US20060260250A1 - Prefabricated tile assembly - Google Patents
Prefabricated tile assembly Download PDFInfo
- Publication number
- US20060260250A1 US20060260250A1 US11/411,480 US41148006A US2006260250A1 US 20060260250 A1 US20060260250 A1 US 20060260250A1 US 41148006 A US41148006 A US 41148006A US 2006260250 A1 US2006260250 A1 US 2006260250A1
- Authority
- US
- United States
- Prior art keywords
- tile
- rectangular piece
- patterned
- wear surface
- top clear
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F15/00—Flooring
- E04F15/02—Flooring or floor layers composed of a number of similar elements
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B44—DECORATIVE ARTS
- B44F—SPECIAL DESIGNS OR PICTURES
- B44F11/00—Designs imitating artistic work
- B44F11/06—Imitation of ceramic patterns
Definitions
- This invention relates generally to the manufacture and installation of prefabricated tiles.
- Weinstein provides a system comprising a plurality of prefabricated tiled panels for installation on walls, floors, and counters, and intended for interior or exterior use. Each panel comprises a flat, rigid base member and a number of tiles affixed to the base member with an adhesive and grouted to form a selected tiled array. Weinstein discloses only a panel comprising a flat rigid base with tiles affixed to the base member.
- a prefabricated tile assembly comprising a rectangular piece of tile having four layers including a top clear wear surface, a patterned layer or print film layer, a colored core layer, and backing layer which serves as a bottom surface; two long sides; and two short sides of equal length wherein the top clear wear surface and patterned layer have been routed to form at least two squares by routing along the edges of the top clear wear surface and patterned print film layer of one long side and one short side of the rectangular piece of tile, and across the integrated design at a point halfway along the length of one long side to expose the colored core beneath giving the appearance of a grouted tile installation when installed on the floor with other similar tiles.
- a method for making the prefabricated tile assembly is also provided.
- FIG. 1A is a top view of a first preferred embodiment of the present invention.
- FIG. 1B is an expanded side view of a first preferred embodiment of the present invention.
- FIG. 2 is a top view of a first preferred embodiment of the present invention.
- FIG. 3 is an expanded side view of a first preferred embodiment of the present invention.
- FIG. 4 is another expanded side view of a first preferred embodiment of the present invention.
- FIG. 5A shows a method of making a first preferred embodiment of the present invention.
- FIG. 5B shows a method of making a first preferred embodiment of the present invention.
- FIG. 5C shows a method of making a first preferred embodiment of the present invention.
- FIG. 5D is a perspective view of a first preferred embodiment of the present invention.
- a prefabricated tile assembly 200 comprising a rectangular piece of tile 100 , preferably of polyvinyl chloride, having four layers including a top clear wear surface 101 , a patterned layer or print film layer 102 , a colored core layer 103 that when routed is exposed to create a “grouted” appearance, and backing layer 104 whose lower serves as the bottom surface 105 of the rectangular piece of tile; two long sides 106 and 108 of equal length with leading edges 110 and 112 respectively; and two short sides 107 and 109 of equal length and having leading edges 111 and 113 respectively.
- top clear wear surface 101 and the patterned film layer 102 have been routed from the rectangular piece of tile 100 to form at least two squares 201 and 202 by routing 0.3 mm out to expose the core or grout line from top clear wear surface 101 and patterned print film layer 102 along the leading edge 110 of long side 106 and the leading edge 111 of short side 109 of the rectangular piece of tile 100 and vertically across the rectangular piece of tile 100 along a line 205 running perpendicularly to long sides 108 and 109 between halfway points 203 and 204 each halfway along the length of long sides 106 and 108 to expose the colored core 103 beneath forming a prefabricated tile assembly 200 having beveled edges beveled edges 210 , 212 and 211 that along with beveled line 207 gives squares 201 and 202 the appearance of two square pieces of tile seamlessly bonded together.
- top clear wear surface 101 and patterned print film layer 102 have been completely routed along leading edges 110 and 111 forming beveled edges 210 and 211 and exposing the colored core layer 103 so that the prefabricated tile assembly 200 appears as if the two squares 201 and 202 have been seamlessly bonded together with an integrated grout line.
- top clear wear surface 101 and patterned file layer 102 have been completely routed out of the leading edge 110 of long side 109 to form beveled edge 111 and give the appearance of two pieces of tile joined by a line of grout and bonded together.
- FIG. 5A there is shown a routing table 500 used to manufacture the prefabricated tile assembly by pulling the rectangular piece of tile 100 across the top of the routing table 500 by a conveyor belt 501 to pull the rectangular piece of tile 100 through guide 502 , and then moving rectangular piece of tile 100 over an industrial router 503 having a height adjustable router assembly 504 utilizing interchangeable cutting blades 505 of various widths which completely route through the top clear wear surface 101 and patterned print film layer 102 as described in further detail below. It is also seen that the rectangular piece of tile 100 is next pulled over cutting blades 509 and 511 .
- conveyor belt 501 first pulls rectangular piece of tile 100 under cutting blade 504 while rollers simultaneously apply equal pressure across the bottom surface 105 of the rectangular piece of tile 100 as it moves over cutting blade 505 so that cutting blade 505 routes completely through top clear wear surface 101 and patterned print film layer 102 of leading edge 210 to form beveled edge 210 .
- conveyor belt 501 next pulls rectangular piece of tile 100 under cutting blades 509 and 510 while rollers 511 and 512 apply equal pressure across the bottom surface 105 of the rectangular piece of tile 100 as it moves over cutting blades 509 and 510 .
- cutting blade 509 completely routes through top clear wear surface 101 and patterned print film layer 102 along a line 205 running perpendicularly to long sides 108 and 109 of the rectangular piece of tile 100 between points 203 and 204 and forms groove 207 as cutting blade 510 simultaneously completely routs through top clear wear surface 101 and patterned print film layer 102 of the leading edge 111 of short side 109 of the rectangular piece of tile 100 exposing the top of colored core layer 103 to form a beveled edge resembling a grouted line 211 .
- top clear wear surface 101 and patterned print film surface 102 have been routed completely through to expose the top of colored core layer 103 to form beveled edges 210 and 211 as well as groove 207 , the completed prefabricated tile assembly gives the appearance of two square pieced of tile joined by a line of grout and bonded together.
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- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Ceramic Engineering (AREA)
- Finishing Walls (AREA)
Abstract
A prefabricated tile assembly comprising a rectangular piece of tile having four layers including a top clear wear surface, a patterned layer, and colored core wherein the top clear wear surface and patterned layer have been routed to form at least two squares by cutting along the edges of the piece of tile's top clear wear surface and patterned print film layer on one long side and one short side, and across the top clear wear surface and patterned print film layer at a point halfway along the length of one long side to expose the colored core beneath giving the appearance of two or more grouted tiles is provided, along with a method of making the prefabricated tile assembly.
Description
- This application claims the benefit of Provisional Application No. 60/675,593 filed Apr. 28, 2005. The prior application is hereby incorporated herein by reference as though fully set forth herein.
- Not Applicable.
- Not Applicable.
- 1. Field of the Invention
- This invention relates generally to the manufacture and installation of prefabricated tiles.
- 2. Description of the Related Art
- The closest prior art of which applicant is aware is U.S. Pat. No. 6,330,774 issued to Weinstein. Weinstein provides a system comprising a plurality of prefabricated tiled panels for installation on walls, floors, and counters, and intended for interior or exterior use. Each panel comprises a flat, rigid base member and a number of tiles affixed to the base member with an adhesive and grouted to form a selected tiled array. Weinstein discloses only a panel comprising a flat rigid base with tiles affixed to the base member.
- Floor-coverings that are sold to the manufactured housing and recreational vehicle industries are judged by different criteria than those of the conventional home building industry. Of great importance to the purchasers of product in these industries is the speed with which a product can be properly installed, due to the assembly line nature of this type of construction and fabrication. A modular home may only stay at the flooring station on the assembly line for 45 to 50 minutes, so the speed at which a flooring product may be installed is significant to the adoption or use of the product. Laying a tile floor one tile at a time is highly impractical in this scenario. Therefore, there is a need in the art for a faster-laying tile design assembly.
- In accordance with one embodiment of the present invention, there is provided a prefabricated tile assembly comprising a rectangular piece of tile having four layers including a top clear wear surface, a patterned layer or print film layer, a colored core layer, and backing layer which serves as a bottom surface; two long sides; and two short sides of equal length wherein the top clear wear surface and patterned layer have been routed to form at least two squares by routing along the edges of the top clear wear surface and patterned print film layer of one long side and one short side of the rectangular piece of tile, and across the integrated design at a point halfway along the length of one long side to expose the colored core beneath giving the appearance of a grouted tile installation when installed on the floor with other similar tiles.
- A method for making the prefabricated tile assembly is also provided.
-
FIG. 1A is a top view of a first preferred embodiment of the present invention. -
FIG. 1B is an expanded side view of a first preferred embodiment of the present invention. -
FIG. 2 is a top view of a first preferred embodiment of the present invention. -
FIG. 3 is an expanded side view of a first preferred embodiment of the present invention. -
FIG. 4 is another expanded side view of a first preferred embodiment of the present invention. -
FIG. 5A shows a method of making a first preferred embodiment of the present invention. -
FIG. 5B shows a method of making a first preferred embodiment of the present invention. -
FIG. 5C shows a method of making a first preferred embodiment of the present invention. -
FIG. 5D is a perspective view of a first preferred embodiment of the present invention. - Referring now to
FIGS. 1A, 1B , and 2 there is shown a first preferred embodiment of aprefabricated tile assembly 200 comprising a rectangular piece oftile 100, preferably of polyvinyl chloride, having four layers including a topclear wear surface 101, a patterned layer orprint film layer 102, acolored core layer 103 that when routed is exposed to create a “grouted” appearance, andbacking layer 104 whose lower serves as thebottom surface 105 of the rectangular piece of tile; twolong sides edges short sides edges - Referring now to
FIG. 2 it is seen that the topclear wear surface 101 and thepatterned film layer 102 have been routed from the rectangular piece oftile 100 to form at least twosquares clear wear surface 101 and patternedprint film layer 102 along the leadingedge 110 oflong side 106 and the leadingedge 111 ofshort side 109 of the rectangular piece oftile 100 and vertically across the rectangular piece oftile 100 along aline 205 running perpendicularly tolong sides halfway points long sides colored core 103 beneath forming aprefabricated tile assembly 200 having beveled edgesbeveled edges beveled line 207 givessquares - Referring now to
FIG. 3 viewing the rectangular piece oftile 100 fromlong side 108 it is also seen that the topclear wear surface 101 and patternedprint film layer 102 have been completely routed along leadingedges beveled edges colored core layer 103 so that theprefabricated tile assembly 200 appears as if the twosquares - Referring now to
FIG. 4 viewing the rectangular piece oftile 100 fromlong side 109 it is also seen that the topclear wear surface 101 and patternedfile layer 102 have been completely routed out of the leadingedge 110 oflong side 109 to formbeveled edge 111 and give the appearance of two pieces of tile joined by a line of grout and bonded together. - Referring to
FIG. 5A there is shown a routing table 500 used to manufacture the prefabricated tile assembly by pulling the rectangular piece oftile 100 across the top of the routing table 500 by aconveyor belt 501 to pull the rectangular piece oftile 100 throughguide 502, and then moving rectangular piece oftile 100 over anindustrial router 503 having a heightadjustable router assembly 504 utilizinginterchangeable cutting blades 505 of various widths which completely route through the topclear wear surface 101 and patternedprint film layer 102 as described in further detail below. It is also seen that the rectangular piece oftile 100 is next pulled overcutting blades 509 and 511. - Referring now to
FIG. 5B in a more detailed view of the first step of the method of making the prefabricated tile assembly it is seen thatconveyor belt 501 first pulls rectangular piece oftile 100 undercutting blade 504 while rollers simultaneously apply equal pressure across thebottom surface 105 of the rectangular piece oftile 100 as it moves overcutting blade 505 so thatcutting blade 505 routes completely through topclear wear surface 101 and patternedprint film layer 102 of leadingedge 210 to formbeveled edge 210. - Referring to now to
FIG. 5C in a more detailed view it is further seen that in the nextstep conveyor belt 501 next pulls rectangular piece oftile 100 undercutting blades rollers 511 and 512 apply equal pressure across thebottom surface 105 of the rectangular piece oftile 100 as it moves overcutting blades step cutting blade 509 completely routes through topclear wear surface 101 and patternedprint film layer 102 along aline 205 running perpendicularly tolong sides tile 100 betweenpoints groove 207 ascutting blade 510 simultaneously completely routs through topclear wear surface 101 and patternedprint film layer 102 of the leadingedge 111 ofshort side 109 of the rectangular piece oftile 100 exposing the top ofcolored core layer 103 to form a beveled edge resembling agrouted line 211. - Referring now to
FIG. 5D it seen that the because topclear wear surface 101 and patternedprint film surface 102 have been routed completely through to expose the top ofcolored core layer 103 to formbeveled edges groove 207, the completed prefabricated tile assembly gives the appearance of two square pieced of tile joined by a line of grout and bonded together. - It is to be expressly understood, however, that the examples shown above are for illustrative purposes only, and that the particular materials and construction as well as other details are not to be construed in a manner that would unduly limit the scope of this invention.
Claims (7)
1. A prefabricated tile assembly, comprising:
a rectangular piece of tile having a having four layers including a top clear wear surface, a patterned layer or print film layer, a colored core layer that when routed is exposed to create a “grouted” appearance, and a backing layer which serves as a bottom surface; two long sides of equal length;
and two short sides of equal length; and
wherein the top clear wear surface and patterned layer of the rectangular piece of tile have been routed to form at least two squares by routing along the edges of the rectangular piece of tile's top clear wear surface and patterned print film layer of one long side and one short side, and across the top clear wear surface and patterned print film layer at a point halfway along the length of one long side to expose the colored core beneath, giving the appearance of two or more grouted tiles.
2. The prefabricated tile assembly of claim 1 , wherein the tile is made of plastic.
3. The prefabricated tile assembly of claim 1 , wherein the tile is made of polyvinyl chloride.
4. The prefabricated tile assembly of claim 1 , wherein the tile is made of multidensity fiberboard.
5. The prefabricated tile assembly of claim 1 , wherein the tile is made of wood.
6. A method of manufacturing a prefabricated tile assembly, comprising the steps of:
pulling a rectangular piece of tile having a top clear wear surface, a patterned or print film layer, a colored core layer, and a backing layer which serves as a bottom surface across the top of a routing table using a conveyor belt assembly that moves the tile over an industrial router having a router assembly of adjustable height with interchangeable cutting blades of various widths while applying equal pressure across the bottom surface of the rectangular piece of tile to routing the leading edge from one of the long sides of the rectangular piece of tile by applying the cutting blade to the tile to cut across the top clear wear surface and patterned or print film layer to form a beveled edge; and
routing the edge from one short side of the rectangular piece of tile by applying a second set of cutting blades to the tile to cut through the top clear wear surface and patterned or print film layer along one of the rectangular piece of tile's short side to form a beveled edge while simultaneously using a third blade to cut through the top clear wear surface and patterned print file layer along a line drawn between two points halfway along each long side of the rectangular piece of tile to rout out a groove so as to form two adjacent squares.
7. A method of manufacturing a prefabricated tile assembly, comprising the steps of:
pulling a rectangular piece of tile having a top clear wear surface, a patterned or print film layer, a colored core layer, and a backing layer which serves as a bottom surface across the top of a routing table using a conveyor belt assembly that moves the tile over an industrial router having a router assembly of adjustable height with interchangeable cutting blades of various widths while applying equal pressure across the bottom surface of the rectangular piece of tile and routing edges from one of the long sides of the rectangular piece of tile by applying the cutting blade to the tile to cut across the top clear wear surface and patterned or print film layer to form a beveled edge; and
routing edges from one short side of the rectangular piece of tile by applying a second set of cutting blades to the tile to cut through the top clear wear surface and patterned or print film layer along one of the rectangular piece of tile's short side to form a beveled edge while simultaneously using a third blade to cut through the top clear wear surface and patterned print file layer along a line drawn between two points halfway along each long side of the rectangular piece of tile to rout out a groove so as to form two adjacent squares.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11/411,480 US20060260250A1 (en) | 2005-04-28 | 2006-04-26 | Prefabricated tile assembly |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US67559305P | 2005-04-28 | 2005-04-28 | |
US11/411,480 US20060260250A1 (en) | 2005-04-28 | 2006-04-26 | Prefabricated tile assembly |
Publications (1)
Publication Number | Publication Date |
---|---|
US20060260250A1 true US20060260250A1 (en) | 2006-11-23 |
Family
ID=37447016
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US11/411,480 Abandoned US20060260250A1 (en) | 2005-04-28 | 2006-04-26 | Prefabricated tile assembly |
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US (1) | US20060260250A1 (en) |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20100068385A1 (en) * | 2008-09-16 | 2010-03-18 | Fernback Katharine C | Sheet goods having a large repeat length and tile with numerous patterns |
US8726612B2 (en) | 2008-04-29 | 2014-05-20 | Steven G. Lomske | Modular panel |
US10017320B2 (en) | 2012-04-09 | 2018-07-10 | Danny Wallis | Enclosure and method for forming an enclosure |
-
2006
- 2006-04-26 US US11/411,480 patent/US20060260250A1/en not_active Abandoned
Cited By (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US8726612B2 (en) | 2008-04-29 | 2014-05-20 | Steven G. Lomske | Modular panel |
US20100068385A1 (en) * | 2008-09-16 | 2010-03-18 | Fernback Katharine C | Sheet goods having a large repeat length and tile with numerous patterns |
US8496779B2 (en) | 2008-09-16 | 2013-07-30 | Armstrong World Industries, Inc. | Sheet goods having a large repeat length and tile with numerous patterns |
US10017320B2 (en) | 2012-04-09 | 2018-07-10 | Danny Wallis | Enclosure and method for forming an enclosure |
US10336527B2 (en) | 2012-04-09 | 2019-07-02 | Danny Wallis | Shower enclosure system for aligning lower and upper enclosure members |
US10723544B2 (en) | 2012-04-09 | 2020-07-28 | Danny Wallis | Shower enclosure system for aligning lower and upper enclosure members |
US11524835B2 (en) | 2012-04-09 | 2022-12-13 | Danny Wallis | Kit for building a shower enclosure with well-aligned plumb walls |
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Legal Events
Date | Code | Title | Description |
---|---|---|---|
STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |