U.S. patent application number 15/968249 was filed with the patent office on 2018-08-30 for composite title systems and methods.
The applicant listed for this patent is Mohawk Carpet Corporation. Invention is credited to Jason Abercrombie, Rahul Patki.
Application Number | 20180245333 15/968249 |
Document ID | / |
Family ID | 51935559 |
Filed Date | 2018-08-30 |
United States Patent
Application |
20180245333 |
Kind Code |
A1 |
Patki; Rahul ; et
al. |
August 30, 2018 |
COMPOSITE TITLE SYSTEMS AND METHODS
Abstract
Composite floor tile systems and methods are disclosed.
Embodiments of this disclosure can comprise a composite floor tile
having a ceramic upper layer with one or more reinforcing layers.
The reinforcing layer or layers can comprise a reinforcing
material, such as fiberglass, and an adhesive. An under layer can
be disposed under, or integrated with, the reinforcing layer, and
can comprise a ceramic or a polymer laminate. A bottom layer can
comprise a pressure sensitive adhesive, or other adhering system,
that attaches to various substrates. Embodiments of this disclosure
can improve ease of installation of tile, improve strength of tile,
and reduce the weight of tile, among other advantages.
Inventors: |
Patki; Rahul; (Dallas,
TX) ; Abercrombie; Jason; (Dallas, TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Mohawk Carpet Corporation |
Calhoun |
GA |
US |
|
|
Family ID: |
51935559 |
Appl. No.: |
15/968249 |
Filed: |
May 1, 2018 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
14287532 |
May 27, 2014 |
|
|
|
15968249 |
|
|
|
|
61827498 |
May 24, 2013 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
Y10T 428/31504 20150401;
Y10T 428/24967 20150115; Y10T 428/2848 20150115; E04B 1/82
20130101; Y10T 428/24752 20150115; Y10T 428/2495 20150115; E04F
15/087 20130101; Y10T 428/26 20150115 |
International
Class: |
E04B 1/82 20060101
E04B001/82; E04F 15/08 20060101 E04F015/08 |
Claims
1. A composite floor tile comprising: a ceramic upper layer
defining the top of the floor tile; an under layer disposed under
the upper layer, wherein the under layer comprises a polymer
laminate; and a reinforcing layer disposed between the upper layer
and the under layer.
2. The composite floor tile of claim 1, wherein the reinforcing
layer comprises fiberglass.
3. The composite floor tile of claim 1, wherein the reinforcing
layer comprises non-woven fiberglass.
4. The composite floor tile of claim 1, wherein the reinforcing
layer comprises fiberglass, an adhesive, or a combination
thereof.
5. The composite floor tile of claim 1, the reinforcing layer is
produced from organic polymer material.
6. The composite floor tile of claim 1, wherein the reinforcing
layer is attached to the bottom of the upper layer by epoxy
glue.
7. The composite floor tile of claim 1, wherein the bottom layer is
attached to the bottom of the reinforcing layer by epoxy glue.
8. The composite floor tile of claim 1, wherein the polymer
laminate is a rigid polymer laminate.
9. The composite floor tile of claim 1, wherein the polymer
laminate comprises polyethylene, polypropylene or
polyvinylchloride.
10. The composite floor tile of claim 1, wherein the polymer
laminate comprises one or more fillers incorporated therein.
11. The composite floor tile of claim 1, wherein the thickness of
the under layer is from about 1 millimeter to about 5
millimeters.
12. The composite floor tile of claim 1, wherein the reinforcing
layer and the bottom layer are combined into an integrated second
layer.
13. The composite floor tile of claim 1, wherein the under layer
comprises one or more extended edges that extend horizontally
beyond the edges of the upper layer.
14. The composite floor tile of claim 1, further comprising a
bottom layer disposed under the under layer, the bottom layer
comprising at least one of a pressure sensitive adhesive, a
cork-polymer, and an interlocking fabric.
15. The composite floor tile of claim 1, having a thickness of
about 2 mm to about 18 mm.
16. The composite floor tile of claim 1, having a thickness of
about 3 mm to about 15 mm.
17. The composite floor tile of claim 1, wherein the reinforcing
layer is integrated into at least one of the upper layer and the
under layer.
18. The composite floor tile of claim 1, wherein the reinforcing
layer is integrated into the upper layer.
Description
CROSS-REFERENCE TO RELATED APPLICATION AND PRIORITY CLAIM
[0001] This application is a continuation and claims the benefit,
under 35 U.S.C. .sctn. 120, of U.S. patent application Ser. No.
14/287,532, filed 27 May 2014, entitled "Composite Tile Systems and
Methods," which claims the benefit, under 35 U.S.C. .sctn. 119(e),
of U.S. Provisional Patent Application No. 61/827,498, filed 24 May
2013, entitled "Composite tile Systems and Methods," the entire
contents and substance of both applications are incorporated herein
by reference in their entirety as if fully set forth below.
BACKGROUND
1. Field of the Invention
[0002] Embodiments of this disclosure relate to tile systems and
methods, and more particularly, to composite tile systems and
methods.
2. Description of Related Art
[0003] A variety of tile systems and methods are known. In general,
tile is a manufactured material used for covering floors, walls,
roofs, and other similar areas. In many situations, tile can
provide a desirable appearance, texture, feel, or other surface
characteristic that is difficult or impossible to achieve by other
means. Tiles are commonly made from ceramic materials, although
they can be made from a variety of other materials such as wood,
stone, metal, and glass.
[0004] Although ceramic tile has existed for some time, there
exists a need to improve the current state of the art in ceramic
tile across several general areas. First, installation of ceramic
tile should be made easier. Traditional tile installation methods
involve mixing, spreading, and curing of adhesives such as thinset,
mortar, and grout. These processes are time consuming and
laborious, and require an excessive amount of cleaning. While there
are available interlocking tile systems that eliminate adhesives
and setting materials, these tiles are less durable and prone to
fracture, among other problems.
[0005] Second, the impact resistance of ceramic tile should be
improved. This is true for all tiles, and especially true for easy
installing or thin floor tile. Porcelain, a commonly used tile
material, is a high strength, high modulus of elasticity material,
which is true of many materials used to manufacture tile. However,
like many conventional tile materials, such as various ceramics,
porcelain is brittle and susceptible to breaking during
manufacturing, transportation, and use. In fact, porcelain's
fracture toughness and impact resistance are significantly weaker
than other flooring materials like laminate, hardwood, and luxury
vinyl.
[0006] Third, it would be beneficial to reduce the weight of
ceramic tile. As mentioned above, Porcelain is a common ceramic
used in tiles, but standard porcelain tiles have a minimum
thickness of 8 mm and a density of between 2.2 and 3.0 g/cm.sup.3.
Thus, these tiles are relatively heavy, which increases
transportation costs and makes installing and handling the tiles
more difficult. While there are thinner porcelain tiles available
on the market today, with thicknesses below 8 mm, the thinner
profile comes at significant cost as these tiles are less durable
and prone to fracture.
[0007] Moreover, traditional porcelain tiles have inferior walking
comfort and acoustic insulation compared to other floor covering
materials such as laminates, carpet, hardwood, and vinyl.
Accordingly, these characteristics should also be improved.
[0008] What is needed, therefore, is a tile that is easy to
install, has high impact resistance, and is lightweight. The tile
should also be comfortable to walk on and have improved acoustic
insulation. It is to these needs that embodiments of this
disclosure are primarily directed.
SUMMARY
[0009] Briefly described, composite tile systems and methods that
may address at least one or all of the shortcomings discussed above
are taught by this disclosure. More specifically, embodiments of
this disclosure comprise a composite floor tile having a first,
upper layer and one or more second, reinforcing layers below the
material of the upper layer. The upper layer can comprise a
ceramic, such as porcelain. The reinforcing layer can comprise
fiberglass and hot melt adhesive. A third, under layer can be
disposed below the reinforcing layer and can comprise a ceramic,
similar to or the same as the upper layer, or can comprise a
polymer laminate. The tile can also comprise a fourth, bottom layer
that can be an adhesive layer.
[0010] In some embodiments, the tile comprises a plurality
porcelain tiles or layers with a thin, reinforcing layer of polymer
glue and/or fiberglass therebetween, creating a durable periodic
structure. The reinforcing layer can be produced from inorganic
fibers and/or organic polymer materials. Such fiber and/or polymer
materials generally may have a high strength to weight ratio, lower
elastic modulus, and a higher thermal expansion coefficient than
the ceramic used in the tile. The reinforcing layer can comprise a
woven fiberglass layer, a non-woven fiberglass layer, a knit
fiberglass layer, or can comprise randomly oriented short
fiberglass strands. The reinforcing layer can also comprise a hot
melt adhesive, such as hot melt glue.
[0011] The fourth, bottom layer, can comprise a pressure sensitive
adhesive that bonds with various substrates, such as concrete or
wood, and can eliminate the need to use thinset adhesive or mortar.
In some embodiments, for example, the bottom layer can comprise a
double sided pressure sensitive adhesive tape. In other embodiments
the fourth, bottom layer can comprise a cork-polymer layer that
creates a physical friction bond with various substrates. The
fourth, bottom layer can also comprise a tack fast loop fabric,
such as a loop and hook fabric (such as Velcro.RTM.), that
interlocks with an underlayment on the subfloor.
[0012] In some embodiments, the third, under layer can comprise a
polymer laminate instead of a ceramic. In some embodiments, the
polymer laminate can comprise filling materials. Moreover, in some
embodiments, the second, reinforcing layer and the third, under
layer can be combined into an integrated second layer that provides
advantages of the two separate layers.
[0013] In some embodiments, the reinforcing layer can be adhered
to, or integrated into, the upper layer or the under layer or both.
If the reinforcing layer is adhered to the upper layer or the under
layer, it can be directly adhered thereto or adhered via
intermediate layers.
[0014] Traditionally, thin ceramic tile, such as porcelain tiles
less than 6 mm thick, or similar, do not exceed the 250 pound-force
breaking strength that is commonly required for floor installation.
Conventionally, these tiles also have low impact resistance, poor
walking comfort, etc. This disclosure addresses these problems by
integrating reinforcing materials, situated in layers, or being one
or more layers themselves, close to the upper surface of the
composite tile, such as on the bottom side of the upper layer.
These materials can be capable of absorbing and dissipating impact
energy and vibration, thereby improving the strength, walking
comfort, and acoustic properties of the tile. In this manner, tiles
with desirable qualities can be produced.
[0015] Accordingly, the composite tile systems and methods of this
disclosure may combine the durability of thicker ceramic tile with
the comfort, light-weight, and impact resistance of non-ceramic
materials. Moreover, the systems and methods of this disclosure can
add a self-adhering feature for ease of installation.
[0016] Embodiments of this disclosure can comprise a composite tile
comprising an upper layer defining the top of the tile, an under
layer disposed under the upper layer, and a reinforcing layer
disposed between the upper layer and the under layer. In some
embodiments, the reinforcing layer can comprise fiberglass. In some
embodiments, the reinforcing layer can further comprise an
adhesive. In some embodiments, the reinforcing layer can comprise
at least one of fiberglass, short strand fibers, carpet fibers, and
carbon fibers. In some embodiments, the upper layer and the under
layer can comprise a ceramic and the reinforcing layer can comprise
fiberglass and a hot melt adhesive. In some embodiments, the upper
layer and the under layer can have the same thickness and the
reinforcing layer can be thinner than the upper layer and the under
layer. In some embodiments, the upper layer can comprise a ceramic
and the under layer can comprise a polymer laminate. In some
embodiments, the polymer laminate can have an embedded filler and
the filler can comprise at least one of cork, crumb rubber, carpet
fibers, and chalk. In some embodiments, the polymer laminate can be
a rigid polymer laminate. In some embodiments, the upper layer can
comprise porcelain that includes at least one of mullite, kyanite,
calcined alumina, and high temperature refractory materials. In
some embodiments, the composite tile can further comprise a bottom
layer disposed under the under layer and the bottom layer can
comprise at least one of a pressure sensitive adhesive, a
cork-polymer, and an interlocking fabric. In some embodiments, the
composite tile can further comprise a bottom layer disposed under
the under layer and the bottom layer can comprise a pressure
sensitive double-sided tape. In some embodiments, the composite
tile can further comprise a bottom layer disposed under the under
layer and the bottom layer can comprise extended edges that extend
horizontally beyond the upper layer. In some embodiments, the upper
layer can comprise porcelain and can be about 3 mm thick, the under
layer can comprise porcelain and can be about 3 mm thick, and the
reinforcing layer can comprise fiberglass and can be about 1 mm
thick. In some embodiments, the reinforcing layer is about 1 mm or
less thick.
[0017] Embodiments of this disclosure can comprise a composite tile
comprising a first, upper layer defining the top of the tile and a
second, reinforcing layer under the upper layer. In some
embodiments, the second layer can comprise fiberglass and a polymer
laminate. In some embodiments, a bottom layer can be disposed under
the second, reinforcing layer and the bottom layer can comprise at
least one of a pressure sensitive adhesive, a cork-polymer, and an
interlocking fabric.
[0018] Embodiments of this disclosure can comprise a method of
manufacturing composite tile comprising providing an upper layer,
providing a reinforcing layer on a bottom side of the upper layer,
and hot pressing the upper layer and the reinforcing layer
together. In some embodiments, the method can further comprise
providing an under layer on a bottom side of the reinforcing layer,
and the hot pressing of the upper layer and the reinforcing layer
together can include hot pressing the upper layer, the reinforcing
layer, and the under layer together. In some embodiments, providing
a reinforcing layer can comprise providing an adhesive and
providing a reinforcing material onto and into the adhesive.
[0019] These and other aspects of this disclosure are described in
the Detailed Description below and the accompanying figures. Other
aspects and features of embodiments of this disclosure will become
apparent to those of ordinary skill in the art upon reviewing the
following description of embodiments of this disclosure in concert
with the figures. While features of this disclosure may be
discussed relative to certain embodiments and figures, all
embodiments of this disclosure can include one or more of the
features discussed herein. While one or more embodiments may be
discussed as having certain advantageous features, one or more of
such features may also be used with the various embodiments of the
invention discussed herein. In similar fashion, while exemplary
embodiments may be discussed below as system or method embodiments,
it is to be understood that such exemplary embodiments can be
implemented in various devices, systems, and methods of this
disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] Various features and advantages of this disclosure may be
more readily understood with reference to the following Detailed
Description taken in conjunction with the accompanying drawing
figures, wherein like reference numerals designate like structural
elements, and in which:
[0021] FIG. 1 depicts a perspective view of a tile, in accordance
with some embodiments of this disclosure.
[0022] FIG. 2 depicts an exploded view of the tile of FIG. 1, in
accordance with some embodiments of this disclosure.
[0023] FIG. 3 depicts a perspective view of a tile, in accordance
with some embodiments of this disclosure.
[0024] FIG. 4 depicts an exploded view of the tile of FIG. 3, in
accordance with some embodiments of this disclosure.
[0025] FIG. 5 depicts a perspective view of a tile, in accordance
with some embodiments of this disclosure.
[0026] FIG. 6 depicts a method of manufacturing a tile, in
accordance with some embodiments of this disclosure.
DETAILED DESCRIPTION
[0027] To facilitate an understanding of the principles and
features of the various embodiments of the invention, various
illustrative embodiments are explained below. Although exemplary
embodiments of the invention are explained in detail as being
composite tile systems and methods, it is to be understood that
other embodiments are contemplated, such as embodiments employing
other types of tiles, tile manufacturing methods, or tile
installation methods. Accordingly, it is not intended that the
invention is limited in its scope to the details of construction
and arrangement of components set forth in the following
description or examples. The invention is capable of other
embodiments and of being practiced or carried out in various ways.
Also, in describing the exemplary embodiments, specific terminology
will be resorted to for the sake of clarity.
[0028] It must also be noted that, as used in the specification and
the appended claims, the singular forms "a," "an" and "the" include
plural references unless the context clearly dictates otherwise.
For example, reference to a component is intended also to include
composition of a plurality of components. References to a
composition containing "a" constituent is intended to include other
constituents in addition to the one named.
[0029] Also, in describing the exemplary embodiments, terminology
will be resorted to for the sake of clarity. It is intended that
each term contemplates its broadest meaning as understood by those
skilled in the art and includes all technical equivalents which
operate in a similar manner to accomplish a similar purpose.
[0030] Ranges may be expressed herein as from "about" or
"approximately" or "substantially" one particular value and/or to
"about" or "approximately" or "substantially" another particular
value. When such a range is expressed, other exemplary embodiments
include from the one particular value and/or to the other
particular value.
[0031] By "comprising" or "containing" or "including" is meant that
at least the named compound, element, particle, or method step is
present in the composition or article or method, but does not
exclude the presence of other compounds, materials, particles,
method steps, even if the other such compounds, material,
particles, method steps have the same function as what is
named.
[0032] It is also to be understood that the mention of one or more
method steps does not preclude the presence of additional method
steps or intervening method steps between those steps expressly
identified. Similarly, it is also to be understood that the mention
of one or more components in a composition does not preclude the
presence of additional components than those expressly
identified.
[0033] The materials described as making up the various elements of
the invention are intended to be illustrative and not restrictive.
Many suitable materials that would perform the same or a similar
function as the materials described herein are intended to be
embraced within the scope of the invention. Such other materials
not described herein can include, but are not limited to, for
example, materials that are developed after the time of the
development of the invention.
[0034] To facilitate an understanding of the principles and
features of this disclosure, various illustrative embodiments are
explained below. In particular, various embodiments of this
disclosure are described as composite tile systems and methods.
Some aspects of the invention, however, may be applicable to other
contexts, and embodiments employing these aspects are contemplated.
For example and not limitation, some aspects of the invention may
be applicable to various types of coverings, floor decoration, or
wall decoration. Accordingly, where terms such as "floor tile" or
"tile" or related terms are used throughout this disclosure, it
will be understood that other devices, entities, objects, or
activities can take the place of these in various embodiments of
the invention.
[0035] As described above, a problem with existing ceramic tile
systems and methods is that the tiles are heavy, susceptible to
damage from impact, and difficult to install. In addition,
traditional ceramic tiles have inferior walking comfort and
acoustic insulation compared to many other flooring materials.
Embodiments of this disclosure, however, can overcome one or more
of these deficiencies.
[0036] As shown in FIG. 1, in some embodiments, this disclosure can
comprise a composite tile 100, such as a composite floor tile, wall
tile, ceiling tile, roof tile, or the like. The tile 100 can have a
top side 105 and a bottom side 110. In addition, the tile can have
a thickness h measured from the top side 105 of the tile 100 to the
bottom side 110 of the tile 100.
[0037] As shown in FIGS. 1-4, the tile 100 can comprise a plurality
of layers. The multi-layered configuration can enable the tile 100
to have improved features, including some or all of being light,
strong, easy to install, comfortable to walk on, and acoustically
insulating. FIGS. 1-2 show that, in certain embodiments, the tile
100 can comprise four layers, while FIGS. 3-4 show that, in some
embodiments, the tile 100 can comprise three layers.
[0038] FIG. 2 is an exploded view of the tile of FIG. 1. As shown
in FIG. 2, embodiments of this disclosure can comprise a tile 100
with an upper layer 205. The upper layer 205 can comprise the top
side 105 of the tile 100, which can provide a desirable exposed
surface for a floor, wall, ceiling, roof, or the like. As
illustrated in FIG. 2, the upper layer 205 can provide a decorative
or desired appearance. In some embodiments, the upper layer 205 can
comprise a durable, wear resistant material such as porcelain or
stone. The upper layer 205 can also comprise other types of
ceramics or other materials such as, for example, glass or
metal.
[0039] In some embodiments, the upper layer 205 can be thinner than
conventional tiles. For example, in some embodiments, the upper
layer 205 can have a thickness from about 1 mm to about 7.5 mm,
including from about 2 mm to about 4 mm. The thickness of the upper
layer 205 can be at about 3 mm or about 2 mm. The thickness can be
less than about 8 mm, less than about 7 mm or less than about 6 mm.
In some embodiments, the thickness can be about 3 mm to about 6 mm,
from about 3 mm to about 5 mm, or from about 3 mm to about 4.5 mm.
Thus, the upper layer 205 can have a thickness less than 8 mm,
which is a standard thickness of conventional porcelain tiles. The
use of a thinner upper layer 205 can therefore reduce the weight of
the upper layer 205 compared to the weight of a conventional tile.
This reduction in weight, combined with other reductions in weight
mentioned herein, can enable the tile to be easier to handle and
install, and can reduce shipping costs and environmental impact,
among other advantages.
[0040] In embodiments comprising a ceramic upper layer 205, such as
a porcelain layer, the upper layer 205 can have properties that are
enhanced by the ceramic's body formula. The ceramic, for example,
can comprise raw materials that can be used to provide exceptional
strength. This blend can include mullite, kyanite, calcined
alumina, and/or ground up high temperature refractories materials,
along with typical ceramic/porcelain ingredients. The ceramic can
also comprise recycled bulb glass. In some instances, the tile of
this disclosure can allow the use of other materials that might be
otherwise cost-prohibitive in a standard tile, but which can be
used in a tile with less ceramic material. In some instances, the
materials described above can be used to "seed" the ceramic and
form a unique crystal structure. That unique structure can be
capable of superior fired strength and elasticity as compared to a
traditional porcelain ceramic layer of the same thickness.
[0041] In some embodiments, to improve other properties of the
composite tile and related methods, such as the impact resistance,
acoustic insulation, and ease of installation, the tile 100 can
comprise additional layers.
[0042] In some embodiments, for example, the tile 100 can comprise
a second layer 210. The second layer 210 can be a reinforcing layer
that strengthens and increases the impact resistance of the tile
100. In some embodiments, a composite tile 100 comprising at least
a first layer 205 being a ceramic or porcelain upper layer 205 with
a thickness of about 3 to 5 mm and a second layer 210 being a
reinforcing layer comprising fiberglass and glue, for example, may
provide improved impact resistance.
[0043] In some embodiments, as mentioned above, the reinforcing
second layer 210 can comprise a reinforcing fibrous material, such
as woven fiberglass. In other embodiments, the second layer 210 can
comprise a non-woven fiberglass mat, knit fiberglass, or can
comprise other materials, such as randomly oriented short strand
fiber, for example glass fiber or recycled carpet fibers or carbon
fiber or combinations of any of the above. The second layer 210 can
also include an adhesive, such as a hot melt adhesive, and as an
example, hot melt glue. The adhesive can be a polymer adhesive and
can form an integrated structure with the fiberglass, or other
reinforcing material. In some embodiments, the adhesive can
comprise a moisture cured polyurethane, an ambient or heat cured
epoxy, or a thermoplastic hot melt glue, such as EVA hot melt.
[0044] In addition to improving impact resistance, walking comfort,
acoustic properties, etc., the second layer 210 can hold pieces of
the tile 100 together if the tile 100 should break. In other words,
since the second layer 210 can be attached to the layers above and
below it with an adhesive (or since the second layer 210 can be
integrated into one or more of the layers), and since second layer
210 is unlikely to fracture if and when the tile 100 breaks, the
second layer 210 can retain the broken pieces of tile. Accordingly,
the second layer 210 can serve as a shatter proofing mechanism for
the tile 100. The second layer 210 can therefore prevent sharp
pieces of broken tile from spreading across a work area or floor,
and can help prevent injury.
[0045] In some embodiments, the second layer 210 can have a
thickness from about 0.05 mm to about 2 mm, from about 0.1 mm to
about 1.1 mm, from about 0.1 mm to about 0.6 mm, or from about 0.2
mm to about 0.3 mm. In some embodiments, the second layer can be
about 1.25 mm thick, about 1 mm thick, about 0.5 mm thick, or about
0.25 mm thick. In addition, the second layer 210 can be less dense
and therefore lighter than the upper layer 205. Incorporation of
the second layer 210 can therefore help reduce the weight of the
tile 100 compared to a conventional tile of the same or similar
thickness.
[0046] In some embodiments, the second layer 210 can be press
laminated to the bottom of the upper layer 205 using a structural
adhesive such as conventional glue, epoxy, polyurethane, acrylic,
or one of several adhesives, mentioned above, that can be
integrated into the second layer 210 or applied separately. In some
embodiments, the second layer 210 can also be compression molded to
the bottom of the upper layer 205 or reaction injection molded to
the bottom of the upper layer 205 using a thermoset polymer. In
such embodiments, the molding process can be used to shape a third
layer as well. In some embodiments, the second layer 210 can be
attached to the bottom of the upper layer 205 by conventional glue,
epoxy, polyurethane, acrylic, or one of several thermoplastic
adhesives, and/or by hot pressing.
[0047] As discussed above, the second layer 210 can improve
properties of the tile 100, such as impact resistance, acoustic
insulation, etc. To further improve the impact resistance, bending
strength, acoustic insulation, and various other properties,
however, a third, under layer 215 can be disposed on the bottom of
the second layer 210 or incorporated with the second layer 210.
[0048] In some embodiments, the third, under layer 215 can be
similar to the first, upper layer 205. Thus, in some embodiments,
the third layer 215 can comprise a ceramic, such as a porcelain
that can have the same or similar composition as the first layer
205, or the third layer 215 can comprise another material such as,
for example, glass, metal, or stone. In some embodiments, the third
layer 215 can have approximately the same thickness, or range of
thicknesses, as the first layer 205. The third layer 215,
therefore, in combination with the first and second layers 205,
210, can create a periodic structure of two layers with a thin
reinforcing layer in between. Such a periodic structure can be
dispersive in nature to the transmission of mechanical shock waves
through the tile 100 when the tile 100 is impacted by a dropped
object. This can result in exceptionally high impact strength of
the composite tile 100, as shown for example in Table 1 below.
[0049] In other embodiments, the third layer 215 can comprise a
polymer laminate, such as a plastic laminate. In some embodiments,
the polymer laminate can be rigid such that it is not easily
deformable. In some embodiments, the polymer laminate can comprise
a thermoplastic such as polyethylene, polypropylene or
polyvinylchloride, or a thermoset material such as polyurethane. In
some embodiments, moreover, the polymer laminate can comprise one
or more fillers incorporated therein. The filler can be a resilient
and elastic material. The filler can be, for example, cork,
recycled crumb rubber, waste carpet fibers, chalk, wood particles,
and/or plastic particles from recycled waste plastics, such as from
waste PET bottles. The filler can provide additional acoustic
insulation, noise absorption, and thermal insulation properties.
The resilient, elastic nature of the polymer laminate and/or filler
can also improve the walking comfort of the tile 100.
[0050] Cork is an advantageous material to incorporate into the
third layer 215 because cork is a well-suited, naturally occurring
sound insulator and vibration dampener. This is due, at least in
part, to cork's cellular structure. Using about 5 to about 20
percent cork, or about 15 percent cork, for example, in
polyurethane sheets or other polymer sheets, especially
thermoplastic sheets, can significantly increase the sound and
vibration damping properties of a polymer laminate, making the
polymer laminate more desirable for acoustic insulation and
vibration isolation. These desirable properties can also be
achieved at higher cork concentrations from about 20 percent to
about 80 percent. In addition, one advantage of incorporating
polyurethane into the third layer 215 in some embodiments is that,
due to polyurethane's inherent polarity and adhesive nature, it may
bond well with the second layer 210, thereby eliminating the need
for a separate adhesive.
[0051] The third layer 215 can also act as a moisture barrier,
preventing any fluid that may seep up from cracks in the subfloor
from permeating the tile 100. The third layer 215 can also prevent
fluid from contacting the second layer 210.
[0052] The third layer 215 can either be fabricated independently
and glued to the bottom of the second layer 210 or processed
in-situ. Thus, in some embodiments, conventional glue, epoxy,
polyurethane, acrylic, or one of several thermoplastic adhesives
can be used to adhere the third layer 215 to the bottom of the
second layer 210. In other embodiments, the polymer laminate and/or
filler can be placed onto the bottom of the second layer 210. Heat
and pressure can then be applied to cause the polymer laminate and
filler to melt and fuse to the second layer 210, thereby attaching
the third layer 215 (and also the first layer 205) in situ by hot
pressing.
[0053] In some embodiments, such as embodiments employing a ceramic
third layer 215, the third layer 215 can have the same thickness,
or range of thicknesses, as the first layer 205, as discussed
above. In some embodiments, such as embodiments employing a polymer
laminate third layer 215, the third layer 215 can have a thickness
from about 0.5 mm to about 6 mm, from about 1 mm to about 5 mm, or
from about 2 mm to about 4 mm. In some embodiments, such as
embodiments employing a polymer laminate, the third layer 215 can
also be less dense and therefore lighter than the upper layer 205.
Incorporation of the third layer 215 can therefore help reduce the
weight of the tile 100 compared to a conventional tile of the same
or similar thickness, which, as described above, makes installation
easier and reduces shipping costs.
[0054] To improve ease of installation and other qualities of the
tile 100, a fourth, bottom layer 220 can be attached to the bottom
of the third layer 215. As discussed above, traditional tile
installation requires the mixing, spreading, and curing of
adhesives, such as thinset, mortar, and grout. These processes are
extremely time consuming and laborious, and require an excessive
amount of cleaning.
[0055] To alleviate these problems, the bottom layer 220 can
comprise a pressure sensitive adhesive, such as a pressure
sensitive, double-sided adhesive tape. The bottom layer 220 can
therefore enable a user to quickly and easily adhere the tile 100
to a surface, such as a subfloor, wall, or roof, eliminating the
problems caused by use of thinset, mortar, and grout. In other
embodiments, the bottom layer 220 can comprise a cork-polymer layer
that creates a physical friction bond with the subfloor, wall, or
roof. Alternatively, the bottom layer 220 can comprise a tack fast
loop fabric, such as a loop and hook fabric (such as Velcro.RTM.),
that interlocks with an underlayment on the subfloor, wall, or
roof.
[0056] In some embodiments, as shown in FIG. 5, the composite tile
100 comprises a bottom layer 220 that can maintain spacing between
the upper layers 205 of adjacently installed tiles 100. This can
increase ease of installation, and create a conventional look. In
some embodiments, the spacing can be maintained by one or more
extended edges 505 of the bottom layer 220, and/or the under layer
215, that extend horizontally beyond the edges of the upper layer
205. Thus, after installing the tiles 100 adjacent to one another,
the extended edges 505 can cause the bottom layers 220 (and/or the
under layers 215) of the adjacent tiles 100 to abut, but a space to
be present between adjacent upper layers 205. This space can then
be filled with a grouting material, preferably a polymeric grouting
material, for creating a grout joint. The grout may serve
additional purposes, such as the creation of a watertight joint
between two adjacent composite tiles 100 and/or providing a
conventional appearance.
[0057] In some embodiments, the bottom layer 220 can have a
thickness from about 0.01 mm to about 4 mm. In some embodiments,
the bottom layer 220 can have a thickness of about 1 mm or about 2
mm. In some embodiments, like the second layer 210 and, optionally,
the third layer 215, the bottom layer 220 can also be less dense
and therefore lighter than the upper layer 205, making the tile 100
easier to install and cheaper to ship than other tiles of the same
thickness.
[0058] As shown in FIGS. 3-4, embodiments of this disclosure can
also comprise a tile 100 with three layers. In such embodiments,
the upper layer 205 and bottom layer 220 can be substantially the
same as the upper layer 205 and bottom layer 220 described with
reference to the four layer embodiment shown in FIGS. 1-2. For some
three layer embodiments, however, this disclosure can include an
integrated second layer 310. The integrated second layer 310 can
optionally comprise a combination of the second layer 210 and third
layer 215 of the embodiment shown in FIGS. 1-2, as shown in FIG.
4.
[0059] In some embodiments, for example, the integrated second
layer 310 can comprise reinforcing materials, such as the
reinforcing materials incorporated in the second layer 210
(fiberglass, etc.), as discussed above. In addition, the integrated
second layer 310 can also comprise a resilient, elastic material,
such as the resilient, polymer laminate optionally incorporated in
the third layer 215, as also discussed above. These various
materials can be combined in any number of configurations to
produce the integrated second layer 310. In some embodiments, for
example, a fiberglass mat can be disposed within a mixture
comprising polymer laminate and filler to yield the integrated
second layer 310. In other embodiments, a layer of polymer laminate
and filler can be sandwiched between two layers of fiberglass mat
to yield the integrated second layer 310. The adhesive of the
second layer 215 can also be included in the integrated second
layer 310. The make-up of the integrated second layer 310, however,
is not limited to the materials incorporated into the second layer
210 and third layer 215.
[0060] In some embodiments, the integrated second layer 310 can be
attached to the upper layer 205 and bottom layer 220 in the same
manner as described with regard to attaching the upper layer 205 to
the second layer 210 or the second layer 210 to the third layer
215, above. Accordingly, a variety of adhesives and attachment
methods can be employed to attach the integrated second layer 310
to the upper layer 205 and bottom layer 220, for example, hot melt
adhesives and hot pressing.
[0061] Embodiments of this disclosure can comprise tiles 100 and
tile layers with varying thicknesses h (as shown in FIGS. 1 and 3).
In some embodiments, the tile 100 can have a thickness h of about 2
mm to 18 mm, of about 3 m to about 15 mm, of about 4 mm to about 12
mm, of about 5 mm to 8 mm, or of about 6 mm to about 8 mm. The tile
thickness h can be less than about 15 mm, less than about 12 mm,
less than about 10 mm, or less than about 8 mm. In some
embodiments, the tile 100 can have a thickness h of about 7.5 mm,
of about 7 mm, of about 6.5 mm, or of about 6 mm. Accordingly,
embodiments of this disclosure comprise tiles 100 that can be
thinner than common 8 mm porcelain tiles, the same thickness as
conventional tiles, or thicker than conventional tiles. Moreover,
embodiments of this disclosure comprise tiles having different
thicknesses, the different thicknesses being available according to
the particular needs of a given tile application. In fact, the
thickness of each layer, as well as the material comprising each
layer, can be optimized for any number of given tile
applications.
[0062] Embodiments of this disclosure can also comprise tiles 100
with varying length and width dimensions. In some embodiments, for
example, the length and width dimensions are about 12 inches by
about 24 inches, which are common dimensions for residential tile
products and applications. However, larger sizes up to about 40
inches by about 120 inches may be produced for other applications,
such as commercial installations.
[0063] Table 1 below provides information related to the impact
resistance of some embodiments of this disclosure as compared to
existing tiles. Specifically, Table 1 provides the impact
resistance of certain tiles in a standard steel ball drop test
wherein a steel ball with a 38 mm diameter and a mass of
approximately 225 grams is dropped on each type of tile multiple
times from various heights. The maximum height from which the ball
does not fracture the tile was recorded for various iterations of
the test, and the results are provided in Table 1. Specifically,
Table 1 provides the average maximum height from which the ball
does not fracture each type of tile and the standard deviation of
the height for each tile type. This height is the "impact
resistance" for purposes of Table 1. The greater the impact
resistance, the stronger and more resilient the tile.
[0064] As shown in Table 1, the types of tiles tested were: Tile
1--a standard 8 mm porcelain tile; Tile 2--a standard 8 mm
porcelain tile (installed on a subfloor with setting material);
Tile 3--a 3 mm porcelain tile or tile layer such as the first layer
205 or third layer 215 described above; Tile 4--a 3 mm porcelain
tile or tile layer such as the upper layer 205 described above with
a fiberglass and polymer adhesive backing such as the second layer
210 described above; and Tile 5--a tile with a porcelain upper
layer 205, a fiberglass and polymer adhesive second layer 210, and
a porcelain under layer 215, as described above, with a total
thickness h of 7.0 mm. Tile 5 was produced by selecting a 3 mm
thick porcelain tile with a decorative face as the first layer 205,
a woven fiberglass mat and adhesive as the 1 mm thick second layer
210, and for the third layer 215 a second porcelain tile of
approximately the same thickness as the first layer 205. Except as
noted above with regard to Tile 2, the tested samples were kept
free floating on a flat concrete floor during the test. In this
regard, it is noteworthy that installing a tile with setting
material can add to the impact resistance of the tile.
[0065] In Table 1 it can be seen that Tile 5 had the highest impact
resistance during the tests. In fact, the impact resistance is
significantly higher than all other tiles, including Tile 2 (the
standard tile installed), even though Tile 5 was free floating.
Moreover, Tile 4, which does not have under layer 215, had higher
impact resistance than standard Tile 1.
TABLE-US-00001 TABLE 1 Impact Resistance Tile (avg. inches .+-.
std. dev.) Tile 1--Standard 8 mm porcelain tile 8.0 .+-. 1.0 Tile
2--Standard 8 mm porcelain tile 20.0 .+-. 3.0 (installed) Tile 3--3
mm tile/tile layer 6.0 .+-. 1.8 Tile 4--3 mm tile upper layer plus
11.3 .+-. 2.3 fiberglass/adhesive reinforcing layer Tile 5--3 mm
tile upper layer plus 1 mm 46.0 .+-. 2.0 fiberglass/adhesive
reinforcing layer plus 3 mm tile under layer; total thickness of
7.0 mm
[0066] While the table and discussion above discloses that
embodiments of this disclosure are, or are useful for, producing
stronger thin tiles, embodiments of the present invention are, or
are useful for, producing stronger standard thickness tiles as well
as stronger, thicker tiles. For example, while some embodiments of
this disclosure are stronger tiles that are less than 8 mm in
thickness, some tiles of this disclosure are 8 mm in thickness or
more than 8 mm in thickness, and are stronger than conventional
tiles of the same or similar thicknesses regardless of their
thickness. Thus, Table 1 illustrates that some specific tiles 100
have improved impact resistance over other specific tiles, but also
illustrates conceptually that embodiments of this disclosure
provide improved impact resistance over similar conventional tiles
generally.
[0067] As described above, embodiments of the present invention can
comprise methods related to composite tiles 100, such as methods of
manufacturing or installing composite tiles 100. FIG. 6 shows an
exemplary method 600 of manufacturing composite tiles. As shown in
FIG. 6, in some embodiments, a first layer 205 of a tile can be
placed on a conveyor 605. In some embodiments, the first layer 205
can be placed with the top side 105 facing down at step 650.
[0068] In some embodiments, at step 655, a feeder can deposit an
adhesive layer onto the upward facing side of first layer 205
(since the top side 105 is facing down, the upward facing side is
actually the bottom of the first layer). Then, at step 660, a
reinforcing material, such as a fiberglass mat, for example, can be
deposited onto and into the adhesive layer. In other words, in some
embodiments, the reinforcing material can be deposited onto the
adhesive layer and can integrate with the adhesive layer. In some
embodiments, the reinforcing material and adhesive can form the
second layer 210. In some embodiments, the reinforcing layer can be
applied before the adhesive layer, i.e., steps 655 and 660 can be
reversed to form the second layer 210.
[0069] In some embodiments, at step 665, a third, under layer 215
can be deposited onto the bottom side of the second layer 210
(which is facing upward, since the composite tile is upside down).
The layers can then be hot pressed together at step 670. The hot
pressing can cause some adhesive, and/or other materials, to
protrude from the sides of the tile, as shown.
[0070] In some embodiments, at step 675, a fourth, bottom layer 220
can be deposited on the upward facing side of the third layer 215
(which is the bottom of the third layer 215). Then, at step 680, an
edge trimming device can trim the edges of the tile, thereby
determining the final dimensions of the tile 100 and cutting away
any excess material squeezed from the composite tile 100 during hot
pressing. At step 685, the tile can be packaged for shipment.
[0071] In some embodiments, the first and third layers 205, 215 can
be preheated before being introduced into the assembly process. In
this manner, the layers 205, 215 can facilitate hot pressing and
prevent premature drying of the adhesive.
[0072] During manufacturing of embodiments comprising three layers,
such as embodiments with an integrated second layer 310, the
integrated second layer 310 can be formed by introducing a
reinforcing material into a polymer laminate. This can be
accomplished by using the polymer laminate as an adhesive and
embedding the reinforcing layer within the polymer laminate,
similar to the method described above with regard to steps 655 and
660. Alternatively, the integrated second layer 310 can be formed
separately and adhesive can be used to adhere the integrated second
layer 310 to the top layer 205 and the bottom layer 220. In all
embodiments, hot pressing can be employed to secure two or more of
layers 205, 310, and 220 together, similarly to the methods shown
in FIG. 6.
[0073] After reading this disclosure in conjunction with the
figures, those skilled in the art will understand that the tiles
100 disclosed herein can be thinner than conventional tiles, while
also being easier to install, less susceptible to damage from
impact, and lighter. In addition, the tiles 100 disclosed herein
can provide superior walking comfort and acoustic insulation
compared to conventional tiles. It shall be understood by those
skilled in the art that each of the layers disclosed herein are
optional, and that embodiments omitting certain layers, or adding
additional layers, are envisioned. Moreover, the order of the
layers can be changed, as this disclosure is not limited to the
orders described above. For example, in some embodiments, the third
layer 215 can be above the second layer 210.
[0074] While certain systems and methods related to composite tile
systems and methods have been disclosed in some exemplary forms,
many modifications, additions, and deletions may be made without
departing from the spirit and scope of the system, method, and
their equivalents. The embodiments disclosed herein are further
capable of other embodiments and of being practiced and carried out
in various ways. Also, it is to be understood that the phraseology
and terminology employed herein are for the purposes of description
and should not be regarded as limiting the claims.
[0075] Accordingly, those skilled in the art will appreciate that
the conception upon which the application and claims are based may
be readily utilized as a basis for the design of other devices,
methods, and systems for carrying out the several purposes of the
embodiments and claims presented herein. It is important,
therefore, that the claims be regarded as including such equivalent
constructions.
* * * * *