ANTI-SLIP FLOOR TILE ASSEMBLY WITH INLAID TILES AND METHOD OF MAKING AN ANTI-SLIP FLOOR TILE

Abstract

A floor tile is disclosed that includes a metal frame, a backing plate, and a plurality of tiles assembled to the metal frame and the backing plate. The metal frame defines a plurality of openings, and has a thickness T. The openings are separated by a plurality of connected strips that are coated with an anti-slip coating. The backing plate is attached to a bottom side of the metal frame. The plurality of tiles are each assembled into one of the plurality of openings with the backing plate supporting the tiles. The tiles have a height H that is less than T and have a top surface that is recessed below the anti-slip coating on the connected strips.

Description

TECHNICAL FIELD

This disclosure is directed to a method of making an anti-slip floor tile and the floor tile made by the method.

BACKGROUND

Floor tiles are used in a wide variety of applications and are used for their aesthetic appeal, durability, and ease of installation. Floor tile products may be made of ceramic, glass, granite, marble, wood and other hard surface materials. One problem with such floors is that they may become slippery when wet when used in areas such as building lobbies or commercial kitchens. These types of flooring applications are frequently exposed to surface hazards such as water and spilled food, beverages, and cooking products.

This disclosure is directed to solving the above problems and other problems as summarized below.

SUMMARY

According to one aspect of this disclosure, a floor tile is disclosed that includes a metal frame, a backing plate, and a plurality of tiles assembled to the metal frame and the backing plate. The metal frame defines a plurality of openings, and has a thickness T. The openings are separated by a plurality of connected strips that are coated with an anti-slip coating. The backing plate is attached to a bottom side of the metal frame. The plurality of tiles are each assembled into one of the plurality of openings with the backing plate supporting the tiles. The tiles have a height H that is less than T and have a top surface that is recessed below the anti-slip coating on the connected strips.

According to other aspects of this disclosure, the floor tile may further comprise an adhesive applied between the tiles and both the plurality of openings and the backing plate that bonds the tiles to the openings and backing plate.

The metal framework may be aluminum and the anti-slip coating may be a stainless steel coating.

The connected strips may extend in a linear array or may be curved. The connected strips may be formed from a single panel by forming holes in a blank or may be formed separately and then welded together.

The anti-slip coating is a metal coating that is metalized (applied by plasma stream deposition) on the plurality of intersecting strips. The anti-slip coating may be applied by other metal-on-metal application technique provided that the coating provides a textured surface.

According to another aspect of this disclosure, a method is disclosed for making a floor tile. The method includes the following steps beginning with the step of providing a metal frame defining a plurality of openings. Applying an anti-slip coating to an upper surface of the metal frame. Attaching a base plate to a bottom surface of the metal frame. Applying an adhesive between the tiles and both the openings in the metal frame and the base plate. Assembling a plurality of tiles with each tile being assembled into one of the plurality of openings to secure the tiles in the openings on the base plate with a top surface of the tiles being recessed relative the upper surface of the metal frame.

According to other aspects of the method, the method may also include the step of punching the plurality of openings to form the metal frame.

The step of applying the anti-slip coating may be performed by spraying a molten metal coating on the top surface of the metal frame.

The metal framework is preferably made of aluminum, or an aluminum alloy, but may also be formed of another metal such as stainless steel, steel, copper, brass, or the like. The anti-slip coating is preferably stainless steel or a stainless steel alloy but may also be formed of another metal.

According to another aspect of this disclosure, a floor tile is disclosed that includes a metal framework that defines a plurality of connected strips. The plurality of connected strips are coated with an anti-slip coating. A plurality of tiles are assembled to the metal framework between the plurality of connected strips. The tiles have an upper surface that is recessed below the top surface of the connected strips when installed.

According to other aspects of the floor tile, the tiles may be ceramic tiles, glass tiles, marble tiles, wood tiles, or granite tiles.

The plurality of tiles may be attached to the metal framework and the base plate by an adhesive.

The metal framework may define openings that extend from a bottom surface of the metal framework to the top surface of the metal framework.

The above aspects of this disclosure and other aspects will be described below with reference to the attached drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a floor tile assembly made according to one embodiment of this disclosure.

FIG. 2 is an exploded perspective view of a floor tile frame, a base plate and a plurality of tiles aligned with recesses formed in the floor tile frame.

FIG. 3 is a top plan view of a base plate and a floor tile frame that has an anti-slip coating applied to a top surface.

FIG. 4 is a top plan view of a floor tile including the base plate and the coated floor tile frame shown in FIG. 3 and includes tiles disposed in the openings defined by the floor tile frame.

FIG. 5 is a cross-section taken along the line 5-5 in FIG. 3.

FIG. 6 is a cross-section taken along the line 6-6 in FIG. 4.

FIG. 7 is a flow chart illustrating the steps of a method of making and installing the floor tile shown in FIGS. 1-6.

DETAILED DESCRIPTION

The illustrated embodiments are disclosed with reference to the drawings. However, it is to be understood that the disclosed embodiments are intended to be merely examples that may be embodied in various and alternative forms. The figures are not necessarily to scale and some features may be exaggerated or minimized to show details of particular components. The specific structural and functional details disclosed are not to be interpreted as limiting, but as a representative basis for teaching one skilled in the art how to practice the disclosed concepts.

Referring to FIGS. 1 and 2, a floor tile assembly 10 is illustrated in FIG. 1 that includes a metal framework 12 (hereinafter “framework”) and a plurality of tiles 14. The framework 12 may also be referred to as a metal tile support panel, or a metal tile. The metal framework is supported on a base plate 16 that also supports the tiles 14. The tiles 14 are assembled to the framework 12 and permanently affixed with an adhesive (not shown) applied between the framework 12, the base plate 16 and the tiles 14. An anti-slip coating 18 is applied to the framework by spraying molten metal on an upper surface 20 of the framework 12. The molten metal spray may also be applied to the base plate 16.

As shown in FIGS. 3 and 4, the framework 12 is preferably made of aluminum or an aluminum alloy to minimize the weight of the floor tile assembly 10. Alternatively, the framework 12 may be made of steel, stainless steel, or another metal or metal alloy. A plurality of openings 22 are cut in the upper surface 20 of the framework 12. The openings 22 as shown are square, but the openings 22 may be rectilinear, circular, ovate, or irregular in shape depending upon the shape of the tiles 14 that are assembled to the framework 12. The openings 22 are separated by strips 24 formed on the upper surface 20 that are coated with the anti-slip coating 16 and is shown by stippling on the upper surface 20. The openings 22 are each adapted to receive a tile 14.

The anti-slip coating 18 is preferably made of a stainless steel alloy to provide a surface that does not corrode and provide a hard, durable surface covering the framework 12. The stainless steel alloy is preferably applied to the upper surface 20 by spraying molten stainless steel from welding rods (not shown) in an arc-welding process onto the upper surface 18. The process is described in applicant's prior U.S. Pat. No. 5,711,118 the disclosure of which is incorporated by reference.

The tiles 14 are preferably ceramic tiles that provide a durable surface and offer flexibility in design and an aesthetically pleasing appearance. Alternatively, the tiles 14 may be made of marble, glass, wood, fiberglass, plastic, granite, or the like. The tiles 14 may be rectilinear, circular, ovate, or irregular in shape. The tiles 14 are shown with small dots on their top surface in FIG. 4.

FIG. 5 is a cross-section taken through the line 5-5 in FIG. 3. The tiles 14 are shown to be disposed in the openings 22 in FIG. 6. The anti-slip coating 18 is applied to the framework 12 and is above the surface of the tiles 14 when the tiles are attached to a floor to assure that a person walking on the floor tile assembly 10 (shown in FIG. 1) will contact the anti-slip coating 18 on the strips 24 formed between the tiles 14.

Referring to FIGS. 5 and 6, the openings 22 have a depth D and the tiles 14 have a height H that is less than D The tiles have a top surface 26 that is recessed below the anti-slip coating 18 on the strips 24.

The tiles 14 are secured to the framework 12 by a conventional tile adhesive (not shown) applied between the tiles 14 and the openings 22. The adhesive is primarily applied between a bottom surface 28 of the tiles 14 and to a supporting upper surface 30 of the openings 22. The upper surface 30 provides support for the tiles 14. Any gaps between the lateral sides 32 of the tiles and the openings 22 may be filled with adhesive.

Referring to FIG. 7, a method of making the floor tile assembly of FIGS. 1-6 is illustrated by a flow chart. According to the method, a metal blank is provided at 40 that is then punched at 42 to form the plurality of openings 22 in the framework 12. The upper surfaces 20 of the framework 12 is abraded at 44 by shot-blasting to clean and roughen the upper surfaces 20. At 46, a molten metal anti-slip coating 18 is sprayed on an upper surface of the framework 12 and may also be applied to the base plate below the openings 22. At 52, an adhesive is applied between the tiles 14 and the openings 22 at 50 and the tiles 14 are assembled into the openings 22. An optional aspect of the method is that the portion of the anti-slip coating 18 applied to the base plate 16 exposed in the openings 22 increases the roughness of the base plate and improves the adhesion of the tiles to the framework 12. The adhesive is cured at 54 and, after curing, the floor tiles 10 are attached to a floor with a tile adhesive at 56.

The embodiments described above are specific examples that do not describe all possible forms of the disclosure. The features of the illustrated embodiments may be combined to form further embodiments of the disclosed concepts. The words used in the specification are words of description rather than limitation. The scope of the following claims is broader than the specifically disclosed embodiments and also includes modifications of the illustrated embodiments. In addition, the features of various implementing embodiments may be combined to form further embodiments of the invention.

Claims

1. A floor tile comprising: a metal frame defining a plurality of openings, the metal frame having a thickness T, wherein the openings are separated by a plurality of connected strips, and wherein the plurality of connected strips are coated with an anti-slip coating;a backing plate attached to a bottom side of the metal frame; anda plurality of tiles each assembled into one of the plurality of openings with the backing plate supporting the tiles, wherein the tiles have a height H that is less than T, and wherein the tiles have a top surface that is recessed below the anti-slip coating on the connected strips.

2. The floor tile of claim 1 further comprising: an adhesive applied between the tiles and both the plurality of openings and the backing plate, wherein the adhesive bonds the tiles into the openings.

3. The floor tile of claim 1 wherein the metal framework is aluminum and the anti-slip coating is a stainless steel coating.

4. The floor tile of claim 1 wherein the connected strips extend in a linear array.

5. The floor tile of claim 1 wherein the connected strips are curved and intersect with each other to define the openings.

6. The floor tile of claim 1 wherein the anti-slip coating is a metal coating that is flame sprayed on the plurality of intersecting strips.

7. A method of making a floor tile comprising: providing a metal frame defining a plurality of openings;applying an anti-slip coating to an upper surface of the metal frame;attaching a base plate to a bottom surface of the metal frame;applying an adhesive to the tiles; andassembling a plurality of tiles each into one of the plurality of openings and securing the tiles in the openings and on the base plate with an adhesive, wherein a top surface of the tiles is recessed relative the upper surface of the metal frame.

8. The method of making a floor tile of claim 7 further comprising: punching the plurality of openings to form the metal frame.

9. The method of making a floor tile of claim 7 wherein the step of applying the anti-slip coating is performed by spraying a molten metal coating on the top surface of the metal frame.

10. The method of making a floor tile of claim 7 wherein the metal framework is aluminum.

11. The method of making a floor tile of claim 7 wherein the anti-slip coating is stainless steel.

12. A floor tile comprising: a metal tile including a plurality of connected strips defining a plurality of openings, the connected strips having a top surface, wherein the top surfaces of the plurality of connected strips are coated with an anti-slip coating; anda plurality of tiles disposed each in one of the openings in the metal tile between the plurality of connected strips, wherein the tiles have an upper surface that is recessed below the top surface of the connected strips in an installation orientation.

13. The floor tile of claim 12 wherein the plurality of tiles are selected from the group consisting of: ceramic tiles;glass tiles;marble tiles;wood tiles; andgranite tiles.

14. The floor tile of claim 12 wherein the metal tile is aluminum and the anti-slip coating is stainless steel.

15. The floor tile of claim 12 wherein the plurality of tiles are attached to the metal tile and the base plate by an adhesive.

16. The floor tile of claim 12 wherein the openings defined by the connected strips extend from a bottom surface of the metal tile to the top surface of the metal tile.