U.S. patent application number 13/734561 was filed with the patent office on 2013-07-04 for composite tile product.
This patent application is currently assigned to NATIONAL APPLIED CONSTRUCTION PRODUCTS, INC.. The applicant listed for this patent is National Applied Construction Products, Inc.. Invention is credited to Thomas A. Duve.
Application Number | 20130167463 13/734561 |
Document ID | / |
Family ID | 48693717 |
Filed Date | 2013-07-04 |
United States Patent
Application |
20130167463 |
Kind Code |
A1 |
Duve; Thomas A. |
July 4, 2013 |
COMPOSITE TILE PRODUCT
Abstract
A self-adhering composite tile product is configured to be
bonded to a wall or floor subsurface. The composite tile product
includes a first membrane including a modified bitumen material and
a second membrane including a modified bitumen material. The
composite tile product further includes a reinforcing mat,
including a plurality of fibers, that is captured between the first
and second membrane, and an adhesive layer on an exposed surface of
one of the first and second membranes and configured to bond to
said subsurface.
Inventors: |
Duve; Thomas A.; (Bonita
Springs, FL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Construction Products, Inc.; National Applied |
Akron |
OH |
US |
|
|
Assignee: |
NATIONAL APPLIED CONSTRUCTION
PRODUCTS, INC.
Akron
OH
|
Family ID: |
48693717 |
Appl. No.: |
13/734561 |
Filed: |
January 4, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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61582902 |
Jan 4, 2012 |
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13734561 |
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Current U.S.
Class: |
52/390 |
Current CPC
Class: |
E04F 13/21 20130101;
E04F 15/02155 20130101; E04F 15/0215 20130101; E04F 13/0887
20130101 |
Class at
Publication: |
52/390 |
International
Class: |
E04F 13/21 20060101
E04F013/21; E04F 15/02 20060101 E04F015/02 |
Claims
1. A self-adhering composite tile product configured to be bonded
to a wall or floor subsurface, comprising: a first membrane
comprising a modified bitumen material; a second membrane
comprising a modified bitumen material; a reinforcing mat,
comprising a plurality of fibers, that is captured between the
first and second membranes; and an adhesive layer on an exposed
surface of one of the first and second membranes and configured to
bond to said subsurface.
2. The self-adhering composite tile product of claim 1, further
comprising a second adhesive layer on an exposed surface of the
other of the first and second membranes.
3. The self-adhering composite tile product of claim 1, wherein the
reinforcing mat is fixedly attached to each of the first and second
membranes.
4. The self-adhering composite tile product of claim 1, wherein the
reinforcing mat comprises a non-woven fabric sheet.
5. The self-adhering composite tile product of claim 4, wherein the
reinforcing mat comprises at least one of polyester, polypropylene,
and glass fiber.
6. The self-adhering composite tile product of claim 1, further
comprising a release sheet covering said adhesive layer and
configured to prevent inadvertent adherence of said adhesive
layer.
7. The self-adhering composite tile product of claim 1, wherein the
modified bitumen material of the first and second membranes
comprises 35-70% by weight of bitumen.
8. The self-adhering composite tile product of claim 7, wherein the
modified bitumen material of the first and second membranes further
comprises 1-10% by weight of process oils.
9. The self-adhering composite tile product of claim 7, wherein the
modified bitumen material of the first and second membranes further
comprises 1-10% by weight of hydrocarbon resin.
10. The self-adhering composite tile product of claim 7, wherein
the modified bitumen material of the first and second membranes
further comprises 1-10% by weight of antioxidants.
11. The self-adhering composite tile product of claim 7, wherein
the modified bitumen material of the first and second membranes
further comprises 20-60% by weight of at least one high-density
filler material.
12. The self-adhering composite tile product of claim 7, wherein
the modified bitumen material of the first and second membranes
further comprises 5-15% by weight of calcium carbonate.
13. The self-adhering composite tile product of claim 1, wherein
the modified bitumen material of the first and second membranes
comprises: 35-70% by weight of bitumen; 1-10% by weight of process
oils; 1-10% by weight of hydrocarbon resin; 1-10% by weight of
antioxidants; 20-60% by weight of at least one high-density filler
material; and 5-15% by weight of calcium carbonate.
14. The self-adhering composite tile product of claim 1, wherein
the modified bitumen material of the first and second membranes
comprises barium sulfate.
15. The self-adhering composite tile product of claim 1, further
comprising a primer material applied to the adhesive layer and
configured to bond directly to said subsurface.
16. The self-adhering composite tile product of claim 15, wherein
the primer material comprises a vinyl acetate copolymer
emulsion.
17. A self-adhering composite tile product configured to be bonded
to a wall or floor subsurface, comprising: a first membrane
comprising a modified bitumen material with 35-70% by weight of
bitumen; a second membrane comprising a modified bitumen material
with 35-70% by weight of bitumen, the second membrane having
dimensions substantially coextensive with the first membrane; a
reinforcing mat, comprising a plurality of fibers, that is captured
between the first and second membranes; a first adhesive layer on
an exposed surface of one of the first and second membranes and
configured to bond to said subsurface; and a second adhesive layer
on an exposed surface of the other of the first and second
membranes.
18. The self-adhering composite tile product of claim 17, wherein
the modified bitumen material of the first and second membranes
further comprises: 1-10% by weight of process oils; 1-10% by weight
of hydrocarbon resin; 1-10% by weight of antioxidants; 20-60% by
weight of at least one high-density filler material; and 5-15% by
weight of calcium carbonate.
19. The self-adhering composite tile product of claim 17, further
comprising a primer material applied to the first adhesive layer
and configured to bond directly to said subsurface, wherein the
primer material comprises a vinyl acetate copolymer emulsion.
20. The self-adhering composite tile product of claim 17, wherein
the reinforcing mat comprises at least one of polyester,
polypropylene, and glass fiber.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Application No. 61/582,902, filed Jan. 4, 2012, the entire
disclosure of which is hereby incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates generally to composite
articles, and more particularly, to a self-adhering composite tile
product.
BACKGROUND OF THE INVENTION
[0003] Laying of rigid tiles typically involves spreading or
trowelling a suitable adhesive on a substrate, setting the tiles
into the adhesive and permitting the adhesive to cure for about
12-24 hours. Thereafter, any joints between the tiles are grouted
and the grout must cure for approximately 24 more hours before the
tile surface is trafficable. Even for comparatively small tiling
jobs, therefore, the process generally requires about 36 or more
hours of adhesive and grout curing time in addition to the time
devoted to adhesive, tile and grout placement.
[0004] In addition, cracking of tile and similar finish layers is a
common problem in the flooring and general construction industries,
necessitating costly repair as well as causing safety hazards and
potential contractor liability. When tile or other finish flooring
is laid over and bonded to construction board or a subfloor having
cracks or joints, there exists a tendency for the tile or finish
flooring to crack in these areas, due, inter alia, to shifting of
the subsurface, shrinkage, thermal movement, settling, etc. This is
true whether the tile is ceramic, natural stone, wood or other
rigid or substantially rigid tile or finish flooring.
[0005] Further, truly rigid veneer finish layers such as ceramic
tile and the like, because of their inherent brittleness, are
subject to failure even under normal pedestrian or light-duty
vehicular traffic, notwithstanding the degree of cracking in the
subsurface over which the finish layers may be laid. Thus, great
importance is attached to the physical characteristics of the
materials situated between the tiles and the subsurface. If such
materials are too hard, then they will not effectively accommodate
subsurface crack or joint expansion and contraction; if too soft
(and especially also if relatively thick), the intervening
materials may differentially compress whereby the rigid veneer may
fracture under normal shear loading.
BRIEF SUMMARY OF THE INVENTION
[0006] The following presents a simplified summary of the invention
in order to provide a basic understanding of some example aspects
of the invention. This summary is not an extensive overview of the
invention. Moreover, this summary is not intended to identify
critical elements of the invention nor delineate the scope of the
invention. The sole purpose of the summary is to present some
concepts of the invention in simplified form as a prelude to the
more detailed description that is presented later.
[0007] In accordance with one aspect, a self-adhering composite
tile product is configured to be bonded to a wall or floor
subsurface, comprising a first membrane comprising a modified
bitumen material and a second membrane comprising a modified
bitumen material. The composite tile product further comprises a
reinforcing mat, comprising a plurality of fibers, that is captured
between the first and second membrane, and an adhesive layer on an
exposed surface of one of the first and second membranes and
configured to bond to said subsurface.
[0008] In accordance with another aspect, a self-adhering composite
tile product is configured to be bonded to a wall or floor
subsurface, comprising a first membrane comprising a modified
bitumen material with 35-70% by weight of bitumen and a second
membrane comprising a modified bitumen material with 35-70% by
weight of bitumen, the second membrane having dimensions
substantially coextensive with the first membrane. The composite
tile product further comprises a reinforcing mat, comprising a
plurality of fibers, that is captured between the first and second
membrane. The composite tile product further comprises a first
adhesive layer on an exposed surface of one of the first and second
membranes and configured to bond to said subsurface, and a second
adhesive layer on an exposed surface of the other of the first and
second membranes.
[0009] It is to be understood that both the foregoing general
description and the following detailed description present example
and explanatory embodiments of the invention, and are intended to
provide an overview or framework for understanding the nature and
character of the invention as it is claimed. The accompanying
drawings are included to provide a further understanding of the
invention and are incorporated into and constitute a part of this
specification. The drawings illustrate various example embodiments
of the invention, and together with the description, serve to
explain the principles and operations of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The foregoing and other aspects of the present invention
will become apparent to those skilled in the art to which the
present invention relates upon reading the following description
with reference to the accompanying drawings, in which:
[0011] FIG. 1 is an exploded view of an example composite tile
product;
[0012] FIG. 2 is a top plan view of an example method of
application of the composite tile product;
[0013] FIG. 3 is a top plan view of another example method of
application of the composite tile product; and
[0014] FIG. 4 is similar to FIG. 3, but illustrates yet another
example method of application that may be readily adapted at an
installation site to accommodate site-specific installation
requirements.
DESCRIPTION OF EXAMPLE EMBODIMENTS
[0015] Example embodiments that incorporate one or more aspects of
the present invention are described and illustrated in the
drawings. These illustrated examples are not intended to be a
limitation on the present invention. For example, one or more
aspects of the present invention can be utilized in other
embodiments and even other types of devices. Moreover, certain
terminology is used herein for convenience only and is not to be
taken as a limitation on the present invention. Still further, in
the drawings, the same reference numerals are employed for
designating the same elements.
[0016] Conventional and current self-adhering tile assemblies are
successful for wall applications only due to their lack of
compressive load strength in the makeup of the assembly. When used
on floors, these products fail due to cracking under impact loads,
expansion/contraction of the substrate and shrinkage cracking of
the concrete substrate. The current ASTM C-627 standards address
these issues. Moreover, conventional wisdom has held that the use
of bitumen (e.g., rubberized asphalt) may stain or leach colors
(especially black) into attached finished surfaces, may have a
displeasing odor, and/or may have poor adhesive strength.
[0017] The composite tile system 10 described herein is a
self-adhering, reinforced tile mounting system that addresses the
above historical problems and also reduces, such as eliminates, the
need for messy adhesives and mortars, reducing dusty and caustic
conditions in the home and commercial environment. The composite
tile system 10 is intended as an "all-in-one" installation product.
The composite tile system 10 described herein can incorporate
various materials to greatly improve performance, such as
fiberglass or polyester reinforcement, barium sulfate filler and/or
other compounds such as asphalt and calcium carbonate to give the
composite tile system the compressive load strength to withstand
these impact loads also acting as a crack isolation membrane and
sound reduction assembly.
[0018] The composite tile system 10 meets or exceeds various
specifications for ceramic tile and dimensional stone, such as the
specifications ANSI A-118.12-2008 revised (i.e., crack isolation
membranes for thin-set ceramic tile and dimensional stone
installation), and ASTM C-627 (i.e., used to predict a floor's
performance under several different loads, commonly referred to as
the "Robinson Test"), both of which are hereby incorporated herein
by reference. Currently, this the only composite tile system
product produced that meet these standards.
[0019] Turning to the shown example of FIG. 1, the composite tile
product 10 described herein is designed to provide a self-adhering
adhesive system configured to be bonded to a wall, countertop, or
floor subsurface 14, such as for hard surface flooring and wall
products most commonly used on decorative finish layer 12. The
composite tile product 10 is desirably constructed as an individual
self-adhering tile unit, and as shown in the attached drawings, is
an intermediate product located between the decorative finish layer
12 and an underlying substrate or subsurface 14. For example, the
composite tile product 10 can be used with ceramic tile, hardwood
flooring, etc. but can also be applied to construction board or
other materials, such as drywall, concrete, mud beds, plywood,
hardwood, backer board, existing ceramic and porcelain tile,
VCT/VAT, metal, painted floors, and many others.
[0020] The decorative finish layer 12 may be suitably be formed of
any rigid to substantially rigid finishing material, e.g., ceramic
tile, quarry tile, glass, natural or synthetic stone, marble,
slate, hardwood, parquet, cement terrazzo tiles, epoxy terrazzo,
vinyl tile, V.A. tile and the like. For example, the decorative
surface may be a single, rigid, typically ceramic floor or wall
tile having a thickness of approximately 3/16 inch to about 1/2
inch, although generally rigid tiles or similar finish layers of
greater or lesser thickness may be suitably employed. Further,
although illustrated as being of generally square configuration,
the finish layer 12, which establishes the perimetrical
configuration of the entire composite tile product 10, may also be
triangular, rectangular, pentagonal, hexagonal, or other regular or
irregular polygonal and/or curvilinear shape. The composite tile
product 10 can be applied at the factory, distributor or sold as a
stand-alone product at a DIY or retail store.
[0021] In one example, as shown in FIG. 1, the composite tile
system 10 can include five layers, although more or less layers are
contemplated. For example, first and second membranes 20, 22 can be
provided that are modified adhesive components. Both of the first
and second membranes 20, 22 can comprise a modified bitumen
material that may be the same or different for each of the first
and second membranes 20, 22. The modified bitumen material can
include some or all of modified bitumen (e.g., asphalt), SBS
polymers, process oils, hydrocarbon resins, and/or an antioxidant
mixed with high density fillers designed to abate impact and
airborne sound transmission.
[0022] In one example, the modified bitumen material of the first
and second membranes 20, 22 comprises 35-70% by weight of bitumen,
such as 40-60% by weight. In addition or alternatively, the
modified bitumen material comprises 1-10% by weight of process
oils, such as 3-8% by weight. In addition or alternatively, the
modified bitumen material comprises 1-10% by weight of hydrocarbon
resin, such as 3-8% by weight. In addition or alternatively, the
modified bitumen material comprises 1-10% by weight of
antioxidants, such as 3-8% by weight. In addition or alternatively,
the modified bitumen material comprises 20-60% by weight of at
least one high-density filler material. In addition or
alternatively, the modified bitumen material comprises 5-15% by
weight of calcium carbonate.
[0023] Unlike typical modified bitumen membranes that leech asphalt
residue to an attached substrate, the composite tile system with
specialty fillers described above and/or including barium sulfate,
inhibit the leeching of the asphalt compound into the substrate to
which it's bonded up to 150 degrees F. For example, normal asphalt
based membranes will leech asphalt residue in relatively
light-bodied stone used for flooring such as limestone, travertine
and other absorptive tile products. Aromatic oils, which are
typical in roofing membranes, have been reduced to the point of
having no "tobacco juice" effect on soft marbles and light colored
grout. Additionally, the black color of the product has virtually
no effect on light, soft bodied tiles. Calcium carbonate and
styrene-butadiene-styrene block copolymer, such as 10-20% by weight
of the modified bitumen material, can be used together with or as
alternative products to the above. Other bonding systems do not
address the issues of compressive load failure, adhesive leaching
into the surrounding areas and adjustability of the composite tile
system. Other chemicals, such as ground mica, can be used for
thermal insulation and mechanical properties which allows it to be
cut, punched or stamped to size. Barium sulfate can also be used to
contribute to sound reduction capabilities and reduce both STC
(airborne sound) and IIC (impact sound) sound transmission between
floors and walls.
[0024] Additionally, either or both of the first and second
membranes 20, 22 can have a geometry that is complementary, such as
substantially similar to, the geometry of the finish layer 12.
Preferably, the first and second membranes 20, 22 have
substantially similar geometries such that outer perimeters of
thereof are substantially coextensive when the first and second
membranes 20, 22 are arranged in a covering relationship (e.g., see
FIG. 1).
[0025] Additionally, the composite tile product 10 is preferably
able to withstand a minimum of 4000 psi loading when combined with
finish layer 12. The American National Standard (ANSI)
specifications (e.g., see ANSI A-118.12-2008 revised) for the
installation of ceramic tile prescribe a minimum requirement of 50
psi shear bond strength between the tile and the substrate to which
it is attached. As such, the composite tile product 10 can further
include a reinforcing mat 24 comprising a plurality of fibers. In
one example, the reinforcing mat 24 can be captured between the
first and second membranes 20, 22, and may be provided as a
generally central layer. The reinforcing mat 24 may have a similar
geometry to the first and second membranes 20, 22, and may be
substantially coextensive therewith. The reinforcing mat 24 can be
fixedly attached to either or both of the first and second
membranes 20, 22, or could instead be provided as a free-floating
layer between the first and second membranes 20, 22. It is
understood that use of the term "mat" is not intended to provide a
limitation. For example, the reinforcing mat 24 may be unitary or
may be formed of a plurality of elements, and/or may be continuous
or dis-continuous. In one example, the reinforcing mat 24 comprises
a non-woven fabric sheet. In addition or alternatively, the
reinforcing mat 24 comprises at least one of polyester,
polypropylene, nylon, and/or glass fiber, and/or combinations
thereof. Preferably, a nonabsorptive material, such as a polyester
fiber sheet, may be used. A nonabsorptive sheet is preferable
because a sheet which absorbs water tends to swell, forming pockets
under the floor or other finish layer, increasing the likelihood of
compression cracking. Other materials are suited for reinforcement
as well. Thus, the use of the reinforcing mat 24 can provide
strength to the composite tile product 10, and preferably
contributes to the 4000 psi static loading for impact force and
also the shear bond strength in excess of 50 psi between the finish
layer 12 (e.g., tile, etc.) and the subsurface 14 to which it is
attached.
[0026] To facilitate installation of the finish layer 12 on-site,
the composite tile product 10 can further include a first adhesive
layer 30 on an exposed surface of one of the first and second
membranes 20, 22. Similarly, a second adhesive layer 32 can be
provided on an exposed surface of the other of the first and second
membranes 20, 22. By exposed surface, it is referred to the outer
surface of each of the first and second membranes 20, 22 that is
bonded to the finish layer 12 and/or subsurface 14. At least one of
the first and second adhesive layers 30, 32, and preferably both
adhesive layers 30, 32, are configured to bond to the subsurface 14
such that he composite tile product 10 does not have to be oriented
in a specific manner during installation. Similarly, at least one
of the first and second adhesive layers 30, 32, and preferably both
adhesive layers 30, 32, are configured to bond to the finish layer
12. Thus, the composite tile product 10 can be self-bonding to the
finish layer 12 and/or subsurface 14. Additionally, the first and
second adhesive layers 30, 32 can include a pressure sensitive
adhesive to permit easy placement of the composite tile product 10
onto the subsurface 14.
[0027] One or more release sheets 34 can be provided for covering
the first and second adhesive layers 30, 32 and are configured to
prevent inadvertent adherence of the first and second adhesive
layers 30, 32 prior to installation (e.g., during shipping and
storage). For example, the release sheets 34 can include release
film or paper to be removed and discarded during the application of
the composite tile product 10. The release sheets 34 can be
independent such that the removal of one does not affect the other.
Thus, when it is desired to install the composite tile product 10,
the release sheets 34 are removed and the composite tile product 10
is pressed onto the subsurface 14.
[0028] In addition or alternatively, the exposed surfaces of the
first and second membranes 30, 32 and/or the finish layer 12 and/or
subsurface 14 may be coated in situ with an appropriate curable
adhesive, such as mortar or similar compound prior to placement of
the composite tile product 10 to affect the desired bond
therebetween. For example, a primer material 40 can be applied to
either or both of the first and second membranes 20, 22 and is
configured to bond directly to the subsurface 14. Preferably, the
primer material 40 can also be configured to bond directly to the
finish layer 12 such that the same primer material 40 can be used
for both. The primer material 40 can include a synthetic rubber
dispersion in water with a proprietary mixture for delayed set of
the composite system. For example, the primer material 40 can
comprise a vinyl acetate copolymer emulsion. The primer material 40
can be applied by a roller or trowel. The primer material 40
functions as an aid for adhesion of the composite tile product 10
to the subsurface 14 (and/or finish layer 12), and may also delay
the initial product set to provide the installer "open time" to
adjust, reposition, and align tiles before final set time.
Moreover, the primer material 40 can reduce, such as eliminate,
wait time between setting the finish layer 12 (e.g., tiles, etc.)
and grouting, if grout is used. Preferably, the primer material 40
is configured to provide "open time" on a drywall subsurface 14 in
the range of about 30 seconds to about 60 seconds, and/or "open
time" on a concrete subsurface 14 in the range of about 3 minutes
to about 5 minutes, or possibly even hours. Irrespective of how the
composite tile product 10 is bonded to the finish layer 12 or
subsurface 14, the spaces between adjacent finish layers 12 can be
filled with grout or other conventional joint filler material upon
sufficient bonding of the composite tile product 10 to the
subsurface 14.
[0029] As shown in FIG. 2, one of many presently contemplated
beneficial applications or uses for the composite tile products 10
is illustrated. More particularly, an existing floor or wall
subsurface 14 that may or may not have cracks and/or joints (one of
which is own at 28) is first prepared for application of the
composite tile product 10. The composite tile product 10 may be
used over any type of existing floor or wall, such as concrete,
concrete block, masonry, concrete backer board, plywood, particle
board, gypsum wallboard, steel, etc. Preferably, installations
begin with a clean, dry substrate free of wax, sealers, dirt,
grease, oil or other bond-breakers.
[0030] The size and/or shape of the composite tile product 10
should be selected so as to be sufficient to not only cover the
subsurface 14, but also accommodate expansion and contraction of
the joints or cracks 28 whereby reflective cracking in the finish
layer 12 may be effectively avoided. In one example, composite tile
products 10 may be relatively square with a 12 inch by 12 inch
dimension, and may be laid side-by-side to cover meandering cracks
28 such that several inches of the finish layer 12 extends beyond
the ends and to either side of the crack 28. For shorter, narrower,
and/or less erratic cracks, composite tile products 10 of smaller
size (e.g.,. 6 inch by six inch or other size) may be used to
effect the desired subsurface crack or expansion joint coverage.
Further, only those composite tile products 10 that are used to
cover the crack 28 are shown in FIG. 2 (e.g., four finish layers 12
are installed, with a fifth prepared to be installed over an
in-place composite tile product 10), and it is understood that
additional composite tile products 10 and associated finish layers
12 will be laid about as is necessary to cover the balance of the
subsurface 14 intended to be covered. It will be further
appreciated that the composite tile products 10 maybe applied over
new or otherwise unmarred subsurfaces 14. And, regardless of the
condition of the subsurface 14, the composite tile products 10 may
be laid in side-by-side abutting relation or with predetermined
spacing therebetween to establish joints to be filled by any
appropriate grout or similar joint-filling compound.
[0031] During installation, the installer can begin tiling the
finish layers 12 on the subsurface 14 by peeling off the protective
release sheet 30, 32 and attaching the composite tile product 10
thereto. Next, the finish layer 12 with attached composite tile
product 10 is carefully positioned it into place on the subsurface
14. Alternatively, the composite tile product 10 can be positioned
into place on the subsurface 14, and then the finish layer 12 can
be positioned it into place on top of the in-place composite tile
product 10. If desired, the finish layer 12 can be repositioned
while the primer material 40 is still wet and before significant
pressure has been applied. Repositioning of tile is best achieved
while primer material 40 is still in liquid state. As shown in FIG.
1, the primer material 40 can be applied between the finish layer
12 and the composite tile product 10, and may also be applied
between the composite tile product 10 and the subsurface 14. Once
the finish layer 12 is set as desired, significant pressure can be
applied uniformly across the face of the finish layer 12 to
securely bond it to the subsurface 14. Generally, the first and
second membranes 20, 22 are pressure sensitive. Once pressure is
applied, a more permanent bond will take place and a full bond will
take, for example, 12-24 hours. Grout can be applied between
adjacent finish layers 12 (e.g., in spaces between adjacent tiles,
etc.), if desired.
[0032] FIGS. 3-4 illustrate another example method of application
of composite tile product construction that may be readily adapted
at an installation site to accommodate site-specific installation
requirements. For example, as shown, the finish layer 12' can be
constructed as a multi-tile unit including a plurality of generally
rigid tiles. In the illustrated example, nine tiles are arranged in
three rows with three tiles in each row, although tile arrangements
of greater or lesser number are contemplated. The finish layer 12'
may be formed of any of the rigid to substantially rigid materials
identified herein, and may have any geometry. The multi-tile unit
of the finish layer 12' can be disposed, such as fused, adhesively
bonded, or otherwise fixedly attached on a layer of support
material 50. The support material 50 can include a relatively thin,
flexible mesh of natural or synthetic material such as polyester,
glass fiber, polypropylene, nylon, or the like. The tiles are fixed
to the support material 50 to form gaps or joints 52 configured to
receive grout or the like once the finish layer 12' is adhered to
the composite tile product 10 and subsurface 14. As shown in FIG.
4, the subsurface 14 or adjoining structures 60 may present space
constraints or other physical constraints that would otherwise
complicate or prevent placement of an entire finish layer 12'
and/or composite tile product 10. Should the installer encounter a
situation where it is desirable or necessary to modify the tile
arrangement, the installer can easily cut the support material 50
within the area of the joints 52 using an appropriate knife,
shears, scissors, or the like to the desired shape or pattern.
Similarly, the underlying composite tile product 10 can likewise be
cut to match the desired modified shape of the finish layer 12'.
Although different examples are shown in FIGS. 3-4, it is
understood that various geometries or patterns can be used.
[0033] The overall thickness of the composite tile product 10 can
range from about 5 mils to about 150 mils (about 0.005 inches to
about 0.150 inches), though other sizes are contemplated. It is
further contemplated that the first and second membranes 20, 22 can
have substantially similar, or even different, thicknesses.
[0034] Once the composite tile system 10 is installed, it can also
function as a crack isolation membrane to inhibit, such as prevent,
cracking of the decorative surface. It can also function as a
moisture vapor barrier to reduce substrate water migration and
radon, provide positive and negative waterproof protection of the
assembly and/or sound insulation.
[0035] The composite tile system 10 may include additional features
as described in two separate documents both entitled "composite
tile system," which are both hereby incorporated herein by
reference. These document relate to U.S. patent application Ser.
Nos. 07/960,130 and 08/629,836, which include priority claims
dating to at least Oct. 26, 1987.
[0036] The invention has been described with reference to the
example embodiments described above. Modifications and alterations
will occur to others upon a reading and understanding of this
specification. Examples embodiments incorporating one or more
aspects of the invention are intended to include all such
modifications and alterations insofar as they come within the scope
of the appended claims.
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