COMPOSITE TILE PRODUCT

Abstract

A self-adhering composite tile product is configured to be bonded to a wall or floor subsurface. The composite tile product includes a first membrane including a modified bitumen material and a second membrane including a modified bitumen material. The composite tile product further includes a reinforcing mat, including a plurality of fibers, that is captured between the first and second membrane, and an adhesive layer on an exposed surface of one of the first and second membranes and configured to bond to said subsurface.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 61/582,902, filed Jan. 4, 2012, the entire disclosure of which is hereby incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates generally to composite articles, and more particularly, to a self-adhering composite tile product.

BACKGROUND OF THE INVENTION

Laying of rigid tiles typically involves spreading or trowelling a suitable adhesive on a substrate, setting the tiles into the adhesive and permitting the adhesive to cure for about 12-24 hours. Thereafter, any joints between the tiles are grouted and the grout must cure for approximately 24 more hours before the tile surface is trafficable. Even for comparatively small tiling jobs, therefore, the process generally requires about 36 or more hours of adhesive and grout curing time in addition to the time devoted to adhesive, tile and grout placement.

In addition, cracking of tile and similar finish layers is a common problem in the flooring and general construction industries, necessitating costly repair as well as causing safety hazards and potential contractor liability. When tile or other finish flooring is laid over and bonded to construction board or a subfloor having cracks or joints, there exists a tendency for the tile or finish flooring to crack in these areas, due, inter alia, to shifting of the subsurface, shrinkage, thermal movement, settling, etc. This is true whether the tile is ceramic, natural stone, wood or other rigid or substantially rigid tile or finish flooring.

Further, truly rigid veneer finish layers such as ceramic tile and the like, because of their inherent brittleness, are subject to failure even under normal pedestrian or light-duty vehicular traffic, notwithstanding the degree of cracking in the subsurface over which the finish layers may be laid. Thus, great importance is attached to the physical characteristics of the materials situated between the tiles and the subsurface. If such materials are too hard, then they will not effectively accommodate subsurface crack or joint expansion and contraction; if too soft (and especially also if relatively thick), the intervening materials may differentially compress whereby the rigid veneer may fracture under normal shear loading.

BRIEF SUMMARY OF THE INVENTION

The following presents a simplified summary of the invention in order to provide a basic understanding of some example aspects of the invention. This summary is not an extensive overview of the invention. Moreover, this summary is not intended to identify critical elements of the invention nor delineate the scope of the invention. The sole purpose of the summary is to present some concepts of the invention in simplified form as a prelude to the more detailed description that is presented later.

In accordance with one aspect, a self-adhering composite tile product is configured to be bonded to a wall or floor subsurface, comprising a first membrane comprising a modified bitumen material and a second membrane comprising a modified bitumen material. The composite tile product further comprises a reinforcing mat, comprising a plurality of fibers, that is captured between the first and second membrane, and an adhesive layer on an exposed surface of one of the first and second membranes and configured to bond to said subsurface.

In accordance with another aspect, a self-adhering composite tile product is configured to be bonded to a wall or floor subsurface, comprising a first membrane comprising a modified bitumen material with 35-70% by weight of bitumen and a second membrane comprising a modified bitumen material with 35-70% by weight of bitumen, the second membrane having dimensions substantially coextensive with the first membrane. The composite tile product further comprises a reinforcing mat, comprising a plurality of fibers, that is captured between the first and second membrane. The composite tile product further comprises a first adhesive layer on an exposed surface of one of the first and second membranes and configured to bond to said subsurface, and a second adhesive layer on an exposed surface of the other of the first and second membranes.

It is to be understood that both the foregoing general description and the following detailed description present example and explanatory embodiments of the invention, and are intended to provide an overview or framework for understanding the nature and character of the invention as it is claimed. The accompanying drawings are included to provide a further understanding of the invention and are incorporated into and constitute a part of this specification. The drawings illustrate various example embodiments of the invention, and together with the description, serve to explain the principles and operations of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other aspects of the present invention will become apparent to those skilled in the art to which the present invention relates upon reading the following description with reference to the accompanying drawings, in which:

FIG. 1 is an exploded view of an example composite tile product;

FIG. 2 is a top plan view of an example method of application of the composite tile product;

FIG. 3 is a top plan view of another example method of application of the composite tile product; and

FIG. 4 is similar to FIG. 3, but illustrates yet another example method of application that may be readily adapted at an installation site to accommodate site-specific installation requirements.

DESCRIPTION OF EXAMPLE EMBODIMENTS

Example embodiments that incorporate one or more aspects of the present invention are described and illustrated in the drawings. These illustrated examples are not intended to be a limitation on the present invention. For example, one or more aspects of the present invention can be utilized in other embodiments and even other types of devices. Moreover, certain terminology is used herein for convenience only and is not to be taken as a limitation on the present invention. Still further, in the drawings, the same reference numerals are employed for designating the same elements.

Conventional and current self-adhering tile assemblies are successful for wall applications only due to their lack of compressive load strength in the makeup of the assembly. When used on floors, these products fail due to cracking under impact loads, expansion/contraction of the substrate and shrinkage cracking of the concrete substrate. The current ASTM C-627 standards address these issues. Moreover, conventional wisdom has held that the use of bitumen (e.g., rubberized asphalt) may stain or leach colors (especially black) into attached finished surfaces, may have a displeasing odor, and/or may have poor adhesive strength.

The composite tile system 10 described herein is a self-adhering, reinforced tile mounting system that addresses the above historical problems and also reduces, such as eliminates, the need for messy adhesives and mortars, reducing dusty and caustic conditions in the home and commercial environment. The composite tile system 10 is intended as an “all-in-one” installation product. The composite tile system 10 described herein can incorporate various materials to greatly improve performance, such as fiberglass or polyester reinforcement, barium sulfate filler and/or other compounds such as asphalt and calcium carbonate to give the composite tile system the compressive load strength to withstand these impact loads also acting as a crack isolation membrane and sound reduction assembly.

The composite tile system 10 meets or exceeds various specifications for ceramic tile and dimensional stone, such as the specifications ANSI A-118.12-2008 revised (i.e., crack isolation membranes for thin-set ceramic tile and dimensional stone installation), and ASTM C-627 (i.e., used to predict a floor's performance under several different loads, commonly referred to as the “Robinson Test”), both of which are hereby incorporated herein by reference. Currently, this the only composite tile system product produced that meet these standards.

Turning to the shown example of FIG. 1, the composite tile product 10 described herein is designed to provide a self-adhering adhesive system configured to be bonded to a wall, countertop, or floor subsurface 14, such as for hard surface flooring and wall products most commonly used on decorative finish layer 12. The composite tile product 10 is desirably constructed as an individual self-adhering tile unit, and as shown in the attached drawings, is an intermediate product located between the decorative finish layer 12 and an underlying substrate or subsurface 14. For example, the composite tile product 10 can be used with ceramic tile, hardwood flooring, etc. but can also be applied to construction board or other materials, such as drywall, concrete, mud beds, plywood, hardwood, backer board, existing ceramic and porcelain tile, VCT/VAT, metal, painted floors, and many others.

The decorative finish layer 12 may be suitably be formed of any rigid to substantially rigid finishing material, e.g., ceramic tile, quarry tile, glass, natural or synthetic stone, marble, slate, hardwood, parquet, cement terrazzo tiles, epoxy terrazzo, vinyl tile, V.A. tile and the like. For example, the decorative surface may be a single, rigid, typically ceramic floor or wall tile having a thickness of approximately 3/16 inch to about ½ inch, although generally rigid tiles or similar finish layers of greater or lesser thickness may be suitably employed. Further, although illustrated as being of generally square configuration, the finish layer 12, which establishes the perimetrical configuration of the entire composite tile product 10, may also be triangular, rectangular, pentagonal, hexagonal, or other regular or irregular polygonal and/or curvilinear shape. The composite tile product 10 can be applied at the factory, distributor or sold as a stand-alone product at a DIY or retail store.

In one example, as shown in FIG. 1, the composite tile system 10 can include five layers, although more or less layers are contemplated. For example, first and second membranes 20, 22 can be provided that are modified adhesive components. Both of the first and second membranes 20, 22 can comprise a modified bitumen material that may be the same or different for each of the first and second membranes 20, 22. The modified bitumen material can include some or all of modified bitumen (e.g., asphalt), SBS polymers, process oils, hydrocarbon resins, and/or an antioxidant mixed with high density fillers designed to abate impact and airborne sound transmission.

In one example, the modified bitumen material of the first and second membranes 20, 22 comprises 35-70% by weight of bitumen, such as 40-60% by weight. In addition or alternatively, the modified bitumen material comprises 1-10% by weight of process oils, such as 3-8% by weight. In addition or alternatively, the modified bitumen material comprises 1-10% by weight of hydrocarbon resin, such as 3-8% by weight. In addition or alternatively, the modified bitumen material comprises 1-10% by weight of antioxidants, such as 3-8% by weight. In addition or alternatively, the modified bitumen material comprises 20-60% by weight of at least one high-density filler material. In addition or alternatively, the modified bitumen material comprises 5-15% by weight of calcium carbonate.

Unlike typical modified bitumen membranes that leech asphalt residue to an attached substrate, the composite tile system with specialty fillers described above and/or including barium sulfate, inhibit the leeching of the asphalt compound into the substrate to which it's bonded up to 150 degrees F. For example, normal asphalt based membranes will leech asphalt residue in relatively light-bodied stone used for flooring such as limestone, travertine and other absorptive tile products. Aromatic oils, which are typical in roofing membranes, have been reduced to the point of having no “tobacco juice” effect on soft marbles and light colored grout. Additionally, the black color of the product has virtually no effect on light, soft bodied tiles. Calcium carbonate and styrene-butadiene-styrene block copolymer, such as 10-20% by weight of the modified bitumen material, can be used together with or as alternative products to the above. Other bonding systems do not address the issues of compressive load failure, adhesive leaching into the surrounding areas and adjustability of the composite tile system. Other chemicals, such as ground mica, can be used for thermal insulation and mechanical properties which allows it to be cut, punched or stamped to size. Barium sulfate can also be used to contribute to sound reduction capabilities and reduce both STC (airborne sound) and IIC (impact sound) sound transmission between floors and walls.

Additionally, either or both of the first and second membranes 20, 22 can have a geometry that is complementary, such as substantially similar to, the geometry of the finish layer 12. Preferably, the first and second membranes 20, 22 have substantially similar geometries such that outer perimeters of thereof are substantially coextensive when the first and second membranes 20, 22 are arranged in a covering relationship (e.g., see FIG. 1).

Additionally, the composite tile product 10 is preferably able to withstand a minimum of 4000 psi loading when combined with finish layer 12. The American National Standard (ANSI) specifications (e.g., see ANSI A-118.12-2008 revised) for the installation of ceramic tile prescribe a minimum requirement of 50 psi shear bond strength between the tile and the substrate to which it is attached. As such, the composite tile product 10 can further include a reinforcing mat 24 comprising a plurality of fibers. In one example, the reinforcing mat 24 can be captured between the first and second membranes 20, 22, and may be provided as a generally central layer. The reinforcing mat 24 may have a similar geometry to the first and second membranes 20, 22, and may be substantially coextensive therewith. The reinforcing mat 24 can be fixedly attached to either or both of the first and second membranes 20, 22, or could instead be provided as a free-floating layer between the first and second membranes 20, 22. It is understood that use of the term “mat” is not intended to provide a limitation. For example, the reinforcing mat 24 may be unitary or may be formed of a plurality of elements, and/or may be continuous or dis-continuous. In one example, the reinforcing mat 24 comprises a non-woven fabric sheet. In addition or alternatively, the reinforcing mat 24 comprises at least one of polyester, polypropylene, nylon, and/or glass fiber, and/or combinations thereof. Preferably, a nonabsorptive material, such as a polyester fiber sheet, may be used. A nonabsorptive sheet is preferable because a sheet which absorbs water tends to swell, forming pockets under the floor or other finish layer, increasing the likelihood of compression cracking. Other materials are suited for reinforcement as well. Thus, the use of the reinforcing mat 24 can provide strength to the composite tile product 10, and preferably contributes to the 4000 psi static loading for impact force and also the shear bond strength in excess of 50 psi between the finish layer 12 (e.g., tile, etc.) and the subsurface 14 to which it is attached.

To facilitate installation of the finish layer 12 on-site, the composite tile product 10 can further include a first adhesive layer 30 on an exposed surface of one of the first and second membranes 20, 22. Similarly, a second adhesive layer 32 can be provided on an exposed surface of the other of the first and second membranes 20, 22. By exposed surface, it is referred to the outer surface of each of the first and second membranes 20, 22 that is bonded to the finish layer 12 and/or subsurface 14. At least one of the first and second adhesive layers 30, 32, and preferably both adhesive layers 30, 32, are configured to bond to the subsurface 14 such that he composite tile product 10 does not have to be oriented in a specific manner during installation. Similarly, at least one of the first and second adhesive layers 30, 32, and preferably both adhesive layers 30, 32, are configured to bond to the finish layer 12. Thus, the composite tile product 10 can be self-bonding to the finish layer 12 and/or subsurface 14. Additionally, the first and second adhesive layers 30, 32 can include a pressure sensitive adhesive to permit easy placement of the composite tile product 10 onto the subsurface 14.

One or more release sheets 34 can be provided for covering the first and second adhesive layers 30, 32 and are configured to prevent inadvertent adherence of the first and second adhesive layers 30, 32 prior to installation (e.g., during shipping and storage). For example, the release sheets 34 can include release film or paper to be removed and discarded during the application of the composite tile product 10. The release sheets 34 can be independent such that the removal of one does not affect the other. Thus, when it is desired to install the composite tile product 10, the release sheets 34 are removed and the composite tile product 10 is pressed onto the subsurface 14.

In addition or alternatively, the exposed surfaces of the first and second membranes 30, 32 and/or the finish layer 12 and/or subsurface 14 may be coated in situ with an appropriate curable adhesive, such as mortar or similar compound prior to placement of the composite tile product 10 to affect the desired bond therebetween. For example, a primer material 40 can be applied to either or both of the first and second membranes 20, 22 and is configured to bond directly to the subsurface 14. Preferably, the primer material 40 can also be configured to bond directly to the finish layer 12 such that the same primer material 40 can be used for both. The primer material 40 can include a synthetic rubber dispersion in water with a proprietary mixture for delayed set of the composite system. For example, the primer material 40 can comprise a vinyl acetate copolymer emulsion. The primer material 40 can be applied by a roller or trowel. The primer material 40 functions as an aid for adhesion of the composite tile product 10 to the subsurface 14 (and/or finish layer 12), and may also delay the initial product set to provide the installer “open time” to adjust, reposition, and align tiles before final set time. Moreover, the primer material 40 can reduce, such as eliminate, wait time between setting the finish layer 12 (e.g., tiles, etc.) and grouting, if grout is used. Preferably, the primer material 40 is configured to provide “open time” on a drywall subsurface 14 in the range of about 30 seconds to about 60 seconds, and/or “open time” on a concrete subsurface 14 in the range of about 3 minutes to about 5 minutes, or possibly even hours. Irrespective of how the composite tile product 10 is bonded to the finish layer 12 or subsurface 14, the spaces between adjacent finish layers 12 can be filled with grout or other conventional joint filler material upon sufficient bonding of the composite tile product 10 to the subsurface 14.

As shown in FIG. 2, one of many presently contemplated beneficial applications or uses for the composite tile products 10 is illustrated. More particularly, an existing floor or wall subsurface 14 that may or may not have cracks and/or joints (one of which is own at 28) is first prepared for application of the composite tile product 10. The composite tile product 10 may be used over any type of existing floor or wall, such as concrete, concrete block, masonry, concrete backer board, plywood, particle board, gypsum wallboard, steel, etc. Preferably, installations begin with a clean, dry substrate free of wax, sealers, dirt, grease, oil or other bond-breakers.

The size and/or shape of the composite tile product 10 should be selected so as to be sufficient to not only cover the subsurface 14, but also accommodate expansion and contraction of the joints or cracks 28 whereby reflective cracking in the finish layer 12 may be effectively avoided. In one example, composite tile products 10 may be relatively square with a 12 inch by 12 inch dimension, and may be laid side-by-side to cover meandering cracks 28 such that several inches of the finish layer 12 extends beyond the ends and to either side of the crack 28. For shorter, narrower, and/or less erratic cracks, composite tile products 10 of smaller size (e.g.,. 6 inch by six inch or other size) may be used to effect the desired subsurface crack or expansion joint coverage. Further, only those composite tile products 10 that are used to cover the crack 28 are shown in FIG. 2 (e.g., four finish layers 12 are installed, with a fifth prepared to be installed over an in-place composite tile product 10), and it is understood that additional composite tile products 10 and associated finish layers 12 will be laid about as is necessary to cover the balance of the subsurface 14 intended to be covered. It will be further appreciated that the composite tile products 10 maybe applied over new or otherwise unmarred subsurfaces 14. And, regardless of the condition of the subsurface 14, the composite tile products 10 may be laid in side-by-side abutting relation or with predetermined spacing therebetween to establish joints to be filled by any appropriate grout or similar joint-filling compound.

During installation, the installer can begin tiling the finish layers 12 on the subsurface 14 by peeling off the protective release sheet 30, 32 and attaching the composite tile product 10 thereto. Next, the finish layer 12 with attached composite tile product 10 is carefully positioned it into place on the subsurface 14. Alternatively, the composite tile product 10 can be positioned into place on the subsurface 14, and then the finish layer 12 can be positioned it into place on top of the in-place composite tile product 10. If desired, the finish layer 12 can be repositioned while the primer material 40 is still wet and before significant pressure has been applied. Repositioning of tile is best achieved while primer material 40 is still in liquid state. As shown in FIG. 1, the primer material 40 can be applied between the finish layer 12 and the composite tile product 10, and may also be applied between the composite tile product 10 and the subsurface 14. Once the finish layer 12 is set as desired, significant pressure can be applied uniformly across the face of the finish layer 12 to securely bond it to the subsurface 14. Generally, the first and second membranes 20, 22 are pressure sensitive. Once pressure is applied, a more permanent bond will take place and a full bond will take, for example, 12-24 hours. Grout can be applied between adjacent finish layers 12 (e.g., in spaces between adjacent tiles, etc.), if desired.

FIGS. 3-4 illustrate another example method of application of composite tile product construction that may be readily adapted at an installation site to accommodate site-specific installation requirements. For example, as shown, the finish layer 12′ can be constructed as a multi-tile unit including a plurality of generally rigid tiles. In the illustrated example, nine tiles are arranged in three rows with three tiles in each row, although tile arrangements of greater or lesser number are contemplated. The finish layer 12′ may be formed of any of the rigid to substantially rigid materials identified herein, and may have any geometry. The multi-tile unit of the finish layer 12′ can be disposed, such as fused, adhesively bonded, or otherwise fixedly attached on a layer of support material 50. The support material 50 can include a relatively thin, flexible mesh of natural or synthetic material such as polyester, glass fiber, polypropylene, nylon, or the like. The tiles are fixed to the support material 50 to form gaps or joints 52 configured to receive grout or the like once the finish layer 12′ is adhered to the composite tile product 10 and subsurface 14. As shown in FIG. 4, the subsurface 14 or adjoining structures 60 may present space constraints or other physical constraints that would otherwise complicate or prevent placement of an entire finish layer 12′ and/or composite tile product 10. Should the installer encounter a situation where it is desirable or necessary to modify the tile arrangement, the installer can easily cut the support material 50 within the area of the joints 52 using an appropriate knife, shears, scissors, or the like to the desired shape or pattern. Similarly, the underlying composite tile product 10 can likewise be cut to match the desired modified shape of the finish layer 12′. Although different examples are shown in FIGS. 3-4, it is understood that various geometries or patterns can be used.

The overall thickness of the composite tile product 10 can range from about 5 mils to about 150 mils (about 0.005 inches to about 0.150 inches), though other sizes are contemplated. It is further contemplated that the first and second membranes 20, 22 can have substantially similar, or even different, thicknesses.

Once the composite tile system 10 is installed, it can also function as a crack isolation membrane to inhibit, such as prevent, cracking of the decorative surface. It can also function as a moisture vapor barrier to reduce substrate water migration and radon, provide positive and negative waterproof protection of the assembly and/or sound insulation.

The composite tile system 10 may include additional features as described in two separate documents both entitled “composite tile system,” which are both hereby incorporated herein by reference. These document relate to U.S. patent application Ser. Nos. 07/960,130 and 08/629,836, which include priority claims dating to at least Oct. 26, 1987.

The invention has been described with reference to the example embodiments described above. Modifications and alterations will occur to others upon a reading and understanding of this specification. Examples embodiments incorporating one or more aspects of the invention are intended to include all such modifications and alterations insofar as they come within the scope of the appended claims.

Claims

1. A self-adhering composite tile product configured to be bonded to a wall or floor subsurface, comprising:

a first membrane comprising a modified bitumen material;

a second membrane comprising a modified bitumen material;

a reinforcing mat, comprising a plurality of fibers, that is captured between the first and second membranes; and

an adhesive layer on an exposed surface of one of the first and second membranes and configured to bond to said subsurface.

2. The self-adhering composite tile product of claim 1, further comprising a second adhesive layer on an exposed surface of the other of the first and second membranes.

3. The self-adhering composite tile product of claim 1, wherein the reinforcing mat is fixedly attached to each of the first and second membranes.

4. The self-adhering composite tile product of claim 1, wherein the reinforcing mat comprises a non-woven fabric sheet.

5. The self-adhering composite tile product of claim 4, wherein the reinforcing mat comprises at least one of polyester, polypropylene, and glass fiber.

6. The self-adhering composite tile product of claim 1, further comprising a release sheet covering said adhesive layer and configured to prevent inadvertent adherence of said adhesive layer.

7. The self-adhering composite tile product of claim 1, wherein the modified bitumen material of the first and second membranes comprises 35-70% by weight of bitumen.

8. The self-adhering composite tile product of claim 7, wherein the modified bitumen material of the first and second membranes further comprises 1-10% by weight of process oils.

9. The self-adhering composite tile product of claim 7, wherein the modified bitumen material of the first and second membranes further comprises 1-10% by weight of hydrocarbon resin.

10. The self-adhering composite tile product of claim 7, wherein the modified bitumen material of the first and second membranes further comprises 1-10% by weight of antioxidants.

11. The self-adhering composite tile product of claim 7, wherein the modified bitumen material of the first and second membranes further comprises 20-60% by weight of at least one high-density filler material.

12. The self-adhering composite tile product of claim 7, wherein the modified bitumen material of the first and second membranes further comprises 5-15% by weight of calcium carbonate.

13. The self-adhering composite tile product of claim 1, wherein the modified bitumen material of the first and second membranes comprises:

35-70% by weight of bitumen;

1-10% by weight of process oils;

1-10% by weight of hydrocarbon resin;

1-10% by weight of antioxidants;

20-60% by weight of at least one high-density filler material; and

5-15% by weight of calcium carbonate.

14. The self-adhering composite tile product of claim 1, wherein the modified bitumen material of the first and second membranes comprises barium sulfate.

15. The self-adhering composite tile product of claim 1, further comprising a primer material applied to the adhesive layer and configured to bond directly to said subsurface.

16. The self-adhering composite tile product of claim 15, wherein the primer material comprises a vinyl acetate copolymer emulsion.

17. A self-adhering composite tile product configured to be bonded to a wall or floor subsurface, comprising:

a first membrane comprising a modified bitumen material with 35-70% by weight of bitumen;

a second membrane comprising a modified bitumen material with 35-70% by weight of bitumen, the second membrane having dimensions substantially coextensive with the first membrane;

a reinforcing mat, comprising a plurality of fibers, that is captured between the first and second membranes;

a first adhesive layer on an exposed surface of one of the first and second membranes and configured to bond to said subsurface; and

a second adhesive layer on an exposed surface of the other of the first and second membranes.

18. The self-adhering composite tile product of claim 17, wherein the modified bitumen material of the first and second membranes further comprises:

1-10% by weight of process oils;

1-10% by weight of hydrocarbon resin;

1-10% by weight of antioxidants;

20-60% by weight of at least one high-density filler material; and

5-15% by weight of calcium carbonate.

19. The self-adhering composite tile product of claim 17, further comprising a primer material applied to the first adhesive layer and configured to bond directly to said subsurface,

wherein the primer material comprises a vinyl acetate copolymer emulsion.

20. The self-adhering composite tile product of claim 17, wherein the reinforcing mat comprises at least one of polyester, polypropylene, and glass fiber.