Self Aligning Plastic Wall Tile System

Abstract

A system of self-aligning tiles has been devised with novel geometries of connectors and notches in the edges of these tiles to provide for assembly in all directions, both on vertical and horizontal surfaces. These connector mates define regular, parallel, gaps between adjacent tiles in which waterproof grout may be applied to protect the supporting wall. Decorative edge and corner tiles are supplied to enable flush edges; otherwise, gaps of width less than the width of the standard self-aligning tile are filled with partial tiles that are easily sawn with conventional saws to the required size from standard tiles. The tiles are manufactured using injection of thermoplastics into molds, and as such can bear patterns in relief on their cosmetic face. Secondary coatings can be applied to enhance the appearance and hardness of the cosmetic face. Repair of the tile wall after installation is enabled by the unique geometry of the tile connection couplings, allowing individual tiles to be removed and replaced without damaging the adjacent tile

1 . A self-aligning molded tile system comprising rectangular standard tiles and rectangular edge and corner tiles that assemble to each other, both on vertical and horizontal mounting surfaces, said tiles comprising:
 an outward-facing cosmetic face and, for said edge and corner tiles, additionally one or more cosmetic outer edges;   in addition to said cosmetic outer edges, vertical side walls that support said cosmetic face;   at least one horizontally-oriented rectangular notch through the lower portion of one or more said side walls, starting from the bottom edge   at least one hooked spacer to be assembled with said notch on an adjacent tile and of slightly less width than that of said notch, that is located flush with the bottom of at least one side wall that does not have said notches and projecting laterally from said side wall, said hooked spacer comprising a spacer portion of generally rectangular shape attached to said side wall that is of lesser height than that of said side wall yet of greater height than that of said notch and of a lateral dimension typical for the width of grout joints between tiles and with a fillet on the upper lateral edge; followed immediately by a lateral recessed portion of lesser height than said spacer portion and of slightly greater lateral dimension than the thickness of said side wall with said notch, such that clearance with the top of said notch is ensured at all times; followed immediately by a lateral hook portion, with a generally vertical wall projecting upwards from said recess coming to an end that is generally flush with the top of said spacer portion and with an outer surface starting flush with the bottom of said recess portion and curving upward to said end.   
     
     
         2 . The claim in  claim 1 , further that said hooked spacers and said notches of adjacent tiles facilitate assembly in all directions with a fixed tile also having said hooked spacers and said notches to ensure a self-aligning utility and to ensure uniform grout joints for the effective application of grout or sealant. 
     
     
         3 . The claim in  claim 1 , further that said tile system includes non-rectangular tiles, and includes tiles with vertical relief, textures, and coating treatments on said cosmetic face and edges. 
     
     
         4 . (canceled) 
     
     
         5 . The claim in  claim 1 , further that said tile system includes a non-integral self-aligning component which will assemble with the notches of two adjacent tiles to remain affixed to said mounting surface, comprising a generally rectangular spacer portion in the center, of lesser height than that of said side wall of said tile yet of greater height than that of said notch, and with fillets on the upper lateral edges; followed immediately by symmetric lateral recessed portions of lesser height than that of said spacer portion and of slightly greater lateral dimension than the thickness of said side wall with said notch, such that clearance with the top of said notch is ensured at all times; followed immediately by symmetric lateral hook portions, each with a generally vertical wall projecting upwards from said recess coming to an end that is generally flush with the top of said spacer portion and with an outer surface starting flush with the bottom of said recess portion and curving upward to said end. 
     
     
         6 . The claim in  claim 1 , further that said tiles include a plurality of ribs under said cosmetic face and edges that generally extend flush to the bottom of said tile.