Composite tile systems and methods

Abstract

Composite 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.

Description

CROSS-REFERENCE TO RELATED APPLICATION[0001]This application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Patent Application Ser. No. 61 / 827,498, filed 24 May 2013 and entitled Composite Tile Systems and Methods, the entire contents and substance of which is hereby incorporated by reference as if fully set forth below.BACKGROUND[0002]1. Field of the Invention[0003]Embodiments of this disclosure relate to tile systems and methods, and more particularly, to composite tile systems and methods.[0004]2. Description of Related Art[0005]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,...

AI Technical Summary

Benefits of technology

The patent text describes a new kind of composite tile system that combines the strength and durability of traditional ceramic tiles with the comfort and light-weight of non-ceramic materials. The system includes layers of reinforcing materials that absorb and dissipate impact energy, making the tiles stronger and more comfortable to walk on. The system also has a self-adhering feature for easy installation. Overall, the patent text describes a new way to create high-quality composite tiles that are both durable and comfortable.

Problems solved by technology

These processes are time consuming and laborious, and require an excessive amount of cleaning.

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.

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 / cm3. 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.

Moreover, traditional porcelain tiles have inferior walking comfort and acoustic insulation compared to other floor covering materials such as laminates, carpet, hardwood, and vinyl.

Conventionally, these tiles also have low impact resistance, poor walking comfort, etc.

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