GB1138353A - Improvements in or relating to sheet materials - Google Patents

Abstract

1,138,353. Laminated tile assembly. G. B. E. SCHUELER. 4 July, 1966 [12 July, 1965; 16 Dec., 1965], Nos. 29471/65 and 53514/65. Heading B5N. A method for the production of sheet materials comprising grouted surface units 1 on a backing layer comprises positioning the surface units in the desired configuration or pattern with spaces between them to act as grout lines, applying a layer of an adhesive material 3 to the backs of the surface units, and pressing part of the adhesive material into the grout lines while allowing the remainder to form a continuous adhesive backing layer. The sheet material may also include a support layer 4. As described the surface units 1 are ceramic natural or plastic tiles or mosaic units, the adhesive is thermosetting or thermoplastic, natural or synthetic, and is for example an epoxy, acrylic, alkyd, coumarone, polyester, polystyrene, phenol-aldehyde, or amino-aldehyde resin, e.g. polyvinyl acetate. The support layer 4 may be rigid e.g. of chipboard, asbestos, plastics sheeting or reinforced concrete, or flexible e.g. of rubber sheeting. In one embodiment the surface units are removably adhered to a temporary support, e.g. an endless paper belt, and liquid adhesive is applied diagonally from a hopper, excess adhesive being removed by a wiper. Pressure is applied to the liquid adhesive by a source of pressurized air in the hopper. A support layer may be applied to the surface units before or after the temporary support is removed, and is bonded to the units by use of a hot or cold press or rollers. The surface units may be surrounded by a mould whilst the adhesive sets. In an alternative embodiment the adhesive is applied to the surface units as a blanket having a dough-like consistency, and may be pressed into the grout lines by a removable regenerated cellulose sheet, The adhesive, which may include fibres, e.g. of glass or sisal and fillers, e.g. calcium carbonate, may be formed into a blanket by sheeting, calendering, or extrusion, and may be hardened by heat and/or pressure. If the adhesive is not to fill the grout lines completely the surface units are arranged on an elastic, e.g. rubber, support whilst the pressure is applied which forces the adhesive into the grout lines. Alternatively the grout lines are part-filled with powder, or a water-soluble compound. The units and/or adhesive may be coloured. The adhesive or support may include means, e.g. hooks, for attaching the sheet material to a support, e.g. a wall. The sheet materials may be provided with grooves or slots, or other interlocking devices at their edges. The sheet materials may be of a shape other than plane, e.g. semi-cylindrical.