A wall tile and a wall tile covering

Abstract

A wall tile (1) comprising a decorative layer (2) made of a ceramic material and a support layer (3) attached to a lower surface of said decorative layer (2), wherein said support layer (3) is offset to said decorative layer (2).

Description

[0001] A wall tile and a wall tile covering.

[0002] The present invention relates to a wall tile and a wall tile covering. In particular, the present invention relates to a wall tile of the kind comprising a support and a decorative layer wherein the decorative layer is made of a ceramic material.

[0003] Ceramic wall tiles are normally installed using mortar adhesive which require long curing time and complex operation for obtaining a well leveled and aligned installation.

[0004] Recently, several attempts of providing solution for improving installation of wall tiles have been proposed. For example, EP 2376 720 proposes a ceramic tile with an injection molded support layer that comprises locking means at the edges for locking together multiple ceramic tiles. The tile also comprises locking means for fixing the tile to a supporting structure attached to the wall to covered. The injection molded support further surrounds the edges of the ceramic decorative element to form a fake grout. If on one hand, this wall tile assembly removes the need of a mortar and reduces the installation time, on the other hand the installation is complicated by the presence of the supporting structure which needs to be correctly aligned with the tiles. Moreover, the wall tile manufacturing process is complex and expensive.

[0005] US2013284355A1 proposes a peel and stick solution, wherein an adhesive is applied on the back of the tile. The adhesive is protected by a peelable sheet which is removed at the moment of installation. The required strength of the adhesive makes difficult the replacement of the tile which can be necessary to obtain a good alignment of the tiles.

[0006] The present invention aims in the first place to provide an alternative wall tile and wall tile covering, which, in accordance with several of its preferred embodiments, is directed to solve one or more of the problems arising in the state of the art.

[0007] Thereto, the present invention, according to its first independent aspect, relate to a wall tile comprising a decorative layer made of a ceramic material and a support layer attached to a lower surface of said decorative layer, wherein said support layer is offset to said decorative layer. For example, said support layer comprises a first edge which extends beyond a corresponding first edge of the decorative layer, while it comprises a second edge opposite to said first edge which projects inwardly with respect to a respective second edge of the decorative layer. In this way, a recessed space can be formed beneath said second edge of the decorative layer that can accept the extending first edge of an adjacent wall tile in a wall tile. In this way, positioning and aligning of the wall tiles in the installation of the wall covering is simplified.

[0008] In the preferred embodiment, the support layer comprises a couple of contiguous first edges extending beyond a respective couple of first edges of the decorative layer, and a couple of contiguous second edges projecting inwardly with respect to a respective couple of contiguous second edges of the decorative layer. In this way, positioning and aligning of the wall tiles in the installation of the wall covering can be simplified in multiple directions on the wall tiles.

[0009] Said first edge of the support layer extends beyond the respective first edge of the decorative layer for an extending distance, and the second edge projects inwardly for a projecting distance. Preferably said extending distance is larger than said projecting distance. In this way, in the wall covering a gap is formed between decorative edges of adjacent wall tiles. For example, the difference between said extending distance and said projecting distance is above 1,5 mm, preferably above 2 mm. For example, the difference between said extending distance and said projecting distance is below 6mm, preferably below 3 mm.

[0010] In the preferred embodiment, the edges of the support layer are free from mechanical locking elements of the kinds adapted to prevent relative movement of adjacent wall tiles in one or more directions. In particular, said edges are free from mechanical locking elements of the kinds adapted to prevent relative movement of adjacent wall tiles in a direction being parallel to the plane of the decorative layer (and parallel to the wall to be covered). More in detail, said edges of the support layer are designed in such a way that from a coupled configuration they can be drifted apart by means of a movement of adjacent wall tiles in a direction being parallel to the plane of the decorative layer. In this way, during installation wall tiles can be dismantled and repositioned if needed.

[0011] In some embodiments, said support layer can have a first thickness in correspondence of said extending distance which is lower than a second thickness in the rest of the support layer. In this way, a play can be established between the extending portion of the support layer and the recessed space below the decorative layer of the adjacent wall tile. For example, the first thickness can be less than 20% smaller than the second thickness, preferably less than 10% smaller. Anyway, in some embodiments, the thickness of the support layer can be substantially constant on the entire section of the support layer itself.

[0012] Preferably, the thickness of said support layer is smaller than the thickness of the decorative layer, for example being a half or less of the thickness of the decorative layer, for example one third or less. In some embodiments, the thickness of the support layer can be 6 mm or less, preferably 5 mm or less, for example 3 mm.

[0013] The support layer can preferably be made of a polymeric material, preferably a thermoplastic material. Said thermoplastic material can be for example PVC, PP, PE, PET, possibly comprising one or more fillers like mineral or vegetal fibers or particles. In the preferred embodiments, the support layer can be made of SPC. In the most preferred embodiment, the support layer is waterproof, wherein, in the context of the invention, “waterproof’ means that the material is not able to absorb water, or it doesn’t deform as a consequence of water absorption.

[0014] In the most preferred embodiment, the support layer is configured to cover the lower surface of the decorative layer only partially, for example only perimetral portions thereof. For example, a hollow space can be formed below a central portion of the lower surface of the decorative layer. In this way, the hollow portion can provide sound and / or thermal insulation in the wall covering. It is also possible that this hollow portion can host some appliances, like electric or thermal circuits. In addition, in this way, the support layer can be made with economy of material so that the overall cost of the wall tile can be reduced. Moreover, the hollow portion provides space for expansion of the support layer, for example for thermal expansion thereof. In some embodiments, said support layer can cover less than a half of the lower surface of the decorative layer, for example less than one third. In the most preferred embodiment, the support layer can be formed by a plurality of separate bodies, preferably in the form of strips. This feature provides the additional advantage that the support layer can be easily and economically made and adapted to any kind of decorative layer, in particular to decorative layers having substantially any kind of polygonal shape, for example squared, rectangular or hexagonal shape.

[0015] The decorative layer is preferably made of a porcelain tile, a red body ceramic tile, a double fired ceramic tile or a single fire white body tile (also known as monoporosa). Preferably the decorative layer comprises a glazed upper surface, for example, comprising a decorative pattern obtained from inkjet printing.

[0016] The decorative layer can comprise a thickness above 4 mm, preferably 6 mm or more. The decorative layer can comprise a thickness below 12 mm, preferably 10 mm or less.

[0017] The decorative layer and the support layer can be attached together by means of an adhesive. In alternative embodiments the decorative layer can be fixed to the support layer directly without interposition of other materials. For example, the support layer can be welded to the decorative layer, for example by means of thermal lamination. Said adhesive can be hot melt glue, reactive hotmelt glue, epoxy resin, polyester resin, polyurethane glue.

[0018] The invention further concerns a wall covering comprising at least one wall tile according to the first independent aspect of the invention. The wall covering further comprises an adhesive composition for fixing the wall tile to the wall to be covered. Said adhesive composition preferably form a layer between the support layer and the wall to be covered. By using an adhesive composition, for the installation of the wall covering is not needed a specific preparation of the wall, like installation of hangers or other supporting means. Preferably the wall covering further comprises grout filling the gap between the decorative layers of adjacent wall tiles.

[0019] With the intention of better showing the characteristics of the invention, in the following, as an example without any limitative character, several preferred forms of embodiments are described with reference to the accompanying drawings, wherein:

[0020] Figure 1 shows a top view of a wall tile according to the invention;

[0021] Figure 2 on a larger scale shows a cross section along line II-II of figure 1;

[0022] Figure 3 shows a bottom view of the wall tile of figure 1;

[0023] Figure 4 shows a front view of a portion of a wall covering comprising wall tiles of figure 1;

[0024] Figure 5 shows a cross section along line V-V of figure 4.

[0025] Figures 1, 2 a 3 show a wall tile 1 that comprises a decorative layer 2 and a support layer 3 attached to a lower surface of the decorative layer 2.

[0026] The decorative layer 2 is made of a ceramic tile, in the example a red body tile, having upper glazed surface 5 comprising a printed decor 6. The decorative layer comprises a thickness Td between 6 and 10mm.

[0027] The support layer 3 is offset to the decorative layer so that comprises a couple of first edges 7 extending beyond a respective couple of first edges 8 of the decorative layer 2, and comprises a couple of second edges 9 projecting inwardly with respect to a couple of respective second edges 10 of the decorative layer 2.

[0028] As better visible from figure 2, the first edges 7 of the support layer 3 extend from the respective first edges 8 of the decorative layer 2 of an extending distance ED being larger than a projecting distance PD with which the second edges 9 of the support layer 3 project inwardly with respect to the respective second edges 10 of the decorative layer 2. As better visible from figures 2 and 3, the support layer 3 is formed by a plurality of bodies 11 each having the form of a strip. Said bodies are made of the same material , in the example being SPC, i.e. PVC with mineral filler. Said support layer 3 comprises a thickness Ts that in the example is less than a half of the thickness Td of the decorative layer 2, for example 3 mm or less.

[0029] Between said bodies 11 is defined a hollow space 12.

[0030] The support layer 3, in particular each of the bodies 11 is fixed to the lower surface 4 of the decorative layer by means of an adhesive 13, in the example a reactive hotmelt glue.

[0031] Figures 4 and 5 show a wall covering 15 comprising a plurality of wall tiles 1 installed on a wall 16. The wall tiles 1 are fixed on the wall by means of a glue 17, for example a mortar.

[0032] As shown in figure 5, in the wall covering 15 adjacent wall tiles 1 are in a coupled condition wherein one of the first edges 7 of the support layer 3 of one wall tile 1 is inserted in a recessed area formed below the second edge 10 of the decorative layer 2 of the adjacent wall tile 1. In view of the difference between the extending distance ED and the projecting distance PD a gap 18 is formed between adjacent edges of the decorative layers 2. Said gap 18 is at least partially filled with a grout for the impermeabilization of the wall covering 15.

[0033] It is noted that the edges 7,9 of the support layer 3 are free from any mechanical locking elements that would prevent separation of the wall tiles 1, in this way the position of the wall tiles can be easily corrected and adjusted until the glue 17 is set.

[0034] The present invention is in no way limited to the hereinabove described embodiments, but such wall tile and wall tile covering may be realized according to different variants without leaving the scope of the present invention. Further, as is clear from the content of the description, the present invention relates to one or more of the items as listed below:

[0035] 1. A wall tile comprising a decorative layer made of a ceramic material and a support layer attached to a lower surface of said decorative layer, wherein said support layer is offset to said decorative layer.

[0036] 2. The wall tile according to item 1, wherein said support layer comprises a first edge which extends beyond a corresponding first edge of the decorative layer, while it comprises a second edge opposite to said first edge which projects inwardly with respect to a respective second edge of the decorative layer.

[0037] 3. The wall tile according to item 2, wherein that comprises a couple of contiguous first edges extending beyond a respective couple of first edges of the decorative layer, and a couple of contiguous second edges projecting inwardly with respect to a respective couple of contiguous second edges of the decorative layer.

[0038] 4. The wall tile according to item 2 or 3, wherein said first edge of the support layer extends beyond the respective first edge of the decorative layer for an extending distance, and the second edge projects inwardly for a projecting distance.

[0039] 5. The wall tile according to item 4, wherein said extending distance is larger than said projecting distance.

[0040] 6. The wall tile according to item 5, wherein the difference between said extending distance and said projecting distance is above 1,5 mm, preferably above 2 mm.

[0041] 7. The wall tile according to item 5 or 6, wherein the difference between said extending distance and said projecting distance is below 6mm, preferably below 3 mm.

[0042] 8. The wall tile according to any of the preceding items, wherein the support layer comprises edges being free from mechanical locking elements. 9. The wall tile according to item 8, wherein the mechanical locking elements are of the kinds adapted to prevent relative movement of adjacent wall tiles in one or more directions.

[0043] 10. The wall tile according to item 9, wherein said edges are free from mechanical locking elements of the kinds adapted to prevent relative movement of adjacent wall tiles in a direction being parallel to the plane of the decorative layer (and parallel to the wall to be covered).

[0044] 11. The wall tile according to any of the preceding items, wherein the thickness of the support layer can be substantially constant on the entire section of the support layer itself.

[0045] 12. The wall tile according to item 4, wherein said support layer can have a first thickness in correspondence of said extending distance which is lower than a second thickness in the rest of the support layer.

[0046] 13. The wall tile according to item 12, wherein said first thickness can be less than 20% smaller than the second thickness, preferably less than 10% smaller.

[0047] 14. The wall tile according to any of the preceding items, wherein the thickness of said support layer is smaller than the thickness of the decorative layer, for example being a half or less of the thickness of the decorative layer, for example one third or less.

[0048] 15. The wall tile according to any of the preceding items, wherein the thickness of the support layer is 6 mm or less, preferably 5 mm or less, for example 3 mm.

[0049] 16. The wall tile according to any of the preceding items, wherein the support layer is made of a polymeric material, preferably a thermoplastic material.

[0050] 17. The wall tile according to item 16, wherein said thermoplastic material is selected from the group comprising: PVC, PP, PE, PET. 18. The wall tile according to item 16 or 17, wherein said thermoplastic material comprises one or more fillers like mineral or vegetal fibers or particles.

[0051] 19. The wall tile according to any of the preceding items, wherein the support layer can be made of SPC.

[0052] 20. The wall tile according to any of the preceding items, wherein the support layer is waterproof.

[0053] 21. The wall tile according to any of the preceding items, wherein the support layer is configured to cover the lower surface of the decorative layer only partially, for example only perimetral portions thereof.

[0054] 22. The wall tile according to item 21, that comprises a hollow space below a central portion of the lower surface of the decorative layer.

[0055] 23. The wall tile according to item 21 or 22, wherein said support layer covers less than a half of the lower surface of the decorative layer, for example less than one third.

[0056] 24. The wall tile according to any of the preceding items, wherein the support layer is formed by a plurality of separate bodies, preferably in the form of strips.

[0057] 25. The wall tile according to any of the preceding items, wherein the decorative layer is made of a porcelain tile, a red body ceramic tile, a double fired ceramic tile or a single fire white body tile (also known as monoporosa).

[0058] 26. The wall tile according to any of the preceding items, wherein the decorative layer comprises a glazed upper surface, for example, comprising a decorative pattern obtained from inkjet printing.

[0059] 27. The wall tile according to any of the preceding items, wherein the decorative layer comprises a thickness above 4 mm, preferably 6 mm or more.

[0060] 28. The wall tile according to any of the preceding items, wherein the decorative layer comprises a thickness below 12 mm, preferably 10 mm or less. 29. The wall tile according to any of the preceding items, wherein the decorative layer and the support layer are attached together by means of an adhesive.

[0061] 30. The wall tile according to any of the preceding items, wherein said adhesive is selected from the group comprising hot melt glue, reactive hotmelt glue, epoxy resin, polyester resin, polyurethane glue

[0062] 31. The wall tile according to any of the preceding items, wherein the decorative layer is fixed to the support layer directly without interposition of other materials.

[0063] 32. The wall tile according to item 31, wherein the support layer is welded to the decorative layer, for example by means of thermal lamination.

[0064] 33. A wall covering comprising at least one wall tile according to any of the preceding items fixed to a wall.

[0065] 34. The wall covering according to item 33 that further comprises an adhesive composition for fixing the wall tile to the wall.

[0066] 35. The wall covering according to item 33 or 34 that comprises a grout filling a gap between the decorative layers of adjacent wall tiles.

Claims

Claims1. A wall tile (1) comprising a decorative layer (2) made of a ceramic material and a support layer (3) attached to a lower surface of said decorative layer (2), wherein said support layer (3) is offset to said decorative layer (2).

2. The wall tile (1) according to claim 1, wherein said support layer (3) comprises a first edge (7) which extends beyond a corresponding first edge (8) of the decorative layer(2), and wherein the support layer (3) comprises a second edge (9) opposite to said first edge (7) which projects inwardly with respect to a respective second edge (10) of the decorative layer (2).

3. The wall tile (1) according to claim 2, wherein the support layer (3) comprises a couple of contiguous first edges (7) extending beyond a respective couple of first edges (8) of the decorative layer (2), and a couple of contiguous second edges (9) projecting inwardly with respect to a respective couple of contiguous second edges (10) of the decorative layer (2).

4. The wall tile (1) according to claim 2 or 3, wherein said first edge (7) of the support layer (3) extends beyond the respective first edge (8) of the decorative layer (2) for an extending distance (ED), and the second edge (9) projects inwardly for a projecting distance (PD), said extending distance (LD) being longer than said projecting distance (PD).

5. The wall tile (1) according to any of the preceding claims, wherein the support layer(3) comprises edges being free from mechanical locking elements.

6. The wall tile (1) according to any of the preceding claims, wherein the thickness (Ts) of the support layer (3) is substantially constant on the entire section of the support layer itself.

7. The wall tile (1) according to claim 4, wherein said support layer (3) has a first thickness in correspondence of said extending distance (ED) which is lower than a second thickness in the rest of the support layer (3).

8. The wall tile (1) according to claim 7, wherein said first thickness is less than 20% smaller than the second thickness, preferably less than 10% smaller.

9. The wall tile (1) according to any of the preceding claims, wherein the thickness (Ts) of said support layer (3) is smaller than the thickness (Td) of the decorative layer (2), for example being a half or less of the thickness of the decorative layer, preferably one third or less.

10. The wall tile (1) according to any of the preceding claims, wherein the thickness (Ts) of the support layer (3) is 6 mm or less, preferably 5 mm or less, for example 3 mm.

11. The wall tile (1) according to any of the preceding claims, wherein the support layer (3) is made of a polymeric material, preferably a thermoplastic material.

12. The wall tile (1) according to any of the preceding claims, wherein the support layer (3) is waterproof.

13. The wall tile (1) according to any of the preceding claims, wherein the support layer (3) is configured to cover the lower surface of the decorative layer (2) only partially, for example only perimetral portions thereof.

14. The wall tile (1) according to claim 13, that comprises a hollow space below a central portion of the lower surface of the decorative layer (2).

15. The wall tile (1) according to claim 13 or 14, wherein said support layer (3) covers less than a half of the lower surface of the decorative layer (2), for example less than one third.

16. The wall tile (1) according to any of the preceding claims, wherein the support layer(3) is formed by a plurality of separate bodies (11), preferably in the form of strips.

17. The wall tile (1) according to any of the preceding claims, wherein the decorative layer (2) and the support layer (3) are attached together by means of an adhesive.

18. A wall covering (15) comprising at least one wall tile (1) according to anyone of the preceding claims fixed to a wall (16).

19. The wall covering (15) according to claim 18, that further comprises an adhesive composition (17) for fixing the wall tile (1) to the wall.

20. The wall covering according to claim 18 or 19, that comprises a grout (19) filling a gap between the decorative layers of adjacent wall tiles (1).

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