U.S. patent application number 13/773683 was filed with the patent office on 2013-09-05 for method for manufacturing and installing a textured tile flooring product.
The applicant listed for this patent is Ben Dombowsky, Michael Dombowsky. Invention is credited to Ben Dombowsky, Michael Dombowsky.
Application Number | 20130227910 13/773683 |
Document ID | / |
Family ID | 49000679 |
Filed Date | 2013-09-05 |
United States Patent
Application |
20130227910 |
Kind Code |
A1 |
Dombowsky; Michael ; et
al. |
September 5, 2013 |
METHOD FOR MANUFACTURING AND INSTALLING A TEXTURED TILE FLOORING
PRODUCT
Abstract
A method for manufacturing and installing a textured
cementitious tile flooring product, wherein sodium bicarbonate is
used to texture the tile surface and a polyurethane caulking
material provides flexible joints between tiles.
Inventors: |
Dombowsky; Michael; (Moose
Jaw, CA) ; Dombowsky; Ben; (Moose Jaw, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Dombowsky; Michael
Dombowsky; Ben |
Moose Jaw
Moose Jaw |
|
CA
CA |
|
|
Family ID: |
49000679 |
Appl. No.: |
13/773683 |
Filed: |
February 22, 2013 |
Current U.S.
Class: |
52/741.4 ;
264/39; 52/745.13; 52/745.21 |
Current CPC
Class: |
B28B 7/36 20130101; E04B
5/00 20130101; E04B 1/383 20130101; C04B 2111/60 20130101; B28B
7/38 20130101; E04F 15/08 20130101; C04B 28/04 20130101; E04B
1/6801 20130101; Y02W 30/94 20150501; Y02W 30/91 20150501; E04F
15/02016 20130101; Y02W 30/92 20150501; C04B 28/04 20130101; C04B
14/06 20130101; C04B 18/08 20130101; C04B 18/146 20130101; C04B
20/0048 20130101 |
Class at
Publication: |
52/741.4 ;
52/745.21; 52/745.13; 264/39 |
International
Class: |
E04B 5/00 20060101
E04B005/00; E04B 1/68 20060101 E04B001/68; E04B 1/38 20060101
E04B001/38 |
Foreign Application Data
Date |
Code |
Application Number |
Feb 22, 2012 |
CA |
2768393 |
Claims
1. A method of manufacturing a textured cementitious flooring
product, comprising the steps of: (a) preparing a mold; (b)
preparing a cementitious material comprising reactive components;
(c) introducing a sodium bicarbonate layer onto an inner surface of
the mold; (d) introducing the cementitious material into the mold
on top of the sodium bicarbonate layer to form a reaction interface
between the sodium bicarbonate layer and the cementitious material;
(e) agitating the cementitious material to generate a randomly
distributed reaction at the reaction interface to create a surface
texture; (f) allowing the cementitious material to harden into the
flooring product having the surface texture; and (g) removing the
flooring product from the mold.
2. The method of claim 1, wherein the mold is composed of a
material selected from the group consisting of steel, rubber,
plastic and polyvinyl chloride.
3. The method of claim 1, wherein the reactive components are
selected from the group consisting of Portland cement, metakaolin,
fly ash and silica fume.
4. The method of claim 1, further comprising a step of adding a
strengthening agent to the cementitious material at step (b).
5. The method of claim 4, wherein the strengthening agent is
fibrous material.
6. The method of claim 1, further comprising a step of adding a
colouring agent to the cementitious material at step (b).
7. The method of claim 6, wherein the colouring agent is a dye.
8. The method of claim 1, further comprising a step of introducing
a colouring agent on top of the sodium bicarbonate layer after step
(c) but before step (d).
9. The method of claim 1, further comprising a step of applying a
releasing agent to the mold before step (d).
10. The method of claim 9, wherein the releasing agent is oil.
11. A method of installing a deck flooring product comprising at
least two portions, the method comprising the steps of: (a)
providing the portions of the flooring product; (b) providing a
substrate; (c) applying adhesive to the substrate; (d) installing
the portions of the flooring product on top of the adhesive; and
(e) applying a polyurethane joint sealant between adjacent portions
of the flooring product.
12. The method of claim 11, wherein the adhesive is a polyurethane
adhesive.
13. The method of claim 11, wherein the polyurethane joint sealant
is flexible.
14. The method of claim 11, further comprising a step of installing
a waterproof membrane on top of the adhesive after step (c) but
before step (d), the portions of the flooring product then being
installed directly on top of the waterproof membrane.
15. The method of claim 14, further comprising a step of applying
spaced apart and generally parallel adhesive strips on top of the
waterproof membrane before installation of the portions of the
flooring product thereon, the adhesive strips oriented in a
direction of desired water drainage.
16. The method of claim 14, further comprising a step of installing
flashing over outer edges of the waterproof membrane before step
(d).
17. A method of installing a flooring product comprising at least
two portions over radiant heat tubing, the method comprising the
steps of: (a) providing the portions of the flooring product; (b)
providing a substrate; (c) installing a reflective sheet on top of
the substrate; (d) installing a plurality of spaced apart spacers
on top of the reflective sheet; (e) installing radiant heat tubing
on top of the reflective sheet and between the spacers; (f)
applying adhesive to upper surfaces of the spacers; (g) installing
the portions of the flooring product on top of the adhesive; and
(h) applying a polyurethane joint sealant between adjacent portions
of the flooring product.
18. The method of claim 17, wherein the reflective sheet is
composed of aluminum foil.
19. The method of claim 17, wherein the adhesive is a polyurethane
adhesive.
20. The method of claim 17, wherein the polyurethane joint sealant
is flexible.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority from Canadian Patent
Application No. 2,768,393 filed Feb. 22, 2012, the contents of
which are incorporated by reference herein.
TECHNICAL FIELD AND BACKGROUND OF THE INVENTION
[0002] The present invention relates to tiles for use in flooring
and related construction applications, and specifically to such
tiles including cementitious materials.
[0003] It is known in the building construction and remodelling
industries to employ tiles of varying base materials for flooring
and other purposes. For example, the tiles can be composed of
ceramic, cement, porcelain or stone, and are available in many
varieties of colour, texture, size and strength.
[0004] Cement tiles have become a popular choice in the industry,
due in part to the ability to easily introduce colour and texture
into the material before it hardens into the final form, even
mimicking more expensive stone products. Cement can also be
provided with strengthening elements, such as fibre, before
hardening.
[0005] It is known in the industry to employ cement tiles as
flooring materials, particularly given their ability to be coloured
or textured to suit a desired application or design. However,
texturing a cement tile can be time-consuming or, where an
automated process is involved, the pattern can be repetitious and
hence less desirable. Also, as with any sort of flooring tile,
cracking of grout between tiles allows the introduction of moisture
and the resultant negative impact on sub-flooring.
[0006] What is needed, therefore, is a method for manufacturing a
cement flooring tile with a textured surface that enables a
non-repetitious pattern without requiring the expenditure of an
undue amount of manufacturing time. Also, it would be advantageous
to have a method for installing such a flooring tile in such a way
that the risk of grout cracking is reduced.
BRIEF SUMMARY OF THE INVENTION
[0007] The present invention therefore seeks to provide a method of
manufacturing and installing a textured cementitious tile flooring
product, wherein sodium bicarbonate is used to texture the tile
surface and a polyurethane caulking material provides flexible
joints between tiles.
[0008] According to a first aspect of the present invention, there
is provided a method of manufacturing a textured cementitious
flooring product, comprising the steps of: [0009] (a) preparing a
mold in substantially the shape of the flooring product; [0010] (b)
preparing a cementitious material; [0011] (c) introducing a sodium
bicarbonate layer onto an inner surface of the mold; [0012] (d)
introducing the cementitious material into the mold on top of the
sodium bicarbonate layer to form a reaction interface between the
sodium bicarbonate layer and the cementitious material; [0013] (e)
agitating the cementitious material to generate a randomly
distributed reaction at the reaction interface; [0014] (f) allowing
the cementitious material to harden into the flooring product; and
[0015] (g) removing the flooring product from the mold.
[0016] In exemplary embodiments of the first aspect of the present
invention, the inner surface of the mold can be optionally covered
with a releasing agent before introduction of the sodium
bicarbonate layer. The method may also optionally include the
addition of a colouring agent into the mold on top of the sodium
bicarbonate layer but before introduction of the cementitious
material. Also, the method may include the further step of mixing a
strengthening agent into the cementitious material before the
cementitious material is introduced into the mold.
[0017] According to a second aspect of the present invention, there
is provided a flooring product manufactured using the method of the
first aspect.
[0018] According to a third aspect of the present invention, there
is provided a method of installing a deck flooring product,
comprising the steps of: [0019] (a) providing the flooring product;
[0020] (b) providing a substrate; [0021] (c) applying adhesive to
the substrate; [0022] (d) installing the flooring product on top of
the adhesive; and [0023] (e) applying a polyurethane joint sealant
between adjacent portions of the flooring product.
[0024] In exemplary embodiments of the third aspect of the present
invention, a waterproof membrane can be provided on top of the
adhesive, followed by the application of polyurethane strips
positioned in a direction of desired water drainage. Flashing can
also be installed over the outer edge of the membrane.
[0025] According to a fourth aspect of the present invention, there
is provided a method of installing a flooring product over radiant
heat tubing, comprising the steps of: [0026] (a) providing the
flooring product; [0027] (b) providing a substrate; [0028] (c)
installing a reflective sheet on top of the substrate; [0029] (d)
installing spacers on top of the reflective sheet; [0030] (e)
installing radiant heat tubing on top of the reflective sheet and
adjacent the spacers; [0031] (f) applying adhesive to upper
surfaces of the spacers; [0032] (g) installing the flooring product
on top of the adhesive; and [0033] (h) applying a polyurethane
joint sealant between adjacent portions of the flooring
product.
[0034] A detailed description of an exemplary embodiment of the
present invention is given in the following. It is to be
understood, however, that the invention is not to be construed as
being limited to this embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] In the accompanying drawings, which illustrate an exemplary
embodiment of the present invention:
[0036] FIG. 1 is a flowchart illustrating an exemplary method of
manufacturing flooring product according to the present
invention;
[0037] FIG. 2 is a flowchart illustrating an exemplary method of
installing a deck flooring product according to the present
invention;
[0038] FIG. 3 is a flowchart illustrating an exemplary method of
installing a radiant heat flooring product according to the present
invention;
[0039] FIG. 4 is a cut-away perspective view of an installation
according to the method illustrated in FIG. 2;
[0040] FIG. 5 is a cut-away perspective view of an installation
according to the method illustrated in FIG. 3;
[0041] FIG. 6 is a drawing of two tiles caulked together in a flat
orientation; and
[0042] FIG. 7 is a drawing of two tiles caulked together in a bent
orientation.
[0043] An exemplary embodiment of the present invention will now be
described with reference to the accompanying drawings.
DETAILED DESCRIPTION OF THE INVENTION
[0044] As is indicated above, the present invention is directed to
providing a method of manufacturing and installing a textured
cementitious tile flooring product. Sodium bicarbonate is used to
texture the tile surface through reaction with certain reactive
components in the cementitious material, and a polyurethane
caulking material is employed during installation in order to
provide flexible joints between tiles.
[0045] Turning to FIG. 1, a method 10 of manufacturing a flooring
product or tile is disclosed. In the method 10, a mold is prepared
in substantially the shape of the desired flooring product at 14 in
a manner well known in the industry. The mold can be composed of
steel, rubber, plastic, PVC or any other suitable material known to
those skilled in the art as having the desired utility. Once the
mold has been prepared, its inner surfaces can be optionally coated
with a releasing agent such as oil or a similar lubricating agent
at 16; not every mold composition will require such a coating, and
again those skilled in the art would have knowledge suitable to
making this determination. Whether a releasing agent is employed or
not, the next step in the method 10 is the introduction of a layer
of sodium bicarbonate onto the inner surfaces of the mold at 18.
Sodium bicarbonate will enable a reaction that generates a desired
surface texture on the tile, as will be discussed below. The method
10 may also optionally include the addition of a dye or colouring
agent into the mold on top of the sodium bicarbonate layer at 20
but before introduction of the cementitious material; in the
alternative, colouring can be added directly into the cementitious
material when the latter is being prepared.
[0046] At this point, or concurrently with one or more of the above
mentioned steps, a cementitious material is prepared at 12 and
introduced into the mold at 22. The method 10 may include the
further step of mixing one or more strengthening agents such as
fibrous materials into the cementitious material before the
cementitious material is introduced into the mold at 22. It is know
in the art that porcelain, ceramic and stone tiles are vulnerable
to cracking because of a lack of internal reinforcing elements.
Tiles according to the present invention are instead composed of
cement and can therefore incorporate strengthening agents to help
maintain structural integrity under concentrated impact or blows,
with the result that one has a flooring product with the advantage
of added strength and a desirable appearance such as stone.
[0047] The cementitious material is introduced into the mold
interior and directly on top of the sodium bicarbonate layer. This
forms a reaction interface between the sodium bicarbonate layer and
the cementitious material; if a colouring agent has been
introduced, this should not impact the reaction. Cementitious
materials according to the present invention incorporate one or
more of a variety of reactive materials, which can be selected as
to type and volume at the discretion of the manufacturer. While the
largest component in the cementitious material is preferably but
not necessarily Portland cement, materials that will react with
sodium bicarbonate are also present in varying percentages, such as
metakaolin, fly ash and silica fume, although other reactive
components are known to those having skill in the relevant art.
When the cementitious material is introduced on top of the sodium
bicarbonate layer at 22, the sodium bicarbonate comes into contact
with these reactive components and a reaction occurs, thereby
creating pockets, caverns and voids in the concrete--this is the
manner in which the texturing of the tile surface will occur. The
extent of the texturing is therefore due in part to the amount of
sodium bicarbonate used and the amount of reactive components in
the cementitious material.
[0048] While this straightforward surface reaction will result in
some degree of texturing of the tile surface, it has been found
that agitating the cementitious material once it has been poured
into the mold but before it has hardened will result in a more
randomly distributed reaction at the reaction interface and hence
more desirable levels of texturing. It is believed that this is the
result of the agitation of the cementitious material pushing and
dislocating the sodium bicarbonate layer which therefore spatially
randomizes the reaction taking place at the reaction interface.
This agitation takes place at 24 of FIG. 1, and it can be
introduced through manual or automated means, as would be obvious
to one skilled in the art.
[0049] The reaction and resultant texturing having been enabled,
the cementitious material is allowed to harden into the flooring
product at 26, and the flooring product is finally removed from the
mold at 28 and is ready for installation.
[0050] A flooring product having the desired characteristics can
therefore be produced according to the above method 10, and such
flooring product is intended to fall within the scope of the
present invention. A flooring product manufactured according to the
above method 10 can be used in indoor and outdoor applications, and
unlike porcelain or ceramic tile, such a flooring product would be
considered a "structural tile", capable of being laid over a wooden
floor or deck and withstand the anticipated stresses.
[0051] Also, it is known to use natural stone having surface holes
in flooring applications, such as travertine. These holes are
normally filled when used in indoor applications where a smooth
floor is desired, which is achieved by trowelling cement paste into
the voids and then diamond-polishing the stone until smooth. This
same process can be employed with a flooring product according to
the present invention, again providing a flooring product with the
same desirable appearance as natural stone but with greater
structural strength.
[0052] Turning now to FIGS. 2-5, embodiments of flooring product
installation are illustrated. Turning specifically to FIGS. 2 and
4, a method is disclosed for installing flooring product to a deck
wherein polyurethane caulking material is employed during
installation in order to provide flexible joints between tiles.
[0053] The method 30 is set out in FIG. 2, and it begins with
providing a plywood sheeting substrate at 32, although other
substrates are known in the art of deck manufacture and tile
flooring installation. A thinset adhesive is applied to the
substrate at 34, followed by an overlying waterproof deck membrane
at 36; others methods and techniques for waterproofing the
substrate and supporting structure may also be employed. Flashing
is then installed at 38 over the outer edge of the membrane, and
polyurethane adhesive strips are laid down on top of the membrane
and flashing at 40 in a direction of desired water drainage. Tiles
are then installed at 42, and polyurethane joint sealant is
introduced between all adjacent tiles at 44.
[0054] In deck flooring installations involving tile, it is
industry standard to utilize flexible control joints at
approximately 10'-0'' on centre, in both directions, to allow for
some degree of flexibility in the tile flooring, with the rest of
the floor tiles grouted using conventional masonry grout (which
does not allow any significant movement between adjacent tiles
without cracking). The joints in the exemplary embodiment of the
present invention are all filled with a flexible polyurethane
caulking, however, which is injected down into the crevice between
adjacent tiles, ensuring adhesion to each tile edge which gives a
mechanical bond to the depth of the joint. This allows for a
flexible expansion joint between all adjacent tiles and eliminates
the commonly encountered grout cracking.
[0055] FIG. 4 illustrates in a cut-away perspective view how the
various layers are configured in a deck installation 62 in
accordance with the method disclosed in FIG. 2. The plywood
sheeting 66 is placed over and secured to a deck support structure
64, thereby providing a substrate for flooring installation. On the
upper surface of the sheeting 66 is placed, in order: a thinset
adhesive 68; a waterproof deck membrane 70 secured in place by the
thinset adhesive 68; flashing 72 at the edge of the deck and
secured by means known in the art; polyurethane adhesive strips 74
for directing water in a desired direction; tiles 76 secured in
place by the adhesive strips 74; and a flexible polyurethane joint
sealant 78 disposed between the times 76. FIG. 4 also illustrates
the deck installation 62 with a wall component, which would include
cap flashing 82 and common building wrap 80, over which is
positioned and secured a wall basestone 84 (which is of the same
composition as the tiles 76) with joint sealant 78 employed at the
joint.
[0056] Turning now specifically to FIGS. 3 and 5, a method is
disclosed for installing flooring product on top of a radiant heat
tubing system, wherein polyurethane caulking material is employed
during installation in order to provide flexible joints between
tiles. The method 46 is set out in FIG. 3, and it begins with
providing a plywood floor sheeting at 48, although other substrates
are known in the art of tile flooring installation. A perforated
reflective aluminum foil sheet is applied to the sheeting at 50,
followed by an overlying set of 1''.times.4'' spruce sleepers or
spacers at 52. The 1/2'' diameter radiant heat tubing is then
installed at 54 in a manner known in the art on top of the foil
sheet and adjacent the spacers. Polyurethane adhesive is applied at
56 to the top surfaces of the spacers and the tiles are then
installed on top of the adhesive at 58, with polyurethane flexible
joint sealant introduced between all adjacent tiles at 60.
[0057] FIG. 5 illustrates in a cut-away perspective view how the
various layers are configured in a flooring installation 86 in
accordance with the method disclosed in FIG. 3. The foil sheet 90
is placed over and secured to the floor sheeting 88, and the
sleepers/spacers 92 are in turn secured on top of the foil sheet
90. The radiant heat tubing 94 is positioned and secured on top of
the foil sheet 90 and adjacent the sleepers/spacers 92. A
polyurethane adhesive 96 is applied to the upper surfaces of the
sleepers/spacers 92, and the tiles 98 are secured on top of that by
the adhesive 96. A polyurethane flexible joint sealant 100 is then
employed to fill the joints between the tiles 98.
[0058] Turning to FIGS. 6 and 7, the positioning and flexibility
afforded by the polyurethane joint sealant is illustrated. FIG. 6
shows two adjacent tiles 102, each having a textured surface 104.
The tiles 102 are joined by joint sealant 106, which is injected
between the tiles 102 and adheres to the opposing edges 108, 110 of
the tiles 102. FIG. 6 illustrates the tiles 102 in a flat
orientation as would be the case upon installation. FIG. 7
illustrates the tiles 102 in the event that they move out of a flat
orientation into a bent orientation, as might happen as a result of
floor buckling or shifting. As can be seen, the joint sealant 106
is flexible enough and grips the tile edges 108, 110 securely
enough that a significant degree of flexibility is allowed without
breakage of the seal.
[0059] The foregoing is considered as illustrative only of the
principles of the invention. The scope of the claims should not be
limited by the preferred embodiments set forth in the foregoing
examples, but should be given the broadest interpretation
consistent with the specification as a whole.
* * * * *