment illustrated by example only in the accompanying drawings in which: Fig. 1 is a plan view of a tile according to the invention.

Fig. 2 is a side elevation of the tile of Fig. 1.

Fig 3 is a plan view of the tile of Fig. 1.

Fig. 4 is a three quarter view from the front and above of the tile of Fig. I. Fig. 5 is an enlarged scrap view of the portion of Fig. 4 marked B' at 2:1.

Fig. 6 is a partially exploded view of an assembly of tiles.

Fig. 7 is an assembled view corresponding to Fig. 6.

Fig. 8 is an enlarged scrap view of the portion of Fig. 7 marked A', at 2:1.

Fig. 9 is an enlarged scrap view of the portion of Fig. 6 marked C', at 3:1.

With reference to the drawings, a tile 10 comprises a resin/mineral composite, for example of polyester resin and aluminium oxide or of polyester resin and quartz.

Such composite material is typically produced in sheets, is impermeable, durable and is readily cut and machined. The surface of the sheet material is of high quality, and suitable for use in wet areas, such as shower cubicles.

A typical tile, such as illustrated in Figs. 1-5 is cut from sheet material to the required size, for example 150 mm square. Two adjacent edges are machined with a groove 11, and the other two adjacent edges with a mating male upstand 12. The height of the upstand is less than the depth of the groove by a significant amount, for reasons which will become apparent.

The corner detail of Fig. 5 illustrates how the male and female features merge. Also illustrated in Fig. 5 is a continuous chamfer 13 formed around the edge of the intended front face of the tile, and typically at 450W Fig. 8 illustrates an edge section 14, which may be formed by machining a solid bar of material, or by extrusion. This edge section is preferably, but not necessarily of resin/mineral composite.

The edge section 14 includes a female recess 15 adapted to receive the male upstand 12 of a tile, and at right angles a male projection 16, adapted to engage within the groove 11 of a tile. Suitable external chamfers 17 are provided at the corners opposite the projection 16 so as to compliment the tile chamfer 13 and to avoid a sharp edge at an external corner 18.

Fig. 9 illustrates that the same edge section 14 may be used to define a right angled corner, and to locate the male and female forms of adjacent tiles.

The edge section 14 may be formed of a relatively soft material, such as wood or extruded plastic to permit both cutting to length, and cutting to eliminate the male projection 16 where it is not required.

Fig. 6 shows a typical tile assembly operation in which adjacent tiles are slotted into place, one by one, against a pre-flxed edge section 14. Further edge sections are provided at internal and external corners, and at the termination of a planar section.

Fig. 7 shows the assembly of Fig. 6 when complete.

It will be appreciated that the tiles of the invention slot together quickly, and without adhesive. An array of such tiles may be self-supporting. Once engaged the array provides a secure neat planar finish. If required a modest amount of adhesive may be provided to secure the back of some or all tiles to a substrate, but a lesser amount is required than for a conventional ceramic tile because such adhesive is not required to support the weight of tiling on a vertical wall.

It is envisaged that such tiling may be removed for re-use, or replaced after removal for access to the substrate. Resin/mineral composites are inherently more resilient and robust than conventional ceramic tiles.

The chamfer 13 mimics a conventional grout pattern without risk of discolouration or bacterial contamination. The tile assembly, as illustrated in Figs. 6 and 7 is considered substantially shower proof, but may be made fully waterproof by providing a seal or sealing material in the base of the tile groove 11. For example a suitable silicone mastic may be employed.

For this purpose the male upstand 12 is long enough to mechanically engage the groove 11, but does not reach the base of the groove so as to provide a space for a seal or sealing material. A suitable recess 19 is illustrated in Fig. 8 and may comprise 15- 30% of the depth of the groove, typically 2-3 mm for a 150 mm square tile. The male upstand 12 is a close fit widthways and may taper slightly towards the tip thereof to ensure tight interlocking.

It will be understood that even without a seal or sealant, the serpentine nature of the interlocking tile edges is a barrier to water ingress, and the recess 19 provides a vertical drainage channel which may be conveniently allowed to open adjacent a floor or other draining surface.

Claims (10)

1. Claims 1. An interlocking tile of resin/mineral composite, and comprising regular planar member having four sides, two adjacent sides having a female recess and two adjacent sides having a complementary male projection so as to permit side to side interlocking to form a planar multi-tile surface.
2. 2. A tile according to claim I having sides of equal length.
3. 3. A tile according to claim 2 wherein all sides are of the same length.
4. 4. A tile according to any preceding claim wherein the male projection is sufficient to mechanically engage the corresponding female recess, but does not reach the base of the recess when fully engaged.
5. 5. A tile according to claim 4 wherein said recess provides a drainage channel.
6. 6. A tile according to claim 4 or claim 5 wherein said recess accommodates a seal.
7. 7. A tile according to claim 6 wherein said seal is comprised of a sealing mastic.
8. 8. A tile according to any preceding claim wherein the front edge of the tile has a continuous chamfer.
9. 9. A tile according to claim 8 wherein said chamfer is 45° to the plane of the front face.
10. 10. A tile substantially as described herein with reference to the accompanying drawings.