Tile assemblies and method of installation

Abstract

The present invention relates in general to tile assemblies and more particularly to a method of installing a plurality of tile assemblies on a planar surface. Existing tile systems require a large number of steps and take place over a matter of days while one waits for various adhesives and grouts to set. The invention provides a tile system which is much quicker and less complex to install. It relies mainly on a composite tile comprising: a surface tile layer; a rigid carrier being generally the same shape and planar dimensions of the surface tile layer; and adhesive means for bonding the rigid carrier to the underside of the surface tile layer; the rigid carrier having edges extending beyond the edges of the surface tile layer, the rigid carrier edges being operable to matingly engage with complementary edges of carriers of others of the composite tiles.

1 . A composite tile for use with an improved tiling system for a planar surface, said composite tile comprising: 
 a surface tile layer;    a rigid carrier being generally the same shape and planar dimensions of said surface tile layer; and    adhesive means for bonding said rigid carrier to the underside of said surface tile layer;    said rigid carrier having edges extending beyond the edges of said surface tile layer, said rigid carrier edges being operable to matingly engage with complementary edges of carriers of others of said composite tiles.    
   
   
       2 . The composite tile of  claim 1 , wherein said edges of said rigid carrier comprise tongue and groove edges.  
   
   
       3 . The composite tile of  claim 1 , wherein said edges of said rigid carrier interlock with complementary edges of others of said composite tiles.  
   
   
       4 . The composite tile of  claim 1 , wherein said composite tile is a parallelogram in shape and said rigid carrier includes two male edges and two female edges.  
   
   
       5 . The composite tile of  claim 1 , further comprising a malleable gasket applied to at least one of said edges of said rigid carrier.  
   
   
       6 . The composite tile of  claim 5 , wherein said malleable gasket comprises a malleable gasket with such a thickness that when two of said composite tiles are laid adjacent to one another, said malleable gaskets will occupy the spacing between substantially parallel edges of said composite tiles.  
   
   
       7 . The composite tile of  claim 5 , wherein said malleable gasket comprises a malleable gasket with such a thickness that when two of said composite tiles are laid adjacent to one another, said malleable gaskets form a desired profile between said edges.  
   
   
       8 . The composite tile of  claim 5 , further comprising a malleable gasket applied to said rigid carrier edges, said malleable gasket having such a thickness slightly greater than half the width of said spacing between adjacent tile edges, such that when two of said composite tiles are laid adjacent to one another, said malleable gaskets will be in compression.  
   
   
       9 . The composite tile of  claim 5 , further comprising a malleable gasket applied to said rigid carrier edges, said malleable gasket having a thickness determined by the gap between an edge of said tile and a corresponding edge of an adjacent tile plus a further width to provide a compression factor, thereby compensating for variations in planar dimensions of said surface tile layer.  
   
   
       10 . The composite tile of  claim 1 , wherein said rigid carrier is comprised of more than one physical piece.  
   
   
       11 . The composite tile of  claim 1 , wherein said composite tile is a parallelogram in shape and said rigid carrier includes two edges with said malleable gaskets.  
   
   
       12 . The composite tile of  claim 1 , wherein said malleable gasket is formed by injecting a thermoset material into the spacing between substantially parallel edges of said composite tiles and form a desired profile between said edges.  
   
   
       13 . The composite tile of  claim 1 , wherein said malleable gasket is pre-formed and is mechanically inserted into the spacing between substantially parallel edges of said composite tiles and forms a desired profile between said edges.  
   
   
       14 . The composite tile of  claim 1 , wherein said rigid carrier edges interlock with juxtaposed edges of adjacent carriers using a strip magnet on one edge and a strip of ferromagnetic material on the other.  
   
   
       15 . The composite tile of  claim 1 , wherein said rigid carriers are attachable to a planar surface through the use of a hook-and-loop system.  
   
   
       16 . The composite tile of  claim 1 , wherein said rigid carriers are attachable to a planar surface through the use of a magnet and a ferromagnetic material system.  
   
   
       17 . The composite tile of  claim 1 , wherein said surface tile layer comprises a ceramic tile.  
   
   
       18 . The composite tile of  claim 1 , wherein said surface tile layer comprises a stone tile.  
   
   
       19 . The tile assemblies of  claim 1  wherein said malleable gasket is applied to said tile edges prior to the installation of said assemblies on said planar surface.  
   
   
       20 . A method of preparing a composite floor tile for use in an improved floor tiling system, said method comprising the steps of: 
 a) fabricating a rigid carrier, said rigid carrier: 
 being generally the same shape and planar dimensions of a surface tile layer; and  
 having edges extending beyond the edges of said surface tile layer;  
 said rigid carrier edges being fabricated to matingly engage with complementary edges of carriers of others of said composite floor tiles; and  
   b) bonding said rigid carrier to the underside of said surface tile layer.    
   
   
       21 . The method of  claim 20 , further comprising the steps of: 
 c) preparing a mold having length and width dimensions corresponding to those of said rigid carrier;    d) placing said rigid carrier with said surface tile layer thereon, into said mold; and    e) applying a malleable gasket between the edges of said surface tile layer and said mold, said malleable gasket being of sufficient dimensions to fill the gap between adjacent composite tiles when installed, with an additional compression factor.    
   
   
       22 . The method of  claim 21 , wherein said step e) comprises the step of applying a liquid gasket compound between the edges of said surface tile layer and said mold, which will set up to form a malleable gasket.  
   
   
       23 . A composite tile for use with an improved tiling system for a planar surface, said composite tile comprising: 
 a surface tile layer;    a rigid carrier being generally the same shape and planar dimensions of said surface tile layer;    said rigid carrier having edges extending beyond the edges of said surface tile layer, said rigid carrier edges being operable to matingly engage with complementary edges of carriers of others of said composite tiles;    adhesive means for bonding said rigid carrier to the underside of said surface tile layer; and    a malleable gasket applied to at least one of said edges of said rigid carrier, said malleable gasket being applied to said tile edges prior to the installation of said assemblies on said planar surface.    
   
   
       24 . A method of preparing a composite floor tile for use in an improved floor tiling system, said method comprising the steps of: 
 a) fabricating a rigid carrier, said rigid carrier: 
 being generally the same shape and planar dimensions of a surface tile layer; and  
 having edges extending beyond the edges of said surface tile layer;  
 said rigid carrier edges being fabricated to matingly engage with complementary edges of carriers of others of said composite floor tiles; and  
   b) bonding said rigid carrier to the underside of said surface tile layer;    c) preparing a mold having length and width dimensions corresponding to those of said rigid carrier;    d) placing said rigid carrier with said surface tile layer thereon, into said mold; and    e) applying a malleable gasket between the edges of said surface tile layer and said mold, said malleable gasket being of sufficient dimensions to fill the gap between adjacent composite tiles when installed, with an additional compression factor.