U.S. patent application number 10/928295 was filed with the patent office on 2005-04-14 for tile overlay system and method.
Invention is credited to Curtis, Robert G..
Application Number | 20050076606 10/928295 |
Document ID | / |
Family ID | 34425888 |
Filed Date | 2005-04-14 |
United States Patent
Application |
20050076606 |
Kind Code |
A1 |
Curtis, Robert G. |
April 14, 2005 |
Tile overlay system and method
Abstract
A tile overlay system and method for covering a defined base
surface area with tiles of a predetermined size for placement in a
predetermined pattern that forms a space between each tile. The
tiles are placed according to a grid defined on the base surface
area to form the predetermined pattern. Prior to placement of the
tiles, a transparent liquid adhesive is applied over the base
surface area which allows the grid to appear through the layer of
liquid adhesive. While the adhesive is in the liquid form, a
granular filler material is broadcasted in the space between the
tiles. The granular filler material is absorbed into the liquid
adhesive to integrally bond therewith wherein the adhesive layer
cures after the placement of the tiles, and after placement of the
granular filler material thereby bonding the tiles and the granular
filler material to the base surface area. Subsequently, a
continuous transparent top coat is applied in liquid form over the
tiles and granular filler material to form a continuous top surface
that seals the tiles and the granular filler material.
Inventors: |
Curtis, Robert G.;
(Mukilteo, WA) |
Correspondence
Address: |
WILLIAM G. FORSTER
LAW OFFICES
WILLIAM G. FORSTER
P.O. BOX 577
SUMNER
WA
98390
US
|
Family ID: |
34425888 |
Appl. No.: |
10/928295 |
Filed: |
August 27, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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60498883 |
Aug 29, 2003 |
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Current U.S.
Class: |
52/741.1 |
Current CPC
Class: |
E04F 15/02016 20130101;
E04F 15/0215 20130101; E04F 21/22 20130101 |
Class at
Publication: |
052/741.1 |
International
Class: |
E04B 001/00 |
Claims
What is claimed is:
1. A method for constructing a tile overlay system for covering a
base surface area, the method comprising the steps: providing a
plurality of tiles having a predetermined size for placement in a
predetermined pattern that forms a space between each tile; marking
the base surface area to define a grid thereon for positioning the
tiles in the predetermined pattern; placing a transparent liquid
adhesive over the base surface area to allow the grid to appear
through the liquid adhesive layer thereby enabling placement of the
tiles according to the grid; placing the tiles according to the
grid which can be viewed through the transparent adhesive, wherein
the adhesive layer cures after the placement of the tiles in the
predetermined pattern to bond the tiles to the base surface area;
broadcasting a granular filler material in the space between the
tiles while the adhesive is in the liquid form so that the granular
filler material is absorbed into the liquid adhesive to integrally
bond therewith; and applying a continuous transparent top coat in
liquid form over the tiles and granular filler material to form a
continuous top surface that seals the tiles and the granular filler
material.
2. A method for constructing a tile overlay system as recited in
claim 1 further comprising the step: removing the excess granular
filler material prior to applying the top coat.
3. A method for constructing a tile overlay system as recited in
claim 1 further comprising the step: preparing a tile surface on at
least one tile so that the prepared tile surface can be seen
through the transparent top coat.
4. A method for constructing a tile overlay system as recited in
claim 3 wherein the tile surface is prepared by hand painting the
tile surface to exhibit a distinct appearance.
5. A method for constructing a tile overlay system as recited in
claim 3 wherein the tile surface is prepared by fixing a photograph
to the tile surface to exhibit a distinct appearance.
6. A method for constructing a tile overlay system as recited in
claim 1 further comprising the step: marking the base surface area
to define a grid thereon defined by a plurality of intersecting,
crossing lines provided to assist in positioning the tiles in the
predetermined pattern.
7. A method for constructing a tile overlay system as recited in
claim 1 further comprising the step: marking the base surface area
to define a grid thereon defined by a plurality of intersecting,
crossing sets of parallel lines provided to assist in positioning
the tiles in the predetermined pattern.
8. A tile overlay system for covering a surface area, the tile
overlay system comprising: a plurality of tiles having a
predetermined size for placement in a predetermined pattern that
forms a space between each tile; a grid defined on the surface area
for positioning the tiles over the surface area to form the
predetermined pattern; an adhesive layer applied in transparent
liquid form over the surface area to allow the grid to appear
through the liquid adhesive layer to enable placement of the tiles
according to the grid, wherein the adhesive layer cures after the
placement of the tiles in the predetermined pattern to bond the
tiles to the surface area; granular filler material placed. in the
space between the tiles while the adhesive is in the liquid form so
that the filler material is absorbed into the liquid adhesive to
integrally bond therewith; and a continuous transparent top coat
applied in liquid form over the tiles and granular filler material
to form a continuous top surface that seals the tiles and the
granular filler material.
9. A tile overlay system as recited in claim 8 further comprising:
a tile surface prepared on at least one tile so that the prepared
tile surface can be seen through the transparent top coat.
10. A tile overlay system as recited in claim 9 wherein the tile
surface is prepared by hand painting the tile surface to exhibit a
distinct appearance.
11. A tile overlay system as recited in claim 9 wherein the tile
surface is prepared by fixing a photograph to the tile surface to
exhibit a distinct appearance.
12. A tile overlay system as recited in claim 8 wherein the grid is
defined by a plurality of intersecting, crossing lines provided to
assist in positioning the tiles in the predetermined pattern.
13. A tile overlay system as recited in claim 8 wherein, the grid
is defined by a plurality of intersecting, crossing sets of
parallel lines provided to assist in positioning the tiles in the
predetermined pattern.
14. A tile overlay system as recited in claim 8 wherein the tiles
comprise a fabric backing disposed for contact with the liquid
adhesive.
15. A method for constructing a tile overlay system for covering a
base surface area, the method comprising the steps: providing a
plurality of tiles having a predetermined size for placement in a
predetermined pattern that forms a space between each tile; marking
the base surface area to define a grid thereon for positioning the
tiles in the predetermined pattern wherein the grid is defined by a
plurality of intersecting, crossing sets of parallel lines provided
to assist in positioning the tiles in the predetermined pattern;
placing a transparent liquid adhesive over the base surface area to
allow the grid to appear through the liquid adhesive layer thereby
enabling placement of the tiles according to the grid; placing the
tiles according to the grid which can be viewed through the
transparent adhesive, wherein the adhesive layer cures after the
placement of the tiles in the predetermined pattern to bond the
tiles to the base surface area; broadcasting a granular filler
material in the space between the tiles while the adhesive is in
the liquid form so that the granular filler material is absorbed
into the liquid adhesive to integrally bond therewith; removing the
excess granular filler material prior to applying the top coat; and
applying a continuous transparent top coat in liquid form over the
tiles and granular filler material to form a continuous top surface
that seals the tiles and the granular filler material.
16. A method for constructing a tile overlay system as recited in
claim 15 further comprising the step: preparing a tile surface on
at least one tile so that the prepared tile surface can be seen
through the transparent top coat.
17. A method for constructing a tile overlay system as recited in
claim 16 wherein the tile surface is prepared by hand painting the
tile surface to exhibit a distinct appearance.
18. A method for constructing a tile overlay system as recited in
claim 16 wherein the tile surface is prepared by fixing a
photograph to the tile surface to exhibit a distinct
appearance.
19. A tile overlay system as recited in claim 15 wherein the tiles
comprise a fabric backing disposed for contact with the liquid
adhesive.
Description
[0001] This application claims the benefit of U.S. Provisional
Application No. 60/498,883 filed Aug. 29, 2003.
BACKGROUND
[0002] This invention relates generally to coverings and overlays
for horizontal surfaces including countertops and floors, and more
particularly to tile overlay systems for such base surfaces.
[0003] Tile overlay systems have long been provided as a top
covering for base surfaces such as floors and countertops.
Accordingly, a wide range of coverings and overlays for countertops
and floors are available. Many such coverings include individual
"stone" tiles bonded to a base surface and spaced in a way to allow
a cement based grout filler material to fill the uneven grooves
between the individual tiles. Typically, this type of installation
covers the base surface to the extent that the installer cannot see
the base surface through the bonding material. Accordingly, the
tiles have to be positioned by mechanical spacers or the like. In
addition, the grout cannot be placed until the mortar bonding
material sufficiently sets-up so that the installer can remove the
mechanical spacers and work on the set tiles.
[0004] Examples of some early systems include U.S. Pat. No.
4,311,464 issued in January 1982 showing tiles cut and arranged
according to a grid provided on a transparent sheet. Although a
grid is employed, floor tiles in this system are laid in a bed of
mortar, and require mechanical spacers for proper positioning.
[0005] Likewise, U.S. Pat. No. 4,659,409 issued in 1987
illustrating a method for preparing a floor covering by using a
translucent template to simulate, on a reduced scale, the over-lay
material required to fill a floor space. In the final steps,
however, the tiles have to be positioned and grouted in a
traditional manner.
[0006] Additionally, U.S. Pat. No. 4,744,194 issued in 1988 showing
a method of laying tile like members on a floor by employing
interconnected framework to space the floor tiles in a bed of
mortar. Also, U.S. Pat. No. 5,000,890 issued in March 1991
disclosing a conventional method for resetting separated tiles
using grout bonding material.
[0007] Alternatively, U.S. Pat. No. 5,271,200 issued in 1993
showing a tile display system comprising a metallic sub-flooring
provided for placement of magnetic means to secure the tile to the
sub-floor. This system, however, is complicated and does not
provide permanent placement of the tiles.
[0008] Later, in April 1993, U.S. Pat. No. 5,201,130 issued
disclosing a tile template having opposed arms at right angles to
form a mechanical spacer. Like most of the above noted devices, the
'130 patent employs traditional materials such as mortar to set the
tiles.
[0009] U.S. Pat. No. 5,806,270 issued in 1998 to showing a method
of floor construction with a grid system utilizing interlocking
grid members, cushion pads and grout strip members to form a floor.
This construction requires many steps, and also employs grout
material for setting the tiles.
[0010] In 1999, U.S. Pat. No. 5,930,974 issued showing a platform
and support to permit an installer to walk over freshly tiled
areas. Like the installations noted above, spacers and common grout
materials are used to position and set the tiles. In addition, U.S.
Patent application published in September 2002 discloses an
apparatus for "mechanically" spacing tiles which are laid on a bed
of grout in a traditional manner.
[0011] As noted above, most floor systems that employ individual
tile members are installed in a traditional manner where tiles are
spaced according to mechanical spacers over a bed of mortar that
obscures the installer's view of the base surface, and wherein a
cement based grout is finally applied to fill in the spaces between
the tiles.
[0012] Because such arrangements require the step of placing and
removing mechanical spacers to properly place the individual tiles,
the installation is costly and time consuming.
[0013] Accordingly, an improved tile system is needed that hastens
the precise installation of tiles and filler material disposed
between the same to form a durable integral top covering
surface.
SUMMARY
[0014] One object of the invention is to reduce the time required
to install a tile overlay floor system.
[0015] A second object is to reduce the cost of installing a tile
floor system.
[0016] Another object is to improve the durability of a tile
overlay floor system.
[0017] Yet another object is to provide a tile floor system
installed by methods that an installer can quickly learn.
[0018] A further object is to enable the installer to lay the tiles
in proper position, and then quickly thereafter fill the gaps
between the tiles with a filler material.
[0019] Still another object is to provide a tile overlay system
that sets-up to form an integral, continuous gap-free surface.
[0020] The invention is a tile overlay system for covering a
defined base surface area. Typically, the tile overlay system
comprises a plurality of tiles having a predetermined size for
placement in a predetermined pattern that forms a space between
each tile. In the present invention, the tiles are flexible,
however rigid tiles could be substituted with equally satisfactory
results.
[0021] In order to accurately place the tiles, a grid is defined on
the base surface area for positioning the tiles over the same to
form the predetermined pattern. Further, a transparent liquid
adhesive is applied over the base surface area to allow the grid to
appear through the layer of liquid adhesive. In this way, the
installer can place the tiles, according to the grid, over the
adhesive. In addition, while the adhesive is in the liquid form, a
granular dry filler material is broadcasted and spread, over and in
the space between the tiles. Because the granular filler material
is dry, the same is absorbed into the liquid adhesive to integrally
bond therewith, wherein the adhesive layer cures after the
placement of the tiles, and after placement of the granular filler
material thereby bonding the tiles and the granular filler material
to the base surface area.
[0022] Finally, a continuous transparent top coat is applied in
liquid form over the tiles and granular filler material to form a
continuous top surface that seals the tiles and the granular filler
material.
[0023] The foregoing and other objects, features, and advantages of
this invention will become more readily apparent from the following
detailed description of a preferred embodiment which proceeds with
reference to the accompanying drawings, wherein the preferred
embodiment of the invention is shown and described, simply by way
of illustration of the best mode contemplated of carrying out the
invention. As will be realized, the invention is capable of other
and different embodiments, and its several details are capable of
modifications in various obvious respects, all without departing
from the invention. Accordingly, the drawings and description are
to be regarded as illustrative in nature, and not as
restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1 is a perspective view of a finished tile overlay
system with portions broken away to illustrate the corner area with
adjacent walls extending upward from the base surface area that
supports a tile overlay system.
[0025] FIG. 2 is a partial sectional view taken along 2-2
illustrating the relationship of the primary components of a
finished tile overlay system in accordance with the present
invention.
[0026] FIG. 3 is the first illustration in the series of FIGS. 3
through 8 which illustrate in sequence the steps required to
install a tile overlay system in accordance with the present
invention, wherein FIG. 3 is a perspective view with portions
broken away to illustrate the corner area of a base sub-floor with
adjacent walls extending upward therefrom, wherein the base
sub-floor is ready to receive the tile overlay system.
[0027] FIG. 4 is a plan view of a placement grid design scribed or
drawn on the base sub-floor wherein the grid is defined by sets of
crossing, intersecting parallel lines.
[0028] FIG. 5 is perspective view with portions broken away to
illustrate the corner area of a base sub-floor having a placement
grid design, wherein the sub-floor is covered with a substantially
transparent, clear adhesive prior to receiving individual
tiles.
[0029] FIG. 6 is perspective view with portions broken away to
illustrate the corner area of a base sub-floor having a placement
grid design, wherein after the sub-floor is covered with a clear
adhesive, individual tiles are placed according to the placement
grid.
[0030] FIG. 7 is perspective view with portions broken away to
illustrate granular filler material being broadcast over the set
tiles so that the filler fills the spaces and/or gaps between the
individual tiles and flows into the wet adhesive.
[0031] FIG. 8 is perspective view with portions broken away to
illustrate top loose filler, not absorbed into the wet adhesive,
being removed and brushed off the tiles, followed with a top coat
applied over the entire tiled area to form a continuous integral
finish and top surface ready for its intended use.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENT
[0032] The invention is a tile overlay system 20 and method for
covering a defined base surface area 22. Typically, the tile
overlay system 20 comprises a plurality of tiles 24 having a
predetermined size for placement in a predetermined pattern that
forms a space 26, or a gap between each tile 24. In the present
invention, the tiles 24 are flexible, however rigid tiles could be
substituted with equally satisfactory results. Moreover, it should
be noted that for the sake of simplicity the following assumes that
each individual tile 24 is substantially alike and defines a tile
surface 30. However each individual tile 24 could be dissimilar in
that it could incorporate a distinctive tile surface 30 resulting
from the way the tile is formed. For example, each tile 24 could
have a surface image which could include hand painted art, photos,
or a distinctive troweled texture (not illustrated). Typically, the
tiles 24 are constructed as a composite comprising epoxy as a
base.
[0033] In order to accurately place the tiles 24, a grid 34 is
defined on the (sub-floor) base surface area 22 for positioning the
tiles 24 over the same to form the predetermined pattern 36.
Typically, the base surface area 22 lies within the boundary of
walls 37.
[0034] Further, an adhesive 38 is applied in transparent liquid
form over the base surface area 22 to allow the grid 34 to appear
through the liquid adhesive 38. In this way, the installer can
place the tiles 24, according to the grid 34, over the adhesive 38.
In addition, while the adhesive 38 is in the liquid form, a dry
granular filler material 40 is broadcasted in the space 26 between
the tiles 24. Because the granular filler material 40 is typically
dry, the same is absorbed into the liquid adhesive 38 to integrally
bond therewith, wherein the adhesive 38 cures after the placement
of the tiles 24, and after placement of the granular filler
material 40 thereby bonding the tiles 24 and the granular filler
material 40 to the base surface area 22.
[0035] In a final application, a continuous transparent top coat 42
is applied in liquid form over the tiles 24 and granular filler
material 40 to form a continuous top surface 44 that seals the
tiles 24 and the granular filler material 40.
[0036] Considering now in more detail, a tile overlay system 20 in
accordance with the present invention, typically the individual
tiles 24 are constructed to form a flexible material. For this
purpose, a composite mixture of epoxy in combination with a filler
is suitable. Importantly, there are many types of epoxies and
fillers presently available and suitable for manufacturing tiles
according to the present invention. Typically, the tiles 24 are
formed to be approximately 1/8.sup.th inch in thickness, and can
have a tile surface 30 shaped with a trowel as the epoxy mixture
starts to harden or cure. Further, in the hardening process, the
tile could be textured by adding a sand or the like, and skip
troweled to make the tile surface 30 take on the appearance of real
stone. Accordingly, the tile surface 30 can have raised areas, as
well as low areas which enhance the tile surface 30 to look like
real stone (not illustrated).
[0037] Because an adhesive 38 is employed to bond the tiles 24 to a
base surface area 22, a fabric backing 48 can be applied to the
bottom of each tile 30 while the same is in the formation process.
In this way, the fabric backing 48 increases the strength of the
bonding between the tile 30 and, as illustrated in FIGS. 1 through
8, a base sub-floor 46 which defines the base surface area 22.
Although such fabric backing 48 could consist of almost any
commercially available backing material, a fabric backing 48 made
from polyester or polypropylene is employed in the present
invention.
[0038] Turning now to FIG. 4, a grid 34 is laid out on the base
sub-floor 46 prior to laying the tile 24. In the present system,
the grid 34 comprises groups or sets of parallel lines 50 disposed
at right angles and drawn onto the sub-floor with chalk, or the
like. Parallel lines 50 are employed to define the predetermined
tile laying pattern or grid 34, and to define the space 26 between
the individual tiles 24. Specifically, the installer places the
tiles 24 so that each edge 54 thereof align with one of the
parallel lines 50 as illustrated in FIG. 4. Unlike conventional
tile installations, the above noted installation procedure requires
no mechanical spacers to properly place the tiles 24. This not only
speeds installation by making it easier to lay tiles, but reduces
the cost and time of installation.
[0039] Directing attention to FIG. 5, an adhesive 38 is placed to
the base surface area 22 defined by the base sub-floor 46 prior to
laying the tiles 24, and after drawing the grid 34. In the present
invention, the adhesive 38 is clear, or nearly clear so that the
installer can see the grid 34 through the adhesive 38 to lay the
tiles 24 as illustrated in FIG. 6. An adhesive 38 for this purpose
could consist of a clear epoxy mixed from two parts, i.e., an epoxy
base mixed with a hardener. After mixing the adhesive 38, the same
could be applied by troweling the same over the base sub-floor 46.
Because the adhesive 38 is in a liquid or semi-liquid state, it is
self-leveling, thus creating an even thickness coating over which
the tiles 24 are laid.
[0040] As noted above, after placing the tiles 24 over the adhesive
38, according to the grid 34, a granular filler material 40 is
broadcast over the tiles 24 into the space 26 between the tiles 24
as illustrated in FIG. 7. Typically, a dry colored quartz 56 is
employed. Because the quartz is dry, it mixes quickly with the
liquid adhesive 38 and becomes embedded therein as the adhesive
hardens. Importantly, this construction creates a monolithic like
floor covering that is very strong and resistant to deterioration
and wear.
[0041] Following this, and after the adhesive 38 sets up and
hardens, the remaining granular filler material 40 is removed from
the tiles 24. Turning now to FIG. 8, a top coat 42, is spread in
liquid form to cover the entire floor surface to provide a
continuous, hard, sealed coating that further creates a wear
resistant surface. One coating provided for this purpose is a
two-part type polyurethane mixed to cure and form a hard surface.
Although, a polyurethane is employed in the present invention, many
other coatings are available that could be applied to form a top
coat as described above.
[0042] In addition to the above, variations of the above process
can be used. For example, the material used to fill the space 26
between the tiles 24 could be any color dry granular material which
can be absorbed into the adhesive 38. In this way, the installer
could hand paint the hardened filler material to have the look of
cement grout, prior to applying the top coat 42.
[0043] Having illustrated and described the principles of my
invention in a preferred embodiment thereof, it should be readily
apparent to those skilled in the art that the invention can be
modified in arrangement and detail without departing from such
principles. I claim all modifications coming within the spirit and
scope of the accompanying claims.
* * * * *