Surface-covering article used to produce seamless surface coverings

Abstract

A surface-covering article used to produce surface coverings is described. The surface-covering article includes a plurality of tiles disposed adjacent to each other. A first layer made of a first type of resin is applied to one side of the plurality of tiles. A second layer made of a second type of resin is applied to and around another side of the plurality of tiles and into any gap between adjacent tiles to enclose the plurality of tiles within the first and second layers of resin. The second type of resin of the second layer of resin bonds with the first type of resin of the first layer to join the resin layers permanently to each other and to the enclosed plurality of tiles, thereby producing a seamless surface-covering article made of multiple encapsulated tiles and having a continuous surface of resin that seals said any gap between adjacent tiles.

Description

RELATED APPLICATION [0001] This application is a continuation application claiming the benefit of the filing date of co-pending U.S. patent application Ser. No. 10 / 856,070, filed May 28, 2004, titled “Surface-Covering Article and Methods of Installing the Same,” the entirety of which U.S. patent application is hereby incorporated by reference.FIELD OF THE INVENTION [0002] The invention relates to surface coverings. More specifically, the invention relates to a surface-covering article used to produce a seamless surface covering. BACKGROUND OF THE INVENTION [0003] A variety of surface covering products (e.g., tiles, sheets, planks, and the like) are widely used in the building industry. Surface covering products are either natural (e.g., stone, wood, ceramic, and mineral bodies) or man-made (e.g., laminates and plastics). The man-made surface coverings are often fabricated to appear like a natural material. For example, vinyl tiles can include a pattern that imitates the look of marb...

AI Technical Summary

Benefits of technology

The resin-based system ensures a level, durable, and low-maintenance surface that resists water, contaminants, and wear, with improved weight distribution and aesthetic appeal, reducing the need for frequent repairs and enhancing sanitary conditions.

Problems solved by technology

Although some man-made surface coverings can be resilient under foot, they typically are not designed with weight distribution in mind.

As such, some man-made surface coverings tend to warp or displace when a load force is applied to the surface.

The warping and displacement results in an unlevel surface.

Natural tiles share in these disadvantages and are traditionally brittle and tend to crack or break during manufacturing, shipping, and installation.

Although wood is strong and flexible, it rots, warps, and discolors as it weathers.

Such procedures are substantially more costly and labor intensive, and are not always aesthetically, structurally, or functionally satisfactory, over an extended period of time.

It requires labor intensive buffing or polishing, to maintain the top finish and, after an extended period of time, it also becomes necessary to re-grout most areas surrounding the tiles due to discoloration and sanitary concerns.

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