US20040255547A1

US20040255547A1 - Method of forming a tiled floor

Info

Publication number: US20040255547A1
Application number: US10/488,333
Authority: US
Inventors: David Flowers
Original assignee: Flowers David James
Current assignee: REDISET Pty Ltd
Priority date: 2001-08-31
Filing date: 2002-09-02
Publication date: 2004-12-23
Also published as: GB0404465D0; WO2003018934A1; NZ531452A; GB2394971B; GB2394971A; AUPR740301A0

Abstract

A method of forming a tiled floor including the steps of (a) fastening a plurality of base modules (310) having a contoured top surface (330) to a ground surface and (b) laying tiles on the modules so that the surface of the tiles reflects the contoured surface (330) of the modules (310). In one form, the modules (310) are formed from an open grid which is filled by pouring concrete and any excess concrete scarped from the contoured top surface (330) of the grid before tiles are laid.

Description

FIELD OF THE INVENTION

This invention relates to a method of forming a tiled floor.

BACKGROUND OF THE INVENTION

The construction of tiled concrete floors for wet areas, such as in bathrooms, is common. The usual method by which such floors are constructed is for wet concrete to be poured and floated to form a floor pad. Special wet areas such as shower recesses are then shaped by hand trowelling to create a slope in the concrete pad leading toward a floor waste outlet. Titles are then laid on the concrete to complete the floor.

The problem with such forming is that they are highly dependent on the skill of the worker forming the concrete pad. Shower recesses are designed to allow water to flow towards the floor waste outlet that is usually located centrally in the shower recess. If an incorrectly shaped slope is present, water will tend to pool in an unwanted area. The problem is exacerbated when floor tiles are laid over the concrete.

The above problem also becomes more difficult to solve when the application is for an upstairs and/or timber floor system where preparation for waterproofing and mixing of sand and cement at the site is required. Mixing concrete on upper floor levels involves carrying heavy bags of mixture which can contribute to a heavy and strenuous workload often resulting in industrial accidents and back problems. There is also additional time involved in cleaning up the mixing tools necessary and the work areas.

OBJECT OF THE INVENTION

It is therefore an object of the invention to overcome or alleviate one or more of the above disadvantages or provide the consumer with a useful or commercial choice.

SUMMARY OF THE INVENTION

In one form, although not necessary the only or broadest form, the invention resides in a method of forming a tiled floor, the method including the steps of:

fastening a plurality of tiling base modules onto a ground surface, said tiling module comprising a base having a top surface and a bottom surface; and

laying tiles on said top surface of said tiling modules so that the contour of tiles reflects the contour of the top surface of the tiling module.

At least one of the tiling modules may be located over a floor waste outlet. Preferably, the tiling module may have a top surface that is inclined toward said floor waste outlet.

The tiling modules are formed from an open grid. In this instance, concrete may be poured over the module and any excess concrete scraped from the top surface of the module. The concrete is then allowed to set so that the contour of the top surface is also reflected on the concrete.

Alternately, the tiling modules may have a solid top surface. The tiles may be laid directly onto the top surface without the need for concreting.

The modules may be fastened to the floor using adhesives such as glue or mechanical fasteners such as, screws or nails.

In another form, the invention resides in a tiling module for forming a tiled floor, the tiling module comprising:

a base having a bottom surface and top surface;

said bottom surface able to be fastened to a ground surface and said top surface allowing tiles to be laid onto said top surface;

wherein said top surface is contoured to reflect the desired contour of laid tiles.

The base may be formed from an open grid. Alternately, the base may be solid. Still alternately, the base may be formed from a combination of a grid and a solid top surface.

An aperture may be through the base for location of structures such as a floor waste outlet. The top surface may be inclined toward the aperture.

The module may have interconnecting elements adapted to allow interconnection of adjoining modules.

Fastening means may be provided to allow the tiling modules to be fastened to the floor using adhesives such as glue or mechanical fasteners such as, screws or nails. For example, holes may be provided on the base for locating of mechanical fasteners.

Suitably the base has frangible areas to allow portions to be broken off and removed. In the alternative, the base may be made from material that can be cut.

Preferably the modules are fabricated from a corrosion resistant material such as aluminium, stainless steel, galvanised iron or plastic.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the invention, by way of example only, will be made with reference to the accompany drawings in which: [0024]
FIG. 1 is a perspective view of a filed floor formed from tiling modules; [0025]
FIG. 2 is a partial side view of the tiled floor according to FIG. 1; [0026]
FIG. 3 is a plan view of tiling modules used in the floor of FIG. 1; [0027]
FIG. 4 is a perspective view of a surround tiling module according to a first embodiment of the invention; [0028]
FIG. 5 is a perspective of a waste tiling module according to a first embodiment of the invention; [0029]
FIG. 6 is a side view of the joined tiling modules of FIG. 4 and FIG. 5; [0030]
FIG. 7 is a perspective view of a waste tiling module according to a second embodiment of the invention; [0031]
FIG. 8 is a plan view of the tiling module according to FIG. 1; [0032]
FIG. 9 is a side view of the tiling module according to FIG. 1; [0033]
FIG. 10 is a perspective view of a connector; [0034]
FIG. 11 is a perspective view of a surround tiling module according to a third embodiment of the invention; [0035]
FIG. 12 is a cross sectional side view of the surround tiling module of FIG. 11; [0036]
FIG. 13 is a top view of the surround tiling module of FIG. 11; [0037]
FIG. 14 is a bottom view of the surround tiling module of FIG. 11; [0038]
FIG. 15 is a perspective of a different waste tiling module according to a third embodiment of the invention; [0039]
FIG. 16 is a cross sectional side view of the surround tiling module of FIG. 15; [0040]
FIG. 17 is a top view of the surround tiling module of FIG. 15; [0041]
FIG. 18 is a bottom view of the surround tiling module of FIG. 15; [0042]
FIG. 19 is a side view of the joined tiling modules of FIG. 11 and FIG. 15.[0043]

DETAILED DESCRIPTION OF THE DRAWINGS

FIGS. 1 and 2 shows a [0044] tiled floor 1 incorporating adjacent floor tiling modules 10 shown in FIG. 3. The tiled floor 1 is formed by attaching the tiling modules to a ground surface 2 and then laying tiles 3 onto the tiling modules 10. The tiled floor normally includes an aperture 50 for location of a floor waste outlet 4.
Each tiling module includes a base [0045] 20 having a top surface 30 and a bottom surface 40. The bottom surface 40 is flat to sit flush with the ground surface 2. The top surface is configured so that the when the tiles are laid onto the top surface 30 of the tiling module 10, the tiles reflect the contour of the top surface 30. Various tiling modules designs can be used depending various conditions such as load bearing capabilities, weight and ground surface.
FIGS. 4 and 5 show a [0046] surround tiling module 110 and a waste tiling module 210 designed for fitting to timber floors. In this embodiment, the tiling modules 110 and 210 are of a solid configuration made out of PVC, plastic, or a plastic composite materials that is lightweight and waterproof. The tiling modules 110 and 210 are able to support normal floor weights, are 30 mm high at its maximum and are designed as a 1 m×1 m square section.
Each of the [0047] tiling modules 110 and 210 is formed from a base 120 and 220 having a top surface 130 and 230 and a bottom surface 140 and 240.
[0048] Tiling module 110 has a top surface 130 that is inclined at a constant gradient throughout the length of the tiling module 110.
[0049] Tiling module 220 has an aperture 250 located adjacent the centre of the module for location around a floor waste outlet. Frangible portions 251 are located adjacent the aperture 250. The frangible portions are able to be broken to for a larger aperture 250 for larger floor waste outlets. The top surface 230 of tiling module 210 is inclined toward the aperture 250.
The [0050] tiling modules 110 and 210 are designed to be locked together using interlocking tongues 121 and 221 located on each of the modules. The tongues are interlocked as shown in FIG. 6.
A tiled floor is produced by first [0051] fastening tiling modules 120 and 230 to the timber floor using adhesive. The tiling modules are also interlocked together using respective tongues 121 and 221. The tiling modules 120 are 220 are cut and positioned to fit the shape of any area or room shape. Once the tiling modules are fitted, the tiles are laid onto the top surface 130 and 230 of respective tiling modules 110 and 210 to complete the tiled floor.
Any moisture/water, which inadvertently soaks through the tiles covering the tiling modules, is still be directed to flow into the region of the waste outlet without coming into contact with the timber floor itself. The advantage of the modular configuration is that timber floors will not have to be waterproofed except at their edges. The invention in combination with waterproof glue prevents moisture from getting through to a timber floor system. [0052]
Further, the tiles are laid quickly and effectively with the correct fall as reflected by contour of the [0053] top surface 130 and 230 of the tiling modules 110 and 210.
FIGS. [0054] 7 to 9 show a waste tiling module 310 for forming a concrete slab. The tiling module is formed from a base 320 having a top surface 330 and a bottom surface 340. The base 320 is made from polyvinylchloride. The base 320 is in the form of an open grid formed from vertical wall members 321 having holes 322 there between.
The [0055] top surface 330 of the tiling module 310 is inclined so that the top surface falls 330 toward the centre of the tiling module. A floor waste can be located through a centre hole 323. It should be appreciated that other similar tiling modules may be formed to obtain different falls as needed for other areas of a floor.
The [0056] tiling modules 310 come in 1 m×1 m square sections which link and lock together to construct a floor area of any size. The modules are linked and joined by plastic connector pieces 360 shown in FIG. 10. The connector has 361 adapted to accommodate ends of the vertical wall members of adjoining modules. The modules are fixed to reinforcement bars with connector clips (not shown) that click on the sides or comers of the module and click to the reinforcement bars. The module can also be tied the reinforcement bars with wire ties.
To construct a tiled floor, the [0057] tiling modules 320 are located over the areas of the floor including location over the floor waste outlet. Concrete is then poured over the tiling floor modules until the holes 322 are filled with concrete. A scraper is then used to scrape any excess concrete for the top surface 330 of the tiling modules 310. The concrete is then allowed to set. Tiles are then laid on the concrete and top surface 330.
The advantage with this tiled floor is that the tiling modules need not be load bearing. The concrete is load bearing but reflects the contour of the [0058] top surface 330. In turn, the laid tiles also reflect the contour of the top surface.
FIGS. [0059] 11 to 14 show a further embodiment of a surround tiling module 410. The surround tiling module is formed from a base 420 having a sold top surface 430 and a grid formed bottom surface 440. The tiling module is made from high density styrene and is load bearing.
A number of screw holes [0060] 460 are extend through the base 420 of the tiling module 410. The screw holes 460 allow for screws to be located through the surround module and for the tiling module to be fastening to a ground surface.
FIGS. [0061] 15 to 18 show a further embodiment of a waste tiling module similar to the module shown in FIGS. 11 to 14. The waste tiling module 510 is formed from a base 520 having a sold top surface 530 and a grid formed bottom surface 540. The tiling module is made from high density styrene and is load bearing.
A number of screw holes [0062] 560 are extend partially through the base 520 of the tiling module 510. The screw holes 560 allow for screws to be located through the surround module and for the tiling module to be fastening to a ground surface.
In both the [0063] surround tiling module 410 and waste tiling module 510, a lip 600 extends around the base adjacent the top surface. The lip 600 is used for location of sealant between adjacent tiling modules as shown in FIG. 19 or the tiling module and wall. This prevents any water passing between adjacent modules.
Further, the [0064] waste tiling module 510 also has a four-sided flange 570 that extends around the waste tiling module 510. The flange 570 is used to provide waterproofing. Two sides of the flange 570 extend around the outside of the lip 600. This part of the flange 570 is used to abut against a corner of a wall and prevent water from contacting the wall. The other two sides of the flange 570 extend upwardly from the top surface 530. The part of the flange prevents water from escaping through the waste tiling module 510 and potentially falling between adjoining modules 570. The flange 570 is able to be removed, for example using a plane, when not required. For example, if the waste tiling module 510 is located at the centre of a room, then all the flanges 570 will be removed.
The [0065] surround tiling module 40 and waste tilling module 510 can be used as described previously.
The method of forming a tiled floor as disclosed above has many advantages including reduced labour costs, more constant fall of tiled floors and reduced time in completing a tiled floor. [0066]
It should be appreciated that various other changes and modifications may be made to the embodiment described without departing from the spirit or scope of the invention. [0067]

Claims

1. A method of forming a tiled floor, the method including the steps of:

fastening a plurality of tiling base modules onto a ground surface, each said tiling module comprising a base having a top surface and a bottom surface; and

laying tiles on said top surface of said tiling modules so that the contour of tiles reflects the contour of the top surface of the tiling modules.

2. The method of claim 1 wherein at least one of the tiling modules is located over a floor waste outlet.

3. The method of claim 2 wherein the tiling module has top surface that is inclined toward said floor waste outlet.

4. The method of claim 1 wherein the tiling modules are formed from an open grid.

5. The method of claim 4 wherein concrete is over the tiling modules and any excess concrete scraped from the top surface of the module.

6. The method of claim 5 wherein the contour of top surface of the tiling module is reflected by the contour of the scaped concrete.

7. The method of claim 1 wherein the tiling modules have a solid top surface.

8. The method of claim 1 wherein the tiling modules are fastened to the ground surface using adhesives.

10. The method of claim 1 wherein the tiling modules are fastened to the ground surface using mechanical fasteners.

11. A tiling module for forming a tiled floor, the tiling module comprising:

a base having a bottom surface and top surface;

12. The tiling module of claim 11 wherein the base is formed from an open grid.

13. The tiling module of claim 11 wherein the base is formed from a solid structure.

14. The tiling module of claim 11 wherein the base is partially formed from a grid and a solid structure.

15. The tiling module of claim 11 wherein an aperture is located through the base.

16. The tiling module of claim 15 wherein the top surface is inclined toward the aperture.

17. The tiling module of claim 11 wherein the interconnecting elements are provide to allow interconnection of adjoining modules.

18. The tiling module of claim 11 wherein fastening means are provided to allow the tiling module to be fastened to the ground surface.

19. The tiling module of claim 11 comprising frangible portions that are broken off and removed.

20. The tiling module of claim 19 wherein the tiling module is fabricated from a corrosion resistant material.