Compact foam core (DFC) tile with imitated thin slurry lines

Abstract

A floor tile has a plurality of sides and includes at least a top layer, a core layer, and an exposed portion extending outwardly along one side of the tile and having a textured surface that mimics a grout line. The top layer of the tile can include a top surface defined by a wear resistant layer, a polyvinyl chloride (PVC) layer having an optimized density and a dye or colorant, and a decorative layer. The core layer is made of a dense foam material. The exposed portion and textured surface may be formed on the PVC layer at a depth between about 0.9 mm and 2 mm or deeper below the top surface of the tile so as to extend into the core layer and will have a width typically between 2 mm and 5 mm. The total thickness of the tile is preferably in the range of 4 mm to 8 mm.

Description

This application is a divisional application of a PCT invention patent application filed on July 17, 2017 by Fast Style Industrial Co., Ltd. (international application number PCT / IB2017 / 000852) and entitled “Dense Foam Core (DFC) Tiles with Simulated Grout Lines”. Priority declaration

[0001] The present invention claims priority under 35 USC §119(e) to currently pending U.S. Provisional Patent Application Serial No. 62 / 380,122 and filed on August 26, 2016, the entire contents of which are incorporated herein by reference. Technical Field

[0002] The present invention relates to a ceramic tile, such as a floor tile, which is made of a synthetic material and has the appearance of real marble, stone, ceramic or wood, and which provides a very realistic but simulated grout line formed along the length of one or more sides thereof. The ceramic tile of the present invention includes at least a top layer and a core layer, and during the manufacturing process, at least a portion of the top layer is removed along at least one side thereof to define an exposed portion along the side of the ceramic tile, which extends outwardly and away from the ceramic tile below the top surface of the ceramic tile. The exposed portion of the ceramic tile additionally includes a textured surface to closely resemble the look and feel of a real grout line, and may include a colorant to correspond to the overall intended color of the resulting ceramic tile. Background Art

[0003] When constructing a home, building or other structure, there is almost always an unfinished floor surface, such as a concrete slab, a wood substructure or the like, which needs to be finished to provide a more attractive and / or polished appearance. The same is true for most unfinished wall surfaces. In many cases, tiles will be used to finish the floor surface or wall surface, and the tiles are usually made of real marble or stone, or made of porcelain or ceramic according to budgetary constraints. Traditionally, such tiles are fixed on the unfinished floor or wall surface using a cement-like mixture, and one or more tiles are set next to each other and leave a small gap between the edges of adjacent tiles. It is usually boring to form such gaps between tiles, and spacers need to be used to ensure that the tiles are uniform and aligned. In addition, as part of the installation process, such gaps will be filled with grout mixture at a later stage, which forms a "grout line" around the side edges of the tile. In general, the process of installing tiles and forming grout lines requires a lot of time, which increases the labor and overall cost of the project.

[0004] Over the past few years, flooring products and tiles have been made of synthetic materials and constructed to mimic the appearance of real marble, stone or ceramic tiles. For example, laminate flooring and vinyl flooring products are known, including some that mimic the appearance of real stone, marble or ceramic tiles. These flooring products create an optical or visual illusion that makes the tile surface look like real stone, marble or ceramic flooring, or even like real wood flooring. However, traditionally, the manufacture of such flooring products requires that the individual tiles be installed directly adjacent to each other, usually in an abutting relationship, but some of these products are installed with slight separations between them to facilitate installation on uneven floor surfaces. Although this slight separation may be observable, and in some cases may appear to be a small seam or even a micro-groove, these known types of tiles do not provide any structure to reproduce or closely resemble the look and feel of real grout lines. This is also true for existing imitation flooring products that have internal connecting mechanisms to facilitate installation, such as correspondingly arranged "tongue" and "groove" structures formed along one side of the tile. Additionally, some laminate flooring is known to provide the optical illusion of having grout lines, but in reality, the joints of such flooring and / or tiles are completely flat and have simulated grout lines drawn and deepened on the edges by an artist to give the effect of depth.

[0005] While such flooring products or tiles exist, none of them are manufactured with a polyvinyl chloride (PVC) layer of optimal density such that a portion of it can be exposed during the manufacturing process to form a simulated grout line with a very realistic look and feel of a real grout line. Furthermore, none of such tiles or flooring products are manufactured with a polyvinyl chloride (PVC) layer that is combined with a colorant during the manufacturing process to provide the simulated grout line with a variety of colors to match or closely correspond to the overall color of the resulting tile.

[0006] It would therefore be advantageous if a tile or flooring product made from a synthetic material such as, but not limited to, polyvinyl chloride (PVC) was developed that provided the look and feel of a real grout line and thereby could be manufactured in a variety of different colors and designs and, further, could be easily and quickly installed.

[0007] Furthermore, if any such improved tile or flooring product is developed, it would be advantageous if it could be made from a material that is hard and durable enough for a wide variety of applications and also could be easily formed during the manufacturing process to achieve a texture on selected portions that matches the look and feel of real grout lines. Summary of the invention

[0008] The present invention seeks to provide a solution to these and other needs that still exist in the art, and thus the present invention relates to ceramic tiles, primarily but not exclusively intended for flooring applications, which simulate the appearance of an actual tile surface, such as stone, ceramic, or marble, and further, which simulate the appearance of a floor covering, and further, which are formed of a material that can be produced in a variety of different colors and designs. However, the present invention also relates to a ceramic tile that is constructed with simulated grout lines, but with a very realistic look and feel similar to actual grout lines, formed on or substantially along at least one side or edge of the ceramic tile. Furthermore, the ceramic tiles of the present invention can be manufactured in different sizes having a variety of lengths and widths, and can also be manufactured in a variety of shapes, such as, but not limited to, rectangular, square, hexagonal, or octagonal, and the like.

[0009] As will be apparent from the following description, the tile of the present invention comprises at least a top layer and a core layer. The top layer is generally a layer made of a vinyl composite material, wherein the vinyl composite material comprises a synthetic plastic polymer, such as, but not limited to, polyvinyl chloride (PVC). In most embodiments, the top layer of the tile of the present invention comprises at least one PVC layer. However, in at least one preferred embodiment, the top layer also comprises a wear layer and / or a decorative layer. Moreover, the top layer of the tile, particularly the wear layer in one or more of the embodiments, is formed to have a selected thickness depending on the intended use of the tile (e.g., residential use, light contract use, heavy commercial use, or other types of use). Moreover, the density of the polyvinyl chloride (PVC) layer material makes it easy to change the tile of the present invention during the manufacturing process so as to obtain the desired effect of providing a very realistic grout line appearance when viewed by a person standing on or near the floor surface (such as 5 to 6 feet away or more). Also during the manufacturing process, the top surface of the tile (defined by the top layer, and specifically defined by the wear layer in one or more embodiments) can be pressed or changed to achieve a variety of textured surfaces thereon, which helps to provide the tile with the appearance of a real marble, stone, ceramic or real wood surface or other natural textures.

[0010] The core layer of the tile of the present invention can be formed of a "dense foam" material. More specifically, the core layer preferably includes a dense foam material, such as but not limited to a wood plastic composite ("WPC") material, and is further preferably waterproof. Moreover, the material composition and density range of the dense foam ensure that the core layer, and therefore the tile, is sufficiently hard and durable for flooring applications. In addition, the core layer can have a smooth texture and can include one or more sub-layers that serve as a cushion layer or sound barrier. These sub-layers can be made of other materials, such as but not limited to laminate foil, cork, foam or ethyl vinyl acetate.

[0011] The tile of the present invention also includes an exposed portion extending outwardly from and along the length of at least one side of the tile. The exposed portion is associated with the sidewall and defines a gap that preferably extends uniformly and substantially along the side of the tile. The exposed portion further includes a textured surface that is configured to closely mimic the appearance of a real grout line. As shown in the various figures, the exposed portion is formed along at least one side of the tile of the present invention, but in other embodiments, the exposed portion may be arranged along more than one side or even all sides of the tile. The exposed portion is preferably formed on the tile during the manufacturing process, rather than during the installation process. During the manufacturing process, a tool (such as, but not limited to, a knife, a cutting blade, etc.) may be configured and used to uniformly remove a portion of the top surface of the tile along at least one selected side of the tile and will expose at least a portion of the top layer of the tile, and in some embodiments, may expose a portion of the core layer. In addition, the knife, cutting blade, or other tool may also modify the exposed portion, such as by further cutting and / or shaping it to provide a textured appearance that closely mimics the look and feel of a real grout line.

[0012] Additional features of the tiles of the present invention include interconnection mechanisms formed on at least one side of the tile to facilitate installation. For example, the interconnection mechanism may include a "tongue" formed along one side of a tile and a "groove" formed along one side of a different tile, and the tongue and groove are cooperatively configured to interconnect in a paired manner to connect two different tiles together along their correspondingly disposed sides. In addition, the "tongue" side and / or the "groove" side may each be configured as an exposed portion adapted to define a gap along the side or edge of the tile.

[0013] Other features of the tile of the present invention include a bevel, which includes an inclined edge and is formed on the side of the tile, specifically, adjacent to the exposed portion and textured surface of the tile. The sidewall associated with the exposed portion may include a bevel on its upper portion, and generally, the bevel helps to more highly simulate the look and feel of a real grout line. The bevel can be formed in a variety of sizes, but in one embodiment, the angle of inclination of the bevel relative to the top surface of the tile will be in the range of about 30° to about 90°, but in the embodiment shown, the angle will be closer to about 12°. Generally, in embodiments with a bevel, the expected width of the resulting simulated grout line will be a factor in determining the steepness of the corresponding bevel angle. For example, a steeper bevel angle may correspond to a grout line with a smaller width, while a less steep bevel angle may correspond to a grout line with a larger width. Alternatively, the bevel may have a modified structure, such as a two-stage decline from the top surface of the tile to the exposed portion and a textured surface that simulates a grout line. In another embodiment, the bevel may include a "micro" bevel.

[0014] The primary object of the present invention is to provide a tile suitable for use as a flooring surface that is made of a synthetic material and that closely simulates the look of real stone, marble, ceramic or even wood flooring, but also provides simulated grout lines that have a very realistic look and feel similar to real grout lines.

[0015] Another primary object of the present invention is to provide a tile of the present invention made of a synthetic material which can be easily formed during the manufacturing process to define an exposed portion including a gap substantially or completely along a selected side thereof and which can be easily shaped to achieve a textured surface thereon that closely matches the look and feel of a real grout line.

[0016] It is yet another primary object of the present invention to provide a tile having a highly realistic looking but simulated grout line which can also be manufactured in a variety of colors to provide a highly matched and consistent color to the overall color of the resulting tile which has not been achieved in any previously existing product.

[0017] An advantage of the tiles of the present invention, in at least some embodiments, is that the material used to make the tiles is sufficiently hard and durable for a variety of applications, and is also waterproof.

[0018] The tiles of the present invention are characterized in that, in at least some embodiments, there are interconnecting mechanisms formed along at least one edge or more edges of the tile to facilitate the assembly and installation process.

[0019] Another advantage of the tiles of the present invention is that the materials used to make the tiles can take on a variety of different shapes, colors and / or designs.

[0020] These and other objects, features and advantages of the present invention will become more apparent when considering the accompanying drawings and detailed description. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] In order to more fully understand the nature of the present invention, reference should be made to the following detailed description taken in conjunction with the accompanying drawings, in which:

[0022] Figure 1 is a cross-sectional view of a tile according to the present invention, which includes a top layer and a core layer, and shows an exposed portion formed in the top layer.

[0023] Figure 2 Also a cross-sectional view of a tile according to the invention, comprising a Figure 1 The top layer and core layer of the present invention are shown, but the top layer is shown to include a polyvinyl chloride (PVC) layer and a wear-resistant layer.

[0024] Figure 3 Also a cross-sectional view of a tile according to the invention, comprising a Figure 1The top layer and core layer of the present invention are shown, but the top layer is shown to include a polyvinyl chloride (PVC) layer, a decorative layer and a wear-resistant layer.

[0025] Figure 4 Also a transverse view of a tile according to the invention, comprising a tile similar to Figure 2 A top layer and a core layer of the embodiment of the present invention include a top layer having a polyvinyl chloride (PVC) layer and a wear layer, but showing that an exposed portion is formed on the core layer.

[0026] Figure 5 Also a cross-sectional view of a tile according to the invention, comprising a Figure 3 A top layer and a core layer of the present invention include a top layer having a polyvinyl chloride (PVC) layer, a decorative layer and a wear layer, but showing that the exposed portion is formed on the core layer.

[0027] Figure 6 Also a cross-sectional view of a tile according to the invention, but showing a preferred embodiment of the top layer and exposed portion and the core layer and interconnection mechanism.

[0028] 7-A is also a cross-sectional view of a tile according to another preferred embodiment of the present invention, which includes at least a top layer including a polyvinyl chloride (PVC) layer, a core layer, and an interconnection mechanism, and shows an exposed portion having a simulated grout line formed in the PVC layer.

[0029] 7-B is also a cross-sectional view of a tile in yet another embodiment according to the present invention, which includes at least a top layer and a core layer and an interconnection mechanism, and shows an exposed portion having a simulated grout line formed on the core layer.

[0030] Figure 8 yes Figure 1 A perspective view of an embodiment of the invention is shown, comprising a top layer and a core layer.

[0031] Fig. 9 Also similar to Figure 1 A perspective view of the present invention is shown, but another embodiment is shown, wherein the tile includes a top layer and a core layer, the top layer including a wear layer, a decorative layer and a polyvinyl chloride (PVC) layer, and further shows an exposed portion formed by removing most of the top layer so that the exposed portion is set in the PVC layer.

[0032] Fig.10 Also similar to Figure 1 0026] A perspective view of the present invention is shown, but in an embodiment the tile includes a top layer including a wear layer, a decorative layer and a polyvinyl chloride (PVC) layer, and further showing an exposed portion having a simulated grout line formed on the core layer.

[0033] Fig.11 yes Fig. 9A perspective exploded view of the embodiment shown in FIG.

[0034] Fig.12 is a cross-sectional view of an embodiment according to the present invention, wherein a chamfer is formed on the top layer.

[0035] Fig.13 is a transverse cross-sectional view of an alternative embodiment according to the present invention, wherein a chamfer is formed on the core layer.

[0036] Fig.14 is a cross-sectional view of yet another embodiment of the present invention, wherein a micro-bevel is formed on the top layer.

[0037] 15-A is a plan view of a preferred embodiment according to the present invention, showing a tile including an exposed surface having simulated grout lines formed on all edges thereof.

[0038] 15-B is a plan view of several tiles, each similar to the tile depicted in FIG. 15-A having an exposed portion and having simulated grout lines formed on all sides of the exposed portion, each interconnected together to form a floor or wall covering.

[0039] 16-A is a plan view of another preferred embodiment according to the present invention, showing a tile including an exposed surface having simulated grout lines formed on both sides thereof.

[0040] 16-B is a plan view of several tiles, each similar to the tile depicted in FIG. 16-A having an exposed portion and having simulated grout lines formed on both sides of the exposed portion, each interconnected together to form a floor or wall covering.

[0041] 17-A is a plan view of another preferred embodiment according to the present invention, showing a tile including simulated grout lines formed on two adjacent edges.

[0042] 17-B is a plan view of another preferred embodiment according to the present invention, showing a plurality of interconnected tiles, each tile including simulated grout lines formed on two adjacent edges.

[0043] Like reference numerals refer to like parts throughout the several views of the drawings. DETAILED DESCRIPTION

[0044] The present invention relates to a tile 1, such as a floor tile, made of a synthetic material to emulate the look and feel of real stone, marble, ceramic, wood or other material, but which is further configured to provide a simulated grout line having a very realistic look and feel on or along at least one side or edge of the tile 1. Although the tile 1 of the present invention is particularly suitable for use as a floor tile, it can also be easily used on wall surfaces or in a variety of other applications, and should not be considered to be limited to floor applications.

[0045] Generally speaking, the tile 1 of the present invention comprises an upper (top) portion, a lower (core) portion, and a plurality of edges. Figure 1 and Figure 8 , the upper (top) portion may be defined by the top layer 20, and the lower (core) portion may be defined by the core layer 30. Figure 1 As shown, the top layer 20 includes a first surface 22 and a lower (second) surface 24, the first surface 22 at least partially defining the top surface 10 of the tile 1. The core layer 30 includes an upper (third) surface 32, which is adhered to or otherwise connected to the lower (second) surface 24 of the top layer 20 to combine the top layer 20 and the core layer 30 together. The core layer 30 also includes a fourth surface 34, which generally defines the bottom surface 12 of the tile 1, which will be adhered to an unfinished concrete slab or other ground surface in a building. However, in some embodiments, the core layer 30 may include a sub-layer, such as a sub-layer of sound insulation or other material.

[0046] The tile 1 of the present invention may be formed in part from a vinyl material or a vinyl composite material, and may be referred to as a vinyl composite tile (VCT). While the top or upper portion may be formed from a variety of materials, vinyl materials are preferred for a variety of reasons, including the ability to provide a quality product at an affordable price. The top layer 20 will be formed entirely or at least in part from a vinyl composite material or a synthetic plastic polymer such as polyvinyl chloride (PVC). Moreover, as described in more detail herein, in most embodiments, the top layer 20 will include a layer of polyvinyl chloride (PVC), such as plasticized PVC, mixed with a dye or colorant and having an optimal density to allow for easy and consistent formation of a realistic-looking grout line.

[0047] Reference now Figure 2 To Figure 7-B and Figure 9-11 In some embodiments, the top layer 20 will include additional layers. For example, Figure 2 and Figure 4As shown, the top layer 20 is shown as including a wear layer 50 and a polyvinyl chloride (PVC) layer 40. In these and other embodiments, the wear layer 50 includes a top surface 52 that coincides in whole or at least in part with the top surface 10 of the tile. The thickness of the wear layer 50 may vary depending on its intended use, such as residential use, light contract use, heavy commercial use, or other types of uses. The wear layer 50 will preferably be formed during the manufacturing process so as to include one or more design features, such as a texture having some undulations to simulate the look and feel of real stone or marble or a texture having grooves and / or other effects to simulate the look and feel of real wood, for example. In Figure 2 and Figure 4 In the illustrated embodiment, the polyvinyl chloride (PVC) layer 40 is generally disposed between the wear layer 50 and the core layer 30. For example, the polyvinyl chloride (PVC) layer 40 may be connected to the lower surface 54 of the wear layer 50 at its upper surface 42 by adhesive and / or pressing, and similarly may be connected to the upper surface 32 of the core layer 30 at its lower surface 44. The polyvinyl chloride (PVC) layer 40 may include a synthetic plastic polymer material such as polyvinyl chloride (PVC), or may be made of other materials, etc. to include other materials. However, since it includes polyvinyl chloride (PVC), it is referred to herein as the polyvinyl chloride (PVC) layer 40. In a preferred embodiment, the density of the polyvinyl chloride (PVC) layer 40 is in the range of approximately about 2,000 kg / m 3 About 2,400 kg / m 3 .

[0048] Reference now Figure 3 , Figure 5 , Figure 6 , Figures 7-A and 7-B and Figure 9-11 , the top layer 20 of the tile 1 of the present invention may include a wear layer 50, a polyvinyl chloride (PVC) layer 40, and a decorative layer 60. The decorative layer 60 may include a film or sheet that may be made of a variety of materials, such as, but not limited to, polyvinyl chloride (PVC). The decorative layer 60 will also preferably include one or more design features that help provide the realistic appearance of a selected material, such as real stone, real marble, ceramic, wood, or other surface. For example, the decorative layer 60 may include a film having decorative features that correspond to the appearance and coloring of natural wood grain or plank flooring. In Figure 3 , Figures 5 to 7B and Figure 9-11 In the embodiment of the present invention, the decorative layer 60 is disposed in an interconnected relationship between the wear layer 50 and the polyvinyl chloride (PVC) layer 40. These layers can be adhesively connected or interconnected by various adhesives known in the art, such as but not limited to glue. For example, and from Fig. 9 and Fig.11It will be appreciated that the decorative layer 60 includes an upper surface 62 connected to the lower surface 54 of the wear layer 50, and a lower surface 64 connected to the upper surface 42 of the polyvinyl chloride (PVC) layer 40. In addition, the wear layer 50 can be made to have a substantially translucent or transparent appearance. When the wear layer 50 is made of a translucent or transparent material, it allows the design features carried on the decorative layer 60 to be easily seen through it. In one or more embodiments, a coating of another material can be applied to the top surface 10 of the wear layer 50. As an example, the coating can include an epoxy resin (ER) or polyurethane (PU) material, which can be cured using ultraviolet (UV) lighting and a heating process. However, providing a tile 1 with or without a decorative layer 60 is within the scope of the present invention.

[0049] Furthermore, it is within the scope of the present invention to provide a tile 1 comprising waterproof properties. As such, the materials of the top layer 20 as well as the different layers of the core layer 20 may all comprise waterproof properties. Similarly, the adhesive used to connect these layers may also have waterproof properties.

[0050] As previously mentioned, the material composition of the top layer 20 can vary, but in at least one embodiment, the top layer 20 generally includes a mixture of polyvinyl chloride (PVC) and calcium powder, oil, and a blowing agent. In a preferred embodiment, the material composition of the top layer 20 can be about 20% to about 30% polyvinyl chloride (PVC), about 60% to about 70% calcium powder, about 5% to about 10% oil, and about 0.5% to about 5% blowing agent.

[0051] The tile 1 of the present invention also comprises a lower (or core) part, which may be made of Figure 1-14 The core layer 30 shown is defined. The core layer 30 is preferably formed by a "dense foam" material. More specifically, the core layer 30 preferably includes a dense foam material, such as, but not limited to, a wood plastic composite ("WPC") material, and is further preferably waterproof. In addition, the core layer 30 can have a smooth texture and can include one or more sublayers used as a cushion or sound barrier. These sublayers can be made of other materials, such as laminated foil, cork, foam, or ethyl vinyl acetate. Although the material composition of the core layer 30 can vary, in at least one embodiment it comprises a combination of synthetic plastic polymers (such as polyvinyl chloride (PVC)), calcium powder and a foaming agent. In a preferred embodiment, the dense foam material of the core layer 30 includes polyvinyl chloride (PVC) in an amount of approximately between about 50% and about 55%, calcium powder in an amount of approximately between about 40% and about 45%, and a foaming agent in an amount of approximately between about 5% and about 10%. The foaming agent can be a mixture of materials used to enhance stability. Also in a preferred embodiment, the dense foam material of the core layer 30 will have a density of approximately 800 kg / m 3 About 900kg / m 3This helps ensure that the tile 1 is sufficiently hard and durable for flooring applications.

[0052] Typically, the overall thickness of the tile 1 can range from about 4 mm to about 12 mm, depending on the particular embodiment. In one or more embodiments of the tile 1, the overall thickness 30 of the tile 1 from the top surface 10 of the top layer 20 to the bottom surface 34 of the core layer 30 will preferably be generally about 7 mm, and the thickness of the core layer 30 will generally range from 4 mm to about 6 mm. In embodiments of the tile 1 in which the top layer 20 includes a wear layer 50 and a polyvinyl chloride (PVC) layer 40, the thickness of the top layer 20 will generally be about 2 mm. For example, the wear layer 50 can generally range from about 0.3 mm to 0.7 mm between its top surface 52 and lower surface 54. Moreover, the polyvinyl chloride (PVC) layer 40 can generally range from about 1.4 mm to about 1.5 mm in thickness between its upper surface 42 and lower surface 44. In embodiments of the tile 1 that include a decorative layer 60, such as Figure 3 , Figure 5 To Figure 7-B and Figure 9-11 As shown, the thickness of the decorative layer 60 between its top surface 62 and bottom surface 64 may generally be in the range of about 0.05 mm to about 0.1 mm. In the most preferred embodiment of the tile 1 according to the present invention, as shown in FIG. Figure 6 As shown, the core layer 30 comprises a thickness of about 5 mm, while the top layer 20 comprises a thickness of generally about 2 mm, including a wear layer 50 having a thickness of about 0.5 mm, a polyvinyl chloride (PVC) layer 40 having a thickness of about 1.43 mm, and a decorative layer 60 having a thickness of about 0.07 mm. However, other embodiments of the tile 1 having different thicknesses are also within the scope of the present invention, and as described above, the thickness of the tile 1 can be within the preferred range of about 4 mm to about 12 mm.

[0053] However, in an alternative embodiment, Figure 4-5 7-B , the tile 1 of the present invention may include a polyvinyl chloride layer 40 having a substantially reduced thickness between its top surface 42 and lower surface 44. For example, the polyvinyl chloride (PVC) layer 40 may have a thickness of approximately 0.3 mm, which, as described herein below, may facilitate exposing at least a portion of the core layer 30 as the exposed portion 18 during the manufacturing process. In such an embodiment, the overall thickness of the tile 1 will generally be about 5 mm to about 6.5 mm, and preferably about 5.9 mm.

[0054] As mentioned above, the tile 1 of the present invention also includes a plurality of edges, such as 16 or 16', and may also have different shapes and different sizes. Figure 8-11As shown in the illustrative embodiments of Figures 15-A to 17-B, the tile 1 of the present invention can have a generally rectangular shape with four sides 16 or 16'. The dimensions of such a tile 1 having a rectangular shape, by way of example only, can be twelve (12") inches by twenty-four (24") inches, but can be easily altered to other attractive dimensions. As another example, the tile 1 of the present invention can have a square shape. Moreover, the tile 1 of the present invention can also have six or eight sides 16 or 16', as in the case of tiles having hexagonal or octagonal shapes. Other shapes, including those having an odd number of sides, are also possible, depending on the overall visual effect desired.

[0055] The tile 1 of the present invention also includes an exposed portion 18 along at least one side thereof (such as 16). Figure 1-14 As shown, the exposed portion 18 extends outwardly away from the top surface 10 of the tile 1 below the top surface 10 of the tile 1 and is partially defined by the sidewalls 15 formed in at least the top layer 20. As will be described later herein, the exposed portion 18 effectively defines a gap 14 in the plane of the top surface 10 of the tile 1, such as in Figure 8-14 As may be best shown in FIG. 1 , the gap 14 preferably extends uniformly and completely or substantially along the length of the edge 16. In at least one embodiment, such as Figure 6 15-A to 17-B, when a plurality of tiles 1 of the present invention are assembled and installed with their exposed portions 18 disposed in an operational orientation, the plurality of tiles 1 will collectively provide a person standing several feet away (or more) with a highly realistic appearance in terms of their resemblance to a selected material (such as real marble, stone, or ceramic) and in terms of the appearance of the tiles 1 having real grout lines, where the appearance of having real grout lines is largely caused by the depth of the exposed portions 18 and the width of the gaps 14 relative to the top surface 10 of the tile 1, as well as the textured surface of the exposed portions 18. Additionally, the top layer 20 and / or the core layer 30 may be manufactured to include a dye that may match or reflect a variety of grout colors to correspond to the desired coloration of the entire tile 1 .

[0056] Also like Figure 1-14As shown, it can be seen that the exposed portion 18 of the tile 1 (including the sidewalls 15 associated therewith) effectively defines the gap 14. The width W of the exposed portion 18, and the resulting gap 14, will be substantially uniform along the length of the edge 16 of the tile in a preferred embodiment, and can range from a barely perceptible but still visible width to about 6 mm or more, depending on the desired overall surface appearance. However, Figure 6 The preferred embodiment of shows an exposed portion 18 having a width W of about 5 mm. In addition, Figure 6 The embodiment of the embodiment shows the side wall 15 extending into the polyvinyl chloride (PVC) layer 40 of the top layer 20, so that the exposed portion 18 is formed on or in the PVC layer 40 at a depth D of approximately about 0.9 mm below the top surface 10 of the tile. However, the exposed portion 18 can be located at another depth, but preferably within a range of approximately about 0.9 mm to about 2 mm from the top surface 10 of the tile 1. This range should be considered an approximate range because during the production of the tile 1, variations such as within 0.1 mm are possible, which can enhance the realistic appearance of the simulated grout line of the tile 1.

[0057] The above-described exposed portion 18 having a textured surface configured to present the look and feel of a real grout line is ideally achieved during the manufacturing process of the tile 1 used in the present invention. More specifically, during the manufacturing process of the tile 1, a tool such as a press and / or trimmer or other instrument (such as a cutting blade, a contour knife, etc.) can be applied to the tile 1, such as to the top layer 20 along at least one side or edge 16. The press and / or trimmer or other tool can be used to remove all or substantially all of the top layer 20 extending along a selected side 16 of the tile 1 to expose a portion of the polyvinyl chloride (PVC) layer 40 and define the exposed portion 18 extending outwardly about the selected side (such as 16) of the tile 1. In a preferred embodiment, the density of the polyvinyl chloride (PVC) layer 40 should be approximately about 2,000 kg / m 3 About 2,400kg / m 3 , to allow a tool, cutting blade, knife or other instrument to cut and shape the polyvinyl chloride (PVC) layer 40 to form the sidewalls 15 and exposed portions 18 and to form a textured surface thereon that ideally approximates a fine sand texture. In addition, this density range provides sufficient structural integrity for the polyvinyl chloride (PVC) layer 40 so that it will not decompose, crack, tear or otherwise become damaged during the cutting and shaping process. In an alternative embodiment, during the process of manufacturing the tile 1, the tool or instrument used can remove more of the top layer 20 extending along the selected edge 16 of the tile so as to expose a deeper contour of at least a portion of the core layer 30.

[0058] Moreover, in Figure 2-3 , Figure 6, Fig. 9 and Figure 11-14 In the preferred embodiment of the tile 1 shown, the exposed portion 18 is formed on the polyvinyl chloride (PVC) layer 40. It will be clear from the following discussion that during the manufacturing process, when a portion of the top surface 10 of the tile 1 is removed along one edge (e.g., 16) thereof, preferably at a depth of between 0.9 mm and 2 mm below the plane of the top surface 10, at least a portion of the polyvinyl chloride (PVC) layer 40 will be exposed and formed to define the exposed portion 18, which includes the sidewall 15 and the gap 14. Alternatively, and as already described with respect to Figure 4 , Figure 5 7-B , the thickness of the polyvinyl chloride (PVC) layer 40 may be significantly reduced to facilitate exposing at least a portion of the core layer 30 to define the exposed portion 18 and the gap 14 thereon.

[0059] In another embodiment of the tile 1 of the present invention, the top layer may include yet another additional layer for a number of reasons, which will now be described. More specifically, in those embodiments where the top layer 20 includes a polyvinyl chloride (PVC) layer 40 with a dye or colorant, a decorative layer 60, and an additional layer, the additional layer may be in the form of a coating and may be connected and disposed between the polyvinyl chloride (PVC) layer 40 and the decorative layer 60. The additional layer may include a thin layer of raw polyvinyl chloride (PVC) material that is typically black, but in at least one other embodiment, the additional layer may include a coating of a material having a hue close to black. The additional layer is required in some embodiments because the decorative layer 60 is generally designed to be used against or with a dark background so that it can fully reflect the desired hue of the selected color and / or overall design appearing on the decorative layer 60. Therefore, some embodiments of the tile 1 of the present invention may include an additional layer of PVC or a black coating applied to the polyvinyl chloride (PVC) layer 40 to serve as a dark background for the decorative layer 60, which preferably has a hue close to black or other dark background colors, such as but not limited to dark brown or dark gray. Moreover, some embodiments of the tile 1 need to include this additional layer or coating because during the formation of the polyvinyl chloride layer 40, when the raw polyvinyl chloride (PVC) is mixed with the dye or colorant, a high concentration of the dye or colorant can accumulate toward the bottom and top surfaces of the PVC layer 40. Therefore, to help ensure that the color of the imitation grout line formed on the tile 1 or as part of the polyvinyl chloride (PVC) is substantially uniform, in a preferred embodiment, no more than about 0.4 mm of material should be removed from the polyvinyl chloride (PVC) layer 40 itself to produce the exposed surface 18 at the desired depth within the PVC layer where the dye or colorant tends to accumulate. In at least one preferred embodiment, the depth of material removed to form the exposed surface 18 in the PVC layer 40 will be less, and only about 0.33 mm of material should be removed. In other words, because the dye or colorant tends to accumulate at the upper and lower surfaces of the PVC layer 40, in some embodiments, the optimal depth at which the exposed portion 18 will be located or arranged will be about 0.33 mm to 0.4 mm below the top or fifth surface 52 of the polyvinyl chloride (PVC) layer 40. This ensures that the exposed portion 18 is formed on the portion of the polyvinyl chloride (PVC) layer 40 that includes an appropriate or sufficient amount of dye or colorant.

[0060] Reference now Figure 67-A and 7-B, the tile 1 of the present invention may further include an interconnection mechanism formed on the edge 16 or 16' of the tile 1. For example, the interconnection mechanism of the present invention may include a "tongue" edge 70 formed on or along one edge 16 of the tile 1 and a "groove" edge 80 formed on or along different edges 16' of different tiles 1. The "tongue" edge 70 and the "groove" are configured to fit together in a mating engagement and facilitate installation and alignment of the tile 1 during installation. In addition, as Figure 6 - As shown in FIG. 7-B , a “tongue” edge 70 and / or a “groove” edge 80 may be formed on the tile 1 as part of the core layer 30. The “tongue” edge 70 and the “groove” edge 80 may also be configured to allow for slight movement and / or rotation between two adjacent tiles, which allows one tile to be adjusted relative to another tile to accommodate an uneven substrate, or a concrete slab that is not perfectly level, such as is often the case with unfinished floors and / or walls. In this way, Figure 6 As shown in FIG. 7-A , a “tongue” edge 70 or a “groove” edge 80 may be at least partially formed in the top layer 20 .

[0061] Reference now Figure 6 In a preferred embodiment, the tile 1 of the present invention will have an exposed portion 18 formed on its edge 16, the edge 16 corresponding only to the "tongue" edge 70, and not to the "groove" edge 80. Figure 6 In the embodiment of the present invention, the gap 14 defined by the exposed portion 18 and the side wall 15 is also partially defined by the top layer 20 and edge 16' of the adjacent tile 1 including the "groove" edge 80. Alternatively, as shown in the embodiments of Figures 7-A and 7-B, the "tongue" edge 70 and the "groove" edge 80 of the tile 1 can each be constructed to include an exposed portion 18 having a textured surface that simulates a grout line. Other embodiments are also within the scope of the present invention, in which the exposed portion 18 can be formed on a tile 1 having a "groove" edge 80 instead of a "tongue" edge 70. Moreover, the tile 1 of the present invention can be constructed in cooperation with different mechanical connection systems manufactured by multiple manufacturers. These mechanical connection systems can include relatively new "click-lock" type mechanical connection systems used during the installation of various surfaces (such as imitation floor tiles).

[0062] The production process of the tile 1 of the present invention can vary, but generally includes different production sequences. For example, the core layer 30 can be produced by mixing raw materials (such as PVC materials, calcium powder and foaming agents) and any auxiliary materials together and applying heat to melt the mixture. The molten material is then placed in an extruder and the molten material is molded into a board. At this stage, a foaming material can be added to facilitate production, followed by a standing or curing phase of about 24 to 36 hours. The production process of the top layer 20 also includes mixing raw materials (such as PVC materials, calcium powder, oil and foaming agents) and any auxiliary materials together, and applying heat to the mixture to melt it. The molten material can then be pressed during one or more pressing stages to form a vinyl sheet, which is likely to include a textured surface at this time. Thereafter, the vinyl sheet that essentially forms the top layer 20 can be pressed together with a decorative layer 60 (such as a film sheet of polyvinyl chloride (PVC)). An ultraviolet (UV) coating can then be added to the top surface 10, or alternatively, another coating is applied and then further treated using ultraviolet light and heat.

[0063] After production of the top layer 20 and the core layer 30, the separate sheets of the two may be adhesively bonded or glued together to form, for example, Figure 8-11 The desired tile 1 shown in . After applying glue or other adhesive, the assembled layers are pressed in a constant temperature chamber for about 6 hours to about 8 hours, for example, by a cold press. After pressing, the assembled layers can be left in a constant temperature chamber for about 36 hours to about 48 hours to stand or cure. Afterwards, the assembled layers or main boards can be cut into smaller sizes. The main boards generally have a size of about 2 meters to about 3 meters, but can have different sizes. After the assembled layers or main boards are cut into smaller sizes, each individual component can be passed through a machine that gives the individual contours of one or more edges 16 or 16' of the tile. The contour may include forming modifications, roughening or cutting the edges 16 or 16' of the assembled tile 1. At this stage, an exposed surface 18 with a simulated grout line, and either or both of the interconnecting mechanisms can be formed. Thereafter, the tile 1 can be packaged for transportation.

[0064] As previously mentioned, the tile 1 of the present invention can be configured to mimic the feel or texture of a real material (such as real stone, marble, ceramic, wood, or other material). Therefore, during the pressing stage, the wear layer 50 of the tile 1 can be given a customized texture. A computer can be used to configure the press according to the decorative design (such as the visual design of the decorative layer 60) so that the press gives the wear layer 50 a corresponding texture. More specifically, a picture of the desired decorative design can be input into the computer to program the press accordingly.

[0065] In order to be used as a flooring application, a plurality of tiles 1 of the present invention will be arranged adjacent to each other in an operational direction. In this way, the edge of one tile 1 will be arranged adjacent to the edge of a different tile 1. As previously mentioned, the exposed portion 18 of the tile 1 of the present invention and the gap 14 defined thereby can have different sizes. Moreover, now referring to Figure 15-A, in one embodiment of a tile 1 having a rectangular configuration, each of the four edges 16 can have an exposed portion 18 and a textured surface formed thereon. In such an embodiment, the exposed portion 18 and the textured surface formed on each edge 16 can be sized to be approximately equal to half of the total expected resulting size of the simulated grout line formed between the tiles, as shown in Figure 15-B. For example, the width of the exposed portion 18 and the textured surface can be approximately about 2.5 mm to about 3 mm. In this way, the entire simulated grout line including the exposed portion 18 and the textured surface thereon can be formed between two adjacent tiles and have a width approximately between about 5 mm and 6 mm.

[0066] In an alternative embodiment, referring to Figs. 16-A and 17-A, the tile 1 of the present invention may have an exposed portion 18 and a textured surface formed only on two sides 16 thereof, wherein each side is sized to be approximately equal to the entire or substantially entire grout line formed between the tiles. That is, as shown in Figs. 16-A and 17-A, the tile 1 may have two sides 16, each side including an exposed portion 18 and a textured surface formed thereon, and two sides 16' that do not include the exposed portion 18 and the textured surface. For example, Fig. 16BAs may be best shown in FIG. 16-A or FIG. 17-A, each edge 16 of a tile 1 having an exposed portion 18 may be disposed adjacent to an edge 16' of the tile 1 that does not have such a structure. In this embodiment, the exposed portion 18 and the textured surface may be sized to have a width of approximately about or between 5 mm and 6 mm. When two or more such tiles 1 shown in FIG. 16-A or FIG. 17-A are disposed adjacent to each other, as shown in FIG. 16-B and FIG. 17-B, respectively, the resulting visual effect is a complete imitation grout line formed around all edges of each tile. However, other combinations of sizes and locations of the exposed portions 18 are also possible. For example, in one or more embodiments, the exposed portion 18 may also be formed on the tile 1 and within the top surface 10 but in the middle or center portion thereof, rather than on or attached to one or more edges 16 thereof. In such an embodiment, the exposed portion 18 is disposed within the middle or center portion of the tile 1 and extends across or substantially across the top surface 10 between the opposing edges 16 of the tile 1. Such alternative embodiments of the tile 1 may be useful in order to provide a wider selection of possible tile arrangements during installation. For example, as described above, the tiles 1 of the present invention may be provided in a 12" x 24" rectangular shape, and typically, such tiles will be installed in an offset or staggered manner so that the corners of one tile are not directly adjacent or aligned with the corners of another tile. However, for alternative embodiments, the same tiles can provide the appearance of a square shape even if the rectangular tiles 1 are installed in an offset or staggered arrangement because the exposed portion 18 extends along one side 16 of the first tile and can be installed to be aligned with the exposed surface 18 that extends through the middle or center portion of another directly adjacent tile.

[0067] Reference now Figure 12-14 The tile 1 of the present invention may also include a bevel 90 formed on one or more edges 16 of the tile 1 adjacent to the exposed portion 18 and the gap 14. The bevel 90 may be formed at an upper portion on the sidewall 15 associated with the exposed portion 18 to be formed on the top layer 20, particularly on the wear layer 50. The bevel 90 includes an inclined portion that slopes downward, away from the top surface 10 of the tile 1 and toward the sidewall 15 that at least partially defines the exposed portion 18. Preferably, the bevel 90 is formed to extend uniformly along all or substantially all of the edges 16 of the tile 1 and coincide with the sidewall 15, the exposed portion 18, and the gap 14. In addition, the bevel 90 may include a variety of sizes and inclination angles relative to the top surface 22 of the tile 1. For example, the bevel may have an inclination angle ranging from approximately thirty degrees (30°) to approximately ninety degrees (90°). Fig.12 The illustrative embodiment of shows the ramp 90 having an inclination angle of approximately thirty degrees (30°). Fig.13In the illustrated alternative embodiment, the slope 90 may variously include a two-stage drop from the top surface 10 to the side wall 15, thereby defining the exposed portion 18 of the tile 1 and the gap 14. Fig.14 , the bevel 90 may alternatively include a "micro" bevel 90'. As another example, Fig.13 As shown, the bevel 90 may be additionally formed on the exposed portion 18 itself, and may correspond to the core layer 30 and / or the polyvinyl chloride (PVC) layer 40 instead of the top layer 20. In this case, the bevel 90 may have an inclined portion having an inclination angle of approximately about ten degrees (10°).

[0068] Additional features of the tile 1 of the present invention may include a core layer 30 comprised of a material different from that used in vinyl composite tile (VCT), such as that used in stone plastic composite (SPC), sometimes referred to as a "rigid board". Stone plastic composite (SPC) is typically a mixture of materials including dense foamed polyvinyl chloride (PVC) and stone dust or an equivalent material, and is typically about twice (or more) the weight of a core layer 30 that is a wood plastic composite ("WPC") material as described previously herein. Thus, in some embodiments, the core layer 30 of the tile 1 of the present invention may include a stone plastic composite (SPC) that is configured to provide sufficient support for the top layer 20 of the tile 1 of the present invention to make the tile suitable for flooring applications. In embodiments where the core layer 30 includes a stone plastic composite (SPC) material, the top layer 20 may be manufactured without the polyvinyl chloride (PVC) layer 40. This alternative embodiment using an SPC material as the core layer 30 may provide advantages because the SPC material has properties that are able to resist expansion and / or contraction. The coefficient of expansion of the stone plastic composite (SPC) is higher than the coefficient of expansion of other materials used in flooring applications, and therefore, the stone plastic composite (SPC) material reduces the likelihood that the overall tile 1 will bend, buckle, or otherwise expand under environmental conditions. The use of the stone plastic composite (SPC) material may also result in reduced or no dimensional shifts between individual tiles 1 after installation. An embodiment of the present invention including a core layer 30 having a stone plastic composite (SPC) material can have a thickness of about 5 mm, but preferably, the thickness of the core layer 30 will be reduced to about 4 mm.

[0069] Since many modifications, variations and changes in details may be made to the preferred embodiments of the invention described, it is intended that all matter in the foregoing description and shown in the accompanying drawings be interpreted as illustrative rather than restrictive. Therefore, the scope of the invention should be determined by the appended claims and their legal equivalents.

[0070] The present invention has been described so far.

Claims

1. A ceramic tile comprising: (a) a top layer, the top layer comprising at least a wear-resistant layer, a polyvinyl chloride (PVC) layer and a decorative layer; (i) the wear layer at least partially defines the top surface of the tile; (ii) the polyvinyl chloride (PVC) layer has a density of about 2,000 kg / m 3 About 2,400kg / m 3 (about 124.856lb / ft 3 About 149.827 lb / ft 3 ) between the first density; (iii) the decorative layer is disposed between the wear layer and the polyvinyl chloride (PVC) layer, the wear layer comprising a substantially transparent material such that the decorative layer is visually observable through the wear layer, (b) a rigid core layer attached to the top layer, the core layer having a second density less than the first density of the PVC layer; (c) a plurality of sides, at least one exposed portion extending outwardly therefrom along a length of one of the plurality of sides, the at least one exposed portion being configured to present a grout line, (d) said at least one exposed portion is defined within said top layer of said tile at a depth of at least 0.9 millimeters (about 0.035 inches) or more below said top surface; and (e) The tile includes an interconnection mechanism formed along at least one edge of the plurality of edges and corresponding to the at least one exposed portion.

2. The ceramic tile according to claim 1, characterized in that: The rigid core layer also includes at least a dense foam material.

3. The tile according to claim 2, characterized in that: The second density of the rigid core layer is about 800 kg / m 3 About 900kg / m 3 (approx. 49.942 lb / ft 3 Up to 56.185lb / ft 3 )between.

4. The tile according to claim 3, characterized in that: The polyvinyl chloride (PVC) layer has a thickness in a range of about 1.4 mm to about 1.5 mm (about 0.055 inches to about 0.059 inches).

5. The tile according to claim 4, characterized in that: The core layer has a thickness in the range of about 4 mm to about 6 mm (about 0.157 inches to about 0.236 inches).

6. The ceramic tile according to claim 1, characterized in that: The rigid core layer also includes a stone plastic composite material.

7. A tile comprising: a top layer at least partially defining a top surface of the tile, the top layer comprising a polyvinyl chloride (PVC) layer having a first density; a rigid core layer connected to the top layer, the rigid core layer having a second density; a plurality of sides, at least one exposed portion extending along a length of and outwardly from one of the plurality of sides; an interconnection mechanism formed substantially along at least one edge of the plurality of edges and thereby corresponding to the at least one exposed portion; The at least one exposed portion is formed on at least a portion of the polyvinyl chloride (PVC) layer and is configured to present a grout line; The at least one exposed portion is defined within the top layer at a depth in the range of about 0.9 mm to about 2 mm (about 0.035 inch to about 0.079 inch) below the top surface; and The first density of the polyvinyl chloride (PVC) layer is greater than the second density of the rigid core layer.

8. The tile according to claim 7, characterized in that: The polyvinyl chloride (PVC) layer also includes a colorant to generally correspond to a desired visual appearance of the grout line.

9. The tile according to claim 7, characterized in that: The rigid core layer comprises at least a dense foam material.

10. The tile according to claim 9, characterized in that The second density of the rigid core layer is about 800 kg / m 3 About 900kg / m 3 (approx. 49.942 lb / ft 3 Up to 56.185lb / ft 3 )between.

11. The tile according to claim 10, characterized in that The polyvinyl chloride (PVC) layer has a thickness in a range of about 1.4 mm to about 1.5 mm (about 0.055 inches to about 0.059 inches).

12. The tile according to claim 11, characterized in that The core layer has a thickness in the range of about 4 mm to about 6 mm (about 0.157 inches to about 0.236 inches).

13. The tile according to claim 7, characterized in that: The rigid core layer also includes a stone plastic composite material.

14. The tile according to claim 7, characterized in that Further included is a chamfer formed on the sidewall associated with the exposed portion and extending along the at least one side of the plurality of sides.

15. The tile according to claim 13, characterized in that The sloped surface includes an inclination angle of about 12 degrees to about 30 degrees relative to the top surface of the tile.

16. The tile according to claim 7, characterized in that The core layer also includes a colorant selected to correspond to a desired visual appearance of the tile.

17. The tile according to claim 7, characterized in that The exposed portion includes a textured surface that further mimics the grout line.

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