US20090217614A1

US20090217614A1 - Modular flooring

Info

Publication number: US20090217614A1
Application number: US12/278,800
Authority: US
Inventors: Lee Cooper
Original assignee: Individual
Current assignee: Individual
Priority date: 2006-02-08
Filing date: 2007-01-12
Publication date: 2009-09-03
Also published as: EP1989370A1; CN101421474A; GB0700660D0; GB2435056A; GB0602553D0; KR20080098653A; WO2007091015A1

Abstract

A flooring system comprising a plurality of tiles (1), and at least one hinge, each hinge (5), being adapted to be releasably connected along adjacent edges of two tiles so as to join the two tiles together and allow the tiles to pivot relative to one another.

Description

The present invention relates to a modular flooring system, and to tiles and hinges for use in such a flooring system.
Modular floors are often used for temporary public displays and exhibitions, and are also useful in semi-permanent displays, such as in a shop for example. Two types of existing modular floors are platform floors and low level floors.
Platform floors are generally made up of heavy timber tiles around 50 cm square and 8 to 10 cm high. The tiles sit on adjustable feet, providing a cavity underneath for cable management. However, platform flooring is generally fairly heavy, can require tools and skilled labour to install, and is cumbersome to transport. Once assembled, platform floors are too high for some types of public displays and can represent a trip hazard, even when a sloped edge is used. Additionally, it is not possible to easily remove and replace tiles in the centre of the floor.
Low level floors are made up of square tiles, which are again generally 50 cm square and which are laid directly on the ground, with no space underneath for cables. They may be made from steel, foam, wood, plastic or any other suitable material. The tiles used are much flatter than the tiles used in a platform floor. Some types of low level floors use a tongue and groove or other snap fit mechanism to link adjoining tiles. This provides the floor with additional strength and stability when laid out, but makes it hard to remove tiles, especially tiles that are in the centre of the floor.
An example of a low level flooring system is “TempoTile”, which is manufactured by Signature Flooring™. This flooring system uses solid tiles, or tiles formed of a grid or mesh to allow water drainage. The tiles are connected using a hook and eye type arrangement, with hooks provided along two adjacent edges of the tiles and eyes along the remaining two edges.
Both of the above types of floor can be combined with sloped edging, which avoids a large step when going from the existing floor, or the ground, onto the modular flooring.
However, the above existing flooring systems are cumbersome to transport and time consuming to install, and lack flexibility.
Flooring systems are known which can be rolled up for storage, and simply unrolled when they are required. This simplifies the floor laying and removal process. These flooring systems utilise hinge mechanisms formed by a protruding pivot and a recess which are formed in the sides of adjoining tiles, and which can be considered as analogous to the “hook” and “eye” of the flooring system discussed above, but have the function of pivotally connecting the tiles. Examples of such flooring systems are “EventDeck”, which is supplied by Signature Flooring™, and “Rola-Trac”, supplied by Rola-Trac Ltd. In both of these examples, the pivots are T-shaped protrusions, and the recesses are shaped to allow the cross-piece of the T-shape, which is cylindrical, to rotate therein. In this way when a number of tiles are joined in series, they can be rotated relative to each other along the hinged joints and thus they can be rolled up.
A disadvantage of these flooring systems is that they do not allow easy removal and replacement of tiles in the centre of the floor, and the method used for joining the tiles together limits the freedom of design of the tile, and limits the flexibility of lay out of the floor.
Viewed from a first aspect, the present invention provides a flooring system comprising a plurality of tiles, and at least one hinge, each hinge being adapted to be releasably connected along adjacent edges of two tiles so as to join the two tiles together and allow the tiles to pivot relative to one another.
By using a releasably connectable hinge, which is separate from the tiles, greater flexibility is provided in the way the tiles are laid out and the design of the tiles, whilst still retaining the ability to roll up the flooring system. The tile does not need a “hook” (or protruding pivot) side and an “eye” (or recess) side as in the prior art, but instead each side of the tile can be the same. It simply needs to be connectable to the hinge. Further, as each side of the tiles is similar, any edging strip which is used only needs to be connectable to a single type of tile edge or hinge, rather than needing to be connectable to both the “hook” and “eye” edges of the tiles as in the prior art.
Preferably, the hinge is connectable and releasable without the use of tools. This makes it easier to assemble and disassemble the floor.
The tiles may be any tessellating shape, but preferably they are shapes having straight edges to avoid an overcomplicated hinge structure and to facilitate rolling of the floor. In preferred embodiments the tiles are square or rectangular, but it will be appreciated that other shapes, for example hexagonal tiles, could also be used efficiently.
Preferably, the hinge is releasable even when connected to tiles in the centre of a large floor. This allows individual tiles to be easily removed and replaced even from the centre of a floor. Thus, damaged or dirty tiles can be replaced, and access to a cable space or other items beneath the floor is easy to achieve without needing to remove or roll up large sections of the floor.
In preferred embodiments the hinge is made of a flexible material, and the tiles are pivotable relative to one another through bending of the flexible hinge. This avoids the need for moving parts as in the prior art rollable flooring systems, and thus avoids problems generated by wearing of the hinge parts, and jamming or stiffness due to incursion of dirt and suchlike.
The floor tiles may include cavities or recesses on an underside of the tile. Preferably the cavities run along the width and the length of the tile, and may comprise two intersecting channels across the centre of the underside of the tile. These cavities provide space for cables and suchlike to run along, and thus allow cabling to run beneath the flooring system, or to a point in the middle of the floor where they can supply power or network or other connectivity. Advantageously, the flooring system may allow single tiles to be removed to allow access to the cavities beneath.
The hinges may take a number of forms which will be explained in more detail below.
The hinge may be a single elongate element, for example, a flexible strip of material with formations for releasably connecting to adjacent edges of tiles, the elongate element extending along between the adjacent edges of the tiles, or it may comprise two (or more) hinge elements that span between the adjacent edges of the two tiles, the hinge elements being spaced apart from one another along the adjacent edges of the tiles where they span the gap between the tiles. Preferably in this latter embodiment, the hinge elements are separate items, but conceivably the hinge elements could be joined alone one or both sides, for example, to form a ladder or comb like structure with the hinge elements forming the rungs of the ladder or teeth of the comb. The hinge elements could also be joined along a central spine to form an ‘H’ or skeletal-like structure. In all the arrangements, the hinge, whether composed of a single elongate flexible member or a plurality of hinge elements, is formed separately from the tile in order to benefit from optimisation of material properties and, more importantly, to allow the tiles to be removed easily, for example, for replacement or access to cables passing underneath the tiles, even in the centre of the floor without having to separate other tiles.
In the embodiment where the hinge comprises two (or more) hinge elements, the hinge elements can be received in slots provided in the edges of the tiles. These slots preferably extend substantially vertically, i.e., upwards from an opening at the base of the tile. This allows the tile to be removed and slotted back into position without disturbing the hinge elements. It may also allow for a certain amount of unevenness in the underlying surface to be accommodated by the flooring system.
The hinge preferably includes a support for holding the hinge elements in an elevated position between the adjacent edges of the two tiles. This allows the hinge elements to be positioned near or at the top of the tiles, thereby allowing the tiles to pivot more freely about the hinge without having to stretch the material of the hinge elements unduly. The support may be provided with slots for receiving the hinge elements and preferably these extend substantially horizontally from the side of the edge. In this way a pair of hinge members can be fed sideways into the opposing slots of the preferably plate-like support, and the assembly positioned between the adjacent edges of a pair of tiles to act as a hinge that is adapted to be releasably connected along the adjacent edges of the two tiles. When a tile needs to be removed from the centre of the floor, it can be lifted out without the hinge members being displaced. In other arrangements, the slot in the support might be replaced with a key-hole like opening, having a larger hole portion for allowing one end of the hinge element to be inserted and a smaller hole portion for locating the hinge element in position ready for connection of the tiles.
The support preferably includes a recess in the profile of its lower edge for allowing the passage of cables thereunder. If desired, the support may also take some of the load applied to the tiles, but in practice the tiles have been found to accommodate adequately the loading applied to the tiles during normal use that the support does not need to bear any of the load.
Preferably the hinge elements each have a neck extending between a pair of locating portions, these locating portions locating behind the adjacent edges of the two tiles in use to join the two tiles together. The hinge elements are preferably in the form of toggles, for example, having a pair of preferably cylindrical locating portions joined by a neck, the cylindrical locating portions extending at right angles to the axis of the neck. The neck may be profiled to urge the locating portions against the respective edges of the tiles and may include a recess for positioning the hinge elements symmetrically with respect to the support and to grip the sides of the slot. It is possible to make the neck of the hinge elements quite thin using a memory rubber, for example, less than 3 mm in diameter and preferably of the order of around 1-2 mm diameter. The arrangement of this preferred embodiment optimises material costs and function, and the cylindrical locating portions can be made to ‘nest’ in a recess provided in the back surface of the edge of the tile, to help locate the hinge elements near the top surface of the tile and to provide the installer with positive feedback that the tile has been pushed down securely into position. However, the neck and locating portions could be made in variety of different shapes and sizes. As mentioned above, embodiments are also envisaged where the hinge elements are fixed together, for example, by a central spine or the locating portions, but this would require more material to form the hinge elements and is therefore likely to result in higher manufacturing costs.
The tiles may have holes or grilles formed for drainage of liquids between the top and bottom of the tile. This feature is particularly useful in outdoor applications, or in marquees, or in any other situation where water or other liquids could otherwise gather and pool on the top of the flooring system.
The flooring system may include tiles with holes or grommets formed in them, so that cables can easily be passed from beneath the floor to above the floor as required. Because the tiles of the present invention are easy to remove from the centre of a floor, such grommet tiles can be easily inserted and repositioned as required.
The flooring system may include edging strips arranged to releasably connect to the tiles, either directly, or by means of the hinges. These edging strips preferably provide a slope to form the boundary between the flooring system and the existing floor or the ground. The edging strips may have channels or cavities on their undersides to allow cables to run beneath them.
In some arrangements, the hinge is adapted to provide a non-slip area on the floor surface in use. This feature is believed to be novel and inventive in its own right and so, viewed from a second aspect, the present invention provides a flooring system comprising a plurality of tiles, and at least one hinge adapted to pivotally connect the adjacent edges of two tiles together, wherein in use the hinge provides a non-slip area on the floor surface.
By non-slip, it is meant that at least the apex of the hinge, which is substantially level with the floor surface, is formed from a material that provides sufficient friction to grip the shoes of uses walking on the floor. Generally the tile is desired to be tough and hardwearing, and is often also selected for its aesthetic qualities, which often results in a surface which can be slippery to walk on, especially if wet. By using the hinge to provide a non-slip surface, the safety of the flooring system is improved. Thus, to provide a non-slip surface, the apex of the hinge, or an exposed surface of the hinge can be made of a non-slip material, and can be exposed on or protrude above the level of the floor.
The hinge of this embodiment could be formed integrally with a tile, or permanently fitted to a tile. However, it is preferably formed separately from the tile, as this allows greater flexibility when using the flooring system, as discussed above.
Preferably, the hinge is made of a resilient material, such as rubber or an elastically deformable plastic. This allows the non-slip surface to be achieved easily, as resilient materials generally provide a higher degree of friction than the harder materials preferred for the main flooring surface. The use of a resilient material also means that the hinge is flexible.
Where the hinge is a resilient material, the releasable connection to the tiles may be achieved by elastically deforming the hinge to engage and disengage protrusions on the hinge with recesses in the tiles, or vice versa. In a preferred embodiment, this is achieved by stretching the hinge along its length to engage it with the tiles.
This feature is believed to be novel and inventive in its own right.
The tiles can be made of any suitable material and can be used to provide the actual flooring surface. Preferably however, the tiles are provided with a removable overlay to form the flooring surface. This feature is believed to be novel and inventive in its own right and so, viewed from a third aspect, the present invention provides a flooring system comprising a plurality of tiles connected by hinges, each tile being provided with a removable overlay.
The removable overlay, which forms the upper, exposed surface of the floor, allows the appearance, texture and other characteristics of the flooring system to be easily changed simply by changing the overlay. There is no need for a large range of different tiles to be provided, but instead a single tile can be used as a base upon which the desired overlay is fitted to provide the desired floor surface. Additionally, the overlay on an assembled flooring system can be replaced or changed if required, without needing to re-lay the entire floor. This could be to replace damaged or dirty overlay sections, or to change the look of a floor. Further, as the flooring system is used and the floor surface becomes worn, it is only necessary to replace the overlay, which would suffer the most wear as it is the exposed floor surface. Therefore the base tiles themselves will last longer, and the expense of maintaining the floor is reduced.
Combinations of overlay colours and materials and so on may be used to create a mosaic or a patterned floor. The overlay could be, for example, transparent or coloured and/or textured plastic, wood veneer or laminate, metal or any other material required to achieve the desired effect.
The use of an overlay removes some of the limitations on the material used for the tile, as the overlay can be selected to be hardwearing, or can wear as a sacrificial layer, with the tile being selected for toughness and ease of manufacture, or to be lightweight for ease of transport and assembly, rather than being restricted to a hardwearing material.
In one preferred embodiment, Velcro tabs are used to releasably connect the overlay to the tiles. With this arrangement, the tiles are preferably provided with recesses for the Velcro tabs, so that the overlay is supported by the tile surface rather than being supported on the Velcro tabs.
In another preferred embodiment the overlay is retained on the tile by retaining means formed on the hinge.
Preferably, the retaining means comprises flanges formed on the longitudinal edges of the hinge, the flanges extending outwardly over the tile in use so as to overlap with and hold down the overlay when fitted. The flanges may extend over the whole length of the hinge, and may have mitred ends so that the flanges on hinges on adjoining edges of a tile join neatly. With this arrangement, when a tile has hinges on all of its edges, the flanges form a border around the outer edge of the overlay, in the manner of a picture frame for example.
The flanges or the overlay may include a recess or gap in order to allow a tool, for example a screwdriver blade, to be inserted and levered between the hinge, the overlay and/or the tile to remove the overlay. For example, a gap in the flap could be provided where the flap did not overlap the edge of the overlay in order to allow access to the edge of the overlay. Alternatively, the overlay could be removed by having a releasably connected hinge, such that one or more hinges on a tile could be disconnected to allow access to one or more edges of the overlay.
The hinge could be arranged such that the overlay can be fitted and removed by deformation of hinges which are fitted in place on the tile. This may be achieved by using a resilient or elastic material which allows the flanges to deform, thereby allowing the overlay to pass by and be fitted to the tile surface. There may be a recess formed in the tile surface to fit the overlay into.
Viewed from a fourth aspect, the present invention provides a flooring system comprising a plurality of tiles pivotally connected by hinges, wherein the tiles can rotate relative to one another both upwardly and downwardly from a flat configuration.
Generally, rollable floors are arranged so that the tiles can only rotate upwardly relative to adjoining tiles. However, this means that the flooring system is only suitable for generally flat or concave floors. By allowing downward rotation and upward rotation the flooring system can be placed on floors which are convex or undulating as well as flat or concave floors.
Preferably, upward and downward rotation is achieved by locating the hinge pivot axis toward an upper surface of the tile, and angling the side edges of the tile inwardly and downwardly from the hinge pivot axis. The hinge is arranged to pivot about an upper edge of the tile so as not to impede upward rotation. In existing flooring systems, rotation of the tile downwardly is prevented by the bottom edges of adjoining tiles coming into contact. By angling the side edges, the tiles can rotate relative to each other before coming into contact and downward rotation is thus enabled. Preferably the hinge is about level with the upper surface of the tile.
It will be appreciated that the same effect could be achieved by placing the hinge toward a lower edge of the tile, and angling the side edges upwardly and inwardly from the hinge. However, it is preferred that the greatest degree of rotation be upwardly so that the flooring system can be readily rolled up from the floor or ground, and with this arrangement some restriction of the upward rotation due to contact of the tile side edges will necessarily occur. Restricted downward rotation, as may occur in the preferred embodiment, is not a problem, as the floor or ground on which the flooring system is placed will not have as large a convex curvature, as the curvature required when rolling the floor for storage. Additionally, having the hinge at the upper surface enables the exposed surface of the floor to be generally smooth, with no gaps.
In a preferred embodiment, the side edges of the tiles are angled by 15°.
Viewed from a fifth aspect, the present invention provides a hinge for use in a flooring system, which is connectable to two tiles such that when fitted the tiles can pivot relative to each other.
This hinge can be used in the flooring systems discussed above and has similar advantages.
Preferably the hinge is made of a flexible resilient material. For example, the hinge could be rubber. The hinge may be formed in one piece, for example by moulding.
In a preferred embodiment, the hinge comprises a strip of flexible material, with means for joining the hinge to the tiles. Ideally, the hinge is releasably connected to the tiles when in use. The releasable connection may be achieved through using the flexibility of the material to stretch the hinge onto the tile, such that the hinge is retained when it tries to return to its original length. Preferably, the strip remains in tension when retained on the tile. This provides a secure joint between the hinge and the tile(s). It will however be appreciated that the hinge could be retained on the tile even if it was not in tension, as long as the unstretched length of the hinge is such that the hinge is engaged when it returns to its original length (and is therefore not in tension) and cannot be disengaged from the tile without needing to apply force to stretch the hinge.
The means for connection to the tile may be in the form of engaging members extending beneath the strip, which are arranged to engage in recesses provided in the tiles. Preferably, there are engaging members at either end of the strip, and the hinge is arranged to connect to a first tile using engaging members at either end of the strip on one side of the strip, and to connect to a second tile using engaging members at either end of the strip on the opposite side of the strip. The shape of the hinge preferably has symmetry about a line along the centre of the strip and/or a line at the middle of the strip and perpendicular to the strip. A symmetrical shape allows the tiles that connect to the hinge to have the same shape on each side to connect to the hinge.
In a preferred embodiment, the engaging members comprise a first portion extending downwardly from the strip, and a second portion at the distal end of the first portion, the second portion extending perpendicular to the first portion. Thus, the engaging members may comprise a T-shape or an L-shape in cross section. These engaging members allow the hinge to connect to a tile by engaging the engaging members at each side at one end of the hinge in corresponding recesses provided in adjacent tiles, and then stretching the strip to engage the engaging members at the other end of the hinge with corresponding recesses, with the hinge then being retained when the strip tries to return to its unstretched length.
Alternatively, the engaging members could be arranged to engage by deformable portions allowing them to be squeezed through holes in the tiles into recesses, and then spring back into shape within the recess.
The hinge may have flanges formed on the side edges of the strip to retain an overlay on the tile as discussed above. Preferably, the flanges are formed at the upper edge of the strip so that the hinge presents a flat or smoothly rounded surface above the tile/overlay when in use.
Viewed from a sixth aspect, the present invention provides a tile for use in a flooring system, the tile being arranged to be connectable on at least two opposite edges to a hinge, such that when connected on one edge to another tile by the hinge, the tiles can pivot relative to one another about the connected edge.
By providing connectivity to a hinge on two opposite edges, the tile can be assembled into a flooring system which can be rolled up. Preferably the tile is releasably connectable to the hinge. This leads to similar advantages to those discussed above.
In a preferred embodiment, the tile is rectangular or square and is connectable to hinges on all four sides thereof. This allows the floor to be rolled up parallel to either set of edges of the tile.
The tile may have side edges angled downwardly and inwardly from the pivot axis of the hinge, thus providing the advantages discussed above.
Preferably the tile includes connection means for connection to engaging members on the hinge. The connection means may comprise recesses, which may be formed at each end of an edge of the tile, for engagement with corresponding engaging members at each end of the hinge. Preferably, each edge of the tile has recesses formed in the same shape and in the same location. This avoids the need for any particular orientation of the tile to connect to a hinge, and ensures that a single hinge design can connect to each side of the tile.
In a preferred embodiment, the tile is arranged to connect to the T-shaped or L-shaped engaging means, or the toggles of the preferred hinges described above.
The tile may be provided with a slot to fit the first portion of each engaging member, and a retaining hole or shoulder beneath the slot to hold the second portion of each engaging member. There may be a cut-away portion at the end of the slot to allow the engaging portion to be inserted, so that it can then be slid along the slot with the second portion in the retaining hole. The slots and cut-away portions may be arranged so that the engaging member is inserted at outer ends of the edge of the tile, and slid toward the middle of the edge of the tile. The slots and cut-away portions may be positioned so that the hinge needs to be stretched to fit into the cut-away portions, and so that the engaging members retain the hinge in the slots when the hinge tries to return to its original length.
The cut-away portions may extend to the corner of the tile, so that the cut-away portions on adjoining edges of the tile join together. This allows easier access to the slot and retaining hole, and also simplifies the shape of the tile, which simplifies manufacture of the tiles.
The various aspects of the invention discussed above may include, in preferred embodiments, the features and/or preferred features of the other aspects described above.

Certain preferred embodiments of the present invention will now be described by way of example only and with reference to the accompanying drawings in which:

FIG. 1 is a side view of a tile according to a first embodiment of the present invention;

FIG. 2 is a plan view of the tile of FIG. 1;

FIG. 3 is an exploded perspective view of the tile of FIG. 1 from above;

FIG. 4 is a perspective view of the tile of FIG. 1 from below;

FIG. 5 is a side view of a hinge according to a first embodiment of the present invention;

FIG. 6 is a perspective view of the hinge of FIG. 5;

FIG. 7 is a cross-section of the hinge of FIG. 5 holding two of tiles of the type shown in FIG. 1 together;

FIG. 8 is a cross-section of a number of tiles and hinges in use;

FIG. 9 is a plan view of a number of tiles and hinges in use;

FIG. 10 is a plan view of an edge part for the modular floor;

FIG. 11 is a cross section taken along the line X1-X1 of FIG. 10;

FIG. 12 is a plan view of a flooring system according to a second embodiment of the present invention;

FIG. 13 is a view of the underneath of a floor tile according to a second embodiment of the present invention;

FIG. 14 is an exploded perspective view of a floor tile with overlay and feet according to a second embodiment of the present invention;

FIG. 15 is a perspective view of the tile according to a second embodiment of the present invention from below;

FIG. 16 is a side view of two of the floor tiles according to a second embodiment of the present invention attached together;

FIG. 17 shows a side view of a single tile according to a second embodiment with a hinge fitted along its edge;

FIG. 18 is a plan view of a hinge according to a second embodiment of the present invention;

FIG. 19 is a view of the hinge of FIG. 18 from below;

FIG. 20 is a view of the hinge of FIG. 18 from the side;

FIG. 21 is a perspective view of the hinge of FIG. 18;

FIG. 22 is a schematic representation of the hinge of FIG. 18 engaging with two tiles;

FIG. 23 is a side view of an edging strip for use with a floor tile according to a second embodiment of the present invention;

FIGS. 24A and B show a top view and a side view respectively of a tile in accordance with a third embodiment;

FIGS. 25A and B show a bottom view of the tile of FIG. 24, and a section along line A-A of the bottom view respectively;

FIGS. 26 to 28 show a top, side and bottom view respectively of a hinge in accordance with a third embodiment;

FIG. 29 is a perspective view of an area of assembled flooring;

FIG. 30 is a plan view of a connector for use with an edging strip;

FIG. 31 is a cross-sectional view of the connector of FIG. 30;

FIG. 32 shows a partial view of two edging strip sections joined by the connector of FIG. 30;

FIG. 33 shows a cross-section of the edging strip section shown in FIG. 32;

FIG. 34 is a section of a tile in side view showing an embodiment of an overlay retaining system;

FIG. 35 shows a schematic view of an upwardly and downwardly rotatable flooring system;

FIGS. 36 to 39 are side, cross-section, top and bottom views of a tile in accordance with a fourth embodiment, where FIG. 37 is a cross-section through line A-A of FIG. 39;

FIG. 40 is a perspective view of the tile of FIGS. 36 to 39;

FIG. 41 is a perspective view of a hinge element used in the fourth embodiment;

FIG. 42 is a perspective view of a hinge support used in the fourth embodiment;

FIG. 43 shows the assembly of the tiles, hinge support and hinge element of FIGS. 36 to 42;

FIGS. 44 and 45 show an edging strip which can be used with the fourth embodiment;

FIG. 46 shows the connection of two of the edging strips of FIGS. 44 and 45;

FIG. 47 shows an embodiment of a central support for a rolled up flooring 20 system;

FIG. 48 shows a wrap for storage of a rolled up flooring system; and

FIG. 49 shows a flooring system rolled around a central support as in FIG. 47, and being enclosed by the wrap of FIG. 48.

FIGS. 1 to 11 show a first embodiment of the invention. The flooring system includes a number of tiles 1, each tile comprising a tile base 2, an overlay 3 and connecting means 4. As seen in the figures, in particular in FIGS. 1 to 4, the connecting means 4 in the first embodiment are in the form of flange shaped protrusions. The tile base 2 is formed from moulded plastics and is substantially square in section.
The protrusions 4 are located on the sides of the tile base 1, with two protrusions 4 on each side. The protrusions may be integrally formed with the rest of the tile or formed separately and then attached to the tile. The protrusions function as connecting means on the tile and engage with engaging means 6 on the hinge 5, which is shown in FIG. 5 to 8. In this embodiment, the engaging means 6 are keyhole shaped cut-out sections which can be pushed onto the protrusions 4, with the protrusion then being retained in the rounded hole portion of the keyhole shape.
The tile 1 includes a supporting bottom portion 7, which is an integral part of the tile, and comprises four hollow legs, one in each corner of the tile. The legs are hollow to reduce weight, and open at the base to allow the tile 1 to be easily moulded in one piece. The four legs of the supporting structure 7 define two intersecting channels 8 through the tile 1.
The overlay 3 comprises a substantially flat, square piece of flooring, which could for example be a laminate, steel or such like.
As shown in FIGS. 5 to 8, the hinge consists of a long strip bent in two along its centre, with two keyhole shaped cut-outs 6 on each side. The hinge 5 is approximately the same length as one side of tile 1. The hinge 5 is U-shaped and flexible.
The hinge 5 is made from co-extruded rubber and plastic. The apex 9 of the hinge is rubber and the sides 10 of the hinge are plastic. The rubber apex allows the hinge to flex, and the plastic sides allow the hinge to snap-fit with the protrusions 4. The rubber apex also presents a non-slip area on the floor surface, thereby providing grip to persons walking on the floor.
The hinge 5 is connectable to tiles 1 simply by pushing it into place without the use of tools. It can also be easily disconnected by pulling one or both ends up to lever the keyhole shaped recesses 6 off the protrusions 4. FIG. 7 shows a hinge 5 connecting two tiles 1 together. FIG. 8 shows a series of tiles 1 connected together. U-section rubber feet 10 may be attached to the tile 1 to prevent it from slipping across the floor or ground.
FIG. 9 is a plan view of four tiles 1 connected together with hinges 5. When in assembled to form a floor, the tiles are connected on each side (except at the periphery of the floor) to other tiles with a hinge 5.
At the floor's periphery, edge units 11 may be employed. These units are formed from rubber or other suitable plastics materials and provide a slope from the surface of the modular floor to the surface on which the modular floor stands. They comprise connecting means 12 in the form of internal cut-outs, which connect to the connection means 4 around the periphery of the tiles 1 in the same way as the hinges 5. In alternative embodiments, the edge units can be connected to the tiles using the hinges 5, and in this case they would be provided with connection means 12 of the same type as those on the tiles 1. Ribs 13 are provided on the surface of the edge unit to provide grip for persons using the floor. The edge units reduce the trip hazard created by the raised edge of the floor and create a more finished look.
FIGS. 12 to 23 show a second embodiment of the present invention, which consists of tiles 1, each having an overlay 3, and connected by hinges 5 as in the first embodiment. The underside of the tile 1 of the second embodiment also has a similar structure, with supporting portions 7, which include ribs 7 a and tubular legs 7 b. The ribs 7 a define cable channels 8 across the tile base 1.
In this embodiment, the connecting means 4 on the tile 1 and the engaging members 6 on the hinge 5 differ from those in the first embodiment. The connecting means are holes 4 provided along each edge of the tiles 1, which correspond to protruding engaging members 6 provided along the two longitudinal sides of the hinge 5. The hinge 5 of this embodiment is shown in detail in FIGS. 18 to 21, and can be seen connecting the tiles 1 together in FIGS. 12, 16 and 17 in plan view, cross-section and side view respectively. The hinge 5 is formed from a rubber material, or other similar resilient material. The hinge 5 comprises a long strip with a U-shaped cross-section having the engaging members 6 at either end of the U. The engaging members 6 have wedge shaped lower ends, with the upper end of the wedge being larger than the size of the holes 4. The wedge shaped end is pushed into the recess, and deforms so that the upper end squeezes through, and is retained by a shoulder at the base of the hole 4.
Rubber feet 10, shown in FIGS. 14, 16 and 18, are attached to base of the tile 1 by plugging them into the tubular legs 7 b.
The design of the hinge allows for a single tile to be removed from any position in the floor, which provides the user with access to any cables running under the floor at any position on the floor, and allows broken or dirty tiles to be easily replaced.
As with the first embodiment, edge units 11 may be employed at the floor's periphery. These edge units 11 are joined to the tiles 1 by connecting means 12 in the form of protrusions which are similar to the engaging members 6 on the hinges 5.
FIGS. 24 to 28 show a third embodiment. The third embodiment is similar to the embodiments discussed above, but uses a different hinge mechanism 5.
In this embodiment, the tile 1 is provided with connecting means 4 in each corner in its upper surface, the connecting means 4 comprising a slot 14, a retaining hole or shoulder 15 and a cut-away portion 16, as shown in FIGS. 24 and 25, and as discussed in greater detail below. The tile also has recesses 19 into which Velcro tabs, which are used to connect the overlay 3 (not shown) to the tile, are placed.
The hinge 5 is shown in FIGS. 26 to 28 and is made of a flexible resilient material such as rubber. The hinge 5 is formed in one piece by moulding, and comprises an elongate strip, with engaging members 6 for joining the hinge 5 to the tiles 1. The hinge 5 is releasably connected to the tiles 1 through using the flexibility of the material to stretch the hinge 5 onto the tile 1, such that the engaging members 6 are retained by the connecting means 4 on the tile when the hinge 5 tries to return to its original length. The length of the hinge 5 is such that it remains in tension when it is connected to the tile 1, in order to ensure that the engaging members 6 on the hinge 5 are securely retained by the connecting means 4 on the tile 1.
The engaging members 6 extend beneath the strip, and are arranged to engage in recesses 4 provided in the tiles 1. There are two engaging members 6 at either end of the strip. Each of the engaging members 6 comprises a first portion 6 a extending downwardly from the strip, and a second portion at the distal end of the first portion 6 a, the second portion 6 b extending perpendicular to the first portion 6 a. In this embodiment, the engaging members 6 have an L-shaped cross section.
Each edge of the tile 1 has two connecting means 4 provided at either end of the tile edge on an upper surface near the corner of the tile. In each connecting means 4, the slot 14 runs parallel to the edge of the tile 1 and extends downward beneath the tile surface to connect to the retaining hole or shoulder 15, which is wider than the slot 14. The cut-away portion 16 is at the end of the slot 14 and shoulder 15 nearest the corner of the tile 1, and is a recess extending beneath the depth of the slot to allow the engaging portion 6 to be inserted. The cut-away portions 16 of the two connecting means 4 on each corner of the tile 1 extend along the respective edges to the corner of the tile, so that the cut-away portions 16 on adjoining edges of the tile 1 join together. The slot 14 fits the first portion 6 a of the corresponding engaging member 6, and the retaining shoulder 15. beneath the slot 14 holds the second portion 6 b of the corresponding engaging member 6. The hinge 5 can then be slid into the slot 14 and along the slot 14 with the second portion 6 b retained by the retaining shoulder 15. The slots 14 and cut-away portions 16 are arranged so that the engaging member 6 is inserted at outer ends of the edge of the tile 1, and slid toward the middle of the edge of the tile 1. The slots 14 and cut-away portions 16 are positioned so that the hinge 5, when the engaging members 6 at one end have been inserted, needs to be stretched to fit the engaging members 6 at the other end into the corresponding cut-away portions 16. The engaging members 6 therefore retain the hinge 5 in the slots 14 when the hinge 5 tries to return to its original length.
A tab 20 at each end of the hinge 5 allows it to be easily gripped to remove and fit it to the tile 1.
In the above embodiments, the overlay 3 could be, Rimex™ rigidised steel, Amtico™ flooring or inkjet prints, or any other suitable material to give the desired appearance or durability etc. The overlay can be affixed to the tile with double sided tape or could be fixed by Velcro tabs. Further methods of fixing the overlay are discussed below. The overlay is releasably changeable to allow the user the capability of varying the appearance of the floor, or changing the toughness or hardness of the overlay for different purposes. The overlay can be around 1.5 mm to 2 mm in thickness, which means that even if a steel overlay is used, the floor remains lightweight.
The channels 8 allow cables and other utilities to be run beneath the flooring system, for example electrical cables. This avoids the need to run long lengths of cable around the flooring system, and also allows cable to be run beneath the floor to any point in the floor, where the cable can be accessed easily by simply removing a tile. Tiles with holes or grommets formed in their upper surface can be supplied to allow cabling to be easily passed from above the floor to beneath the floor, and these grommet tiles can be fitted to replace a standard tile as required.
The tile base 1 can be moulded from a plastics material, and the tile is approximately 2 cm in height, with a 2 mm thick overlay. The tile is around 10 cm on each edge. The support structure 7 has walls of approximately 3 mm thickness. The channel 8 provided between the support structure parts is approximately 3 cm in width and 1 cm in height. It will of course be appreciated that these dimensions are an example only, and the various parts could be of different sizes to those give above.
FIG. 29 shows an area of a modular floor assembled from tiles 1 and hinges 5 as in the embodiments discussed above, with an edging strip 11 along one side. The floor can be rolled up parallel to either of the sides of the tiles. The small size (approximately 10 cm on a side) of the individual tiles allows for a floor to be laid out in relatively exact areas. The size and hinge of the tiles also allows for the modular floor to be rolled up easily. The floor is designed to be used repeatedly by its owner and can easily be adapted to it display areas of any shape or size.
The floor may be stored in 1000 mm wide rolls, in bags and/or flight cases. When laying the floor it simply needs rolling out into position. The rolls are then connected together using hinges 5 to connect the end tiles to make up the necessary width and/or length. As each tile 1 is only around 10 cm on each side, the floor may be adjusted to fairly specific sizes and shapes by simply removing tiles. Obstacles such as columns may be tackled quickly and easily. Tiles can also be removed to allow cables to come up anywhere in the floor.
Generally, the edging strip 11 will be the length of several tiles. For example, one edging strip 11 might be five tiles long. However, for greater flexibility the edging strip 11 can be formed with weakened portions or tear lines forming a join 23 in the edging strip 11 in order to allow it to be separated into sections of the same length as a single tile. A connector 21 as shown in FIGS. 30 and 31 can then be used to connect the sections of edging strip 11. For this purpose, as shown in FIGS. 32 and 33, the join 23 between the two sections of the edging strip 11 has a recess 22 formed across it, into which the connector 21 can be fitted in use. The connector 21 has protrusions formed upon it, which engage with holes formed in the recess 22 on either side of the join 23 between the two sections of the edging strip 11. The use of an edging strip 11 of this type and a connector 21 allows a floor which is any number of tiles long to be surrounded by edging.
FIG. 34 shows a method of retaining the overlay 3 on the tile 1. The overlay 3 and the tile 1 are shown in cut-away view at the joint of two tiles. In this embodiment the overlay 3 is retained on the tile 1 by flanges 17 on the longitudinal edges of the hinge 5, which extend outward over the tile 1 so as to overlap the overlay 3 when fitted. The overlay 3 can be removed by taking off one or more hinges 5 on a tile to allow access to one or more edges of the overlay 3. Alternatively, the overlay can be fitted and removed by deformation of the flanges 17 whilst the hinges 5 are fitted in place on the tile 1. The hinges 5 are made from a resilient or elastic material which allows the flanges 17 to deform, thereby allowing the overlay to pass by and be fitted to the tile surface. The tile surface includes a recess 18 to fit the overlay into.
These retaining flanges can be applied to any of the above described hinges 5.
FIG. 35 shows a tile 1 in which both upward and downward rotation is possible, as indicated by the arrows on the left-most tile. The hinge 5 is a flexible hinge 5 as discussed in the above embodiments. The tile 1 is modified to have inwardly and downwardly angled side edges, and the angle α is about 15°. The angled sides allow the flooring system to fit to a convex surface.
FIGS. 36 to 46 illustrate a fourth embodiment of a flooring system,
The tiles 1 in this embodiment, as shown in FIGS. 36 to 40, are generally similar to the tile bases in the prior embodiments and have a support structure 7 and channels 8 on the underside. In this embodiment the upper surface of the tile 1 has a patterned and/or contoured surface 41 and forms the exposed surface of the flooring system. Thus, in this embodiment the flooring system is assembled without the use of an overlay. The tile 1 could of course be adapted to use an overlay if desired. The tile 1 is moulded from recycled polypropylene.
The connecting means 4 on this tile 1 comprises a slot 14 extending upward from the base of tile 1 and a contoured inner surface which tapers outward from the base of tile up to a recess 30 at the top of the slot 14. At the base of the tile the edges of the slot 14 curve outward. The slot 14 and tapered surface engage with hinge elements 5 as shown in FIG. 41. The outward curve can be quite pronounced as shown in FIGS. 36 to 40, and serves to guide the hinge elements 5 into place. However, for ease of manufacture a less pronounced curve can be used as shown in FIG. 43.
The hinge elements 5 comprise two locating portions in the form of toggles 31 joined by a neck 32, forming a barbell type shape. To fit the hinge elements 5 to the tiles 1 the neck 32 is placed into the slot 14, with one of the toggles 32 being inside the tile 1 and engaging at the top of the slot with the recess 30. The outward curving edges of the slot 14 serve to guide the hinge element 5 into place within the slot 14. The neck 32 is tapered to bias the toggle against the edge of the tile 1. The other toggle is then outside the tile and can be engaged with a second tile. With two hinge elements 5 in the two slots 14 on the tile 1 two adjacent tiles can be joined together and can rotate relative to each other. The hinge elements 5 are made of stretchy memory rubber or an equivalent material.
This embodiment also includes a hinge support 33, which is placed between the two tiles to support the hinge elements 5. The hinge support 33 is shown in FIG. 42, and includes two slots 34 at right angles to the slots 14 in the tiles. The hinge elements 5 are fitted in the slots 34 of the hinge support 33 in order to prevent vertical sliding of the hinge elements 5 in the slots 14 on the tiles 1. The hinge support 33 also includes a recess 35 which lines up with the channels 8 in the tiles to allow passage of cabling and the like beneath the flooring system. The hinge supports 33 do not need to be flexible and are made of a relatively cheap rigid plastic, such as recycled polypropylene. The use of the two part hinge structure having hinge elements 5 and hinge supports 33 allows the amount of expensive flexible rubber material to be reduced, as only the small hinge elements 5 need to be made of this material, and the hinge elements 5 are significantly smaller in size than the other components of the flooring system.
In the preferred embodiment shown, with the tiles 1 being 10 cm×10 cm square in size, the hinge elements 5 are 11 mm×8 mm and 4 mm deep. Thus, the length of the hinge element 5 including the two toggles 31 and the neck 32 is 11 mm, comprising two toggle diameters of 4 mm and a neck length of 3 mm, and the width of the hinge element, which is the length of the cylindrical toggles 31, is 8 mm. The depth of 4 mm is the toggle diameter.
The tiles 1 are provided with an overhang in order to accommodate the supports 33 between tiles. This overhang can be seen in FIG. 38.
FIG. 43 shows the assembly of hinge elements 5, hinge supports 33 and tiles 1. The bottom left tile has hinge elements 5 and support 33 in place, ready for connection of the protruding toggles of the hinge elements 5 to connect with the adjacent tile on the bottom right of the Figure. Hinge elements 5 and support 33 for connecting the bottom left tile to the upper tile are shown in exploded view.
FIGS. 44 and 45 show a side and rear elevation of an edging strip 11 for use with the flooring system of the fourth embodiment. The edging strip 11 includes connecting means 12 in the form of slots corresponding in size and position to the slots 14 on the tiles 1 of this embodiment. These edging strips 11 can hence be joined to tiles in the same way that adjacent tiles are joined together. The edging strips 11 also have a recess and lug on opposite sides, allowing adjacent edging strips 11 to be engaged with each other by inserting the lug into the recess as shown in FIG. 46. On the angled surface of the edging strip a patterned surface 41 is formed, which provides grip.
These edging strips can be placed around tiles assembled into an area of flooring in a similar manner to that shown in FIG. 29.
FIGS. 47 to 49 show a way of storing the rolled up flooring system of any of the above embodiments. As shown in FIG. 47 central support 36 in the form of a hexagonal prism is made up of two sections 37. The two sections 37 can be separated to access a storage area in the central support 36. This storage area can be used for spare tiles hinges and supports, for tools or for other useful items. The hexagonal shape of the central support 36 allows the flooring system to be rolled easily around it, and the sides of the prism correspond in width to the tiles, allowing the apices of the hexagon to be located at the hinge point of the first layer of tiles 1 rolled around it.
FIG. 48 shows a wrap 38 for the rolled up tiles. The wrap 38 is laid out in a flat configuration and has a number of straps 39 attached. The use of the wrap 38 to secure a roll of tiles 40 is shown in FIG. 49. The wrap 38 can be used to aid rolling of the tiles, and once the flooring system is rolled up the straps 39 can be tied together or secured by buckles or Velcro or similar to secure the roll in its rolled up configuration for storage and transport.
The wrap 38 could be used to secure a flooring system rolled up without the use of the central support 36.
Thus a flooring system has been described comprising: a plurality of tiles, and at least one hinge, each hinge being adapted to be releasably connected along adjacent edges of two tiles so as to join the two tiles together and allow the tiles to pivot relative to one another. In preferred embodiments, the flooring system may also incorporate the following features:

- the tiles may have holes or grilles formed for drainage of liquids between the top and bottom of the tile;
- the flooring system may include tiles with holes or grommets formed in them for passage of cables from beneath the floor to above the floor;
- the flooring system may include edging strips arranged to releasably connect to the tiles, around the periphery of the floor;
- the edging strips may be sloped downward from the floor surface;
- the edging strips may be separable into sections, the sections being joined by connectors, so that the edging can be adapted to a floor of any number of tiles in length or width;
- in use the hinge provides a non-slip area on the floor surface;
- at least one hinge may be adapted to pivotally connect the adjacent edges of two tiles together, wherein in use the hinge provides a non-slip area on the floor surface;
- the apex of the hinge may be formed from a non-slip material;
- the hinge is formed separately from the tile;
- the tiles may be provided with a removable overlay;
- a plurality of tiles connected by hinges, each tile may be provided with a removable overlay;
- the overlay may be retained on the tile by retaining means formed on the hinge;
- the retaining means may comprise flanges formed on the longitudinal edges of the hinge, the flanges extending outwardly over the tile in use so as to overlap with and hold down the overlay when fitted;
- the flanges or the overlay may include a recess or gap in order to allow a tool to be inserted to remove the overlay;
- the overlay may be removed by disconnecting one or more hinges on a tile to allow access to the overlay;
- the tiles can rotate relative to one another both upwardly and downwardly from a flat configuration;
- the upward and downward rotation may be achieved by locating the hinge pivot axis toward an upper surface of the tile, and angling the side edges of the tile inwardly and downwardly from the hinge pivot axis.
- the side edges of the tiles may be angled by 15°; and
- the hinge may be about level with the upper surface of the tile.

There has also been described a hinge for use in a flooring system, which is connectable to two tiles such that when fitted the tiles can pivot relative to each other, and in preferred embodiments, the hinge may also incorporate the following features:

- the hinge may be made of a flexible resilient material;
- the hinge may be formed in one piece;
- the hinge may be arranged to be releasably connected to the tiles when in use;
- the hinge may comprise a strip of flexible material, with means for joining the hinge to the tiles;
- the releasable connection may be achieved through using the flexibility of the material to stretch the hinge onto the tile in use, such that the hinge is retained when it tries to return to its original length;
- the strip may remain in tension when retained on the tile in use;
- the means for joining the hinge to the tile may comprise engaging members extending beneath the strip, which are arranged to engage in use in recesses provided in the tiles;
- there may be engaging members at either end of the strip, with the hinge being arranged to connect in use to a first tile using engaging members at either end of the strip on one side of the strip, and to connect in use to a second tile using engaging members at either end of the strip on the opposite side of the strip;
- the engaging members may comprise a first portion extending downwardly from the strip, and a second portion at the distal end of the first portion, the second portion extending perpendicular to the first portion;
- the hinge may comprise flanges formed on its side edges to retain an overlay on the tile in use; and
- the flanges may be formed at the upper edge of the strip.

There has also been described a tile for use in a flooring system, the tile being arranged to be connectable on at least two opposite edges to a hinge, such that when connected on one edge to another tile by the hinge, the tiles can pivot relative to one another about the connected edge, and in preferred embodiments, the tile may also incorporate the following features:

- the tile is releasably connectable to the hinge;
- the tile may be rectangular or square and connectable to hinges on all four sides thereof;
- the tile may have side edges angled downwardly and inwardly from the location in use of the pivot axis of the hinge;
- it may comprise connection means adapted for connection to engaging members on the hinge in use;
- the connection means may comprise recesses, formed at each end of an edge of the tile, for engagement with corresponding engaging members at each end of the hinge;
- each edge of the tile may have recesses formed in the same shape and in the same location;
- the recesses may comprise a slot and a retaining hole or shoulder beneath the slot;
- the slot may extend parallel to the edge of the tile;
- there may be a cut-away portion at the end of the slot, the cut-away portion having a depth deeper than the slot depth;
- the cut-away portions may be close to corners of the tile and the slot may extend from the cut-away portion toward the middle of the edge of the tile; and
- the cut-away portions may extend to the corner of the tile, so that the cut-away portions on adjoining edges of the tile join together.

Claims

1. A flooring system comprising: a plurality of tiles, and at least one hinge, each hinge being adapted to be releasably connected along adjacent edges of two tiles so as to join the two tiles together and allow the tiles to pivot relative to one another.

2. (canceled)

3. (canceled)

4. (canceled)

5. (canceled)

6. (canceled)

7. (canceled)

8. (canceled)

9. (canceled)

10. (canceled)

11. (canceled)

12. (canceled)

13. (canceled)

14. (canceled)

15. (canceled)

16. (canceled)

17. (canceled)

18. A flooring system as claimed in claim 1, wherein the hinge elements are made of a memory rubber.

19. A flooring system as claimed in claim 1, wherein the tiles are provided with recesses for locating the hinge elements near the top surface of the tile.

20. A flooring system as claimed in claim 1 wherein the tiles are made from recycled polypropylene.

21. A flooring system as claimed in claim 1 wherein the hinge comprises an elongate hinge element which extends along between the adjacent edges of the two tiles.

22. A flooring system as claimed in claim 1, wherein the binge is connectable and releasable without the use of tools.

23. A flooring system as claimed in claim 1, wherein the tiles are square or rectangular.

24. A flooring system as claimed in claim 1, wherein the hinge is releasable even when connected to tiles in the centre of a floor.

25. A flooring system as claimed in claim 1, wherein the hinge comprises a flexible material, and the tiles are pivotable relative to one another through bending of the flexible hinge.

26. A flooring system as claimed in claim 1, wherein the hinge comprises a resilient material.

27. A flooring system as claimed in claim 25, wherein the releasable connection to the tiles is achieved by elastically deforming the hinge to engage and disengage the hinge with the tile.

28. A flooring system as claimed in claim 27, wherein the hinge is elastically deformed along its length.

29. A flooring system as claimed in claim 1, wherein the floor tiles include cavities on an underside of the tile.

30. A flooring system as claimed in claim 29, wherein the cavities comprise two intersecting channels across the width of the underside of the tile.

31. A flooring system as claimed in claim 1, wherein the plurality of tiles are connected together along adjacent edges by hinges to form a floor, the hinges allowing the floor to be rolled up around a central support.

32. A flooring system as claimed in claim 31, wherein the tiles are square or rectangular and hinges of the same type connect adjacent edges of the tiles together.

33. A flooring system as claimed in claim 32, including a central support which is in the form of an elongate polygonal prism having sides which correspond in width to the edges of the tiles so that the tiles in the layer closest to the central support when rolled around the central support binge at locations corresponding to the apices of the elongate polygonal prism.

34. A flooring system as claimed in claim 33 wherein the elongate polygonal prism is hexagonal in cross-section.

35. A flooring system as claimed in claim 33 wherein the central support is hollow and provides a case for carrying other items.

36. A flooring system as claimed in claim 31 when rolled up around a central support, the roll of connected tiles being retained in a storage configuration by a wrap formed from a sheet of flexible material corresponding in width to the length of the central support, and having straps with attachment means to secure the wrap around the roll of connected tiles.

37. (canceled)