WO2007060383A1

WO2007060383A1 - Improvements in and relating to tiling

Info

Publication number: WO2007060383A1
Application number: PCT/GB2006/002235
Authority: WO
Inventors: Neale Andrew Levett
Original assignee: Neale Andrew Levett
Priority date: 2005-11-26
Filing date: 2006-06-19
Publication date: 2007-05-31
Also published as: GB2446354A; GB0524139D0; GB0810756D0

Abstract

A tiling unit (40) is described, along with a support member (1) for use in tiling units, methods of manufacturing tiling units, and methods of tiling. The tiling unit comprises a plurality of tiles (30) coupled to a self-supporting support member, and enables the plurality of tiles to be accurately and conveniently positioned on a surface.

Description

Improvements in and Relating to Tiling

Field of the Invention

The present invention relates to tiling units, to support members for use with the tiling units, to methods of manufacturing tiling units, and to methods of tiling.

Background to the Invention

Tiles are a well known means used to decorate surfaces including floors, walls, tabletops, etc. Generally, tiles are fixed to a surface using a fixing material such as adhesive. Fixing material is applied to the surface and then tiles are pressed in to the fixing material. The fixing material holds the tiles in position.

When the area to be tiled is large, or a large number of small tiles are to be fixed to a surface, correctly positioning the tiles is difficult and time consuming.

To address the issue of positioning, particularly with smaller mosaic-style tiles, a flexible mesh or paper sheet can be attached to a plurality of tiles by the manufacturer. The sheet holds the tiles attached to it at a predetermined maximum separation. The sheet and all of the tiles attached to it can be pressed into fixing material as a single step, with the sheet preventing tiles attached thereto from exceeding a predetermined maximum separation.

However there may still be difficulties in positioning when fixing tiles attached to a flexible mesh or sheet. It is an aim of preferred embodiments of the present invention to address at least one problem associated with the prior art, whether identified herein or otherwise.

Summary of the Invention

According to a first aspect of the present invention there is provided a tiling unit, the tiling unit comprising at least first and second tiles coupled to a support member, wherein the support member is self- supporting.

Suitably, the tiling unit comprises more than two tiles.

Suitably, the support member comprises a substantially planar surface or a planar surface.

Suitably, the support member comprises an aperture. Suitably, the support member comprises a plurality of apertures. Suitably, the support member comprises a lattice made up from a plurality of lattice members.

Suitably, the support member comprises a coupling region to which the tiles are directly or indirectly adhered, and a fixing region for in use engaging a surface and/or a fixing material used to adhere the tiling unit to the surface.

Suitably, a fixing region comprises an engagement member extending from a surface of the fixing region to in use aid keying of the fixing region with fixing material . Suitably, the tiles are coupled to the support member by adhesive. Suitably, the tiles are coupled to the support member by a double sided adhesive intermediary. Suitably, the double sided adhesive intermediary covers the coupling surface.

Suitably, the tiles are coupled in a fixed predetermined position relative to one another. Suitably, the tiles are fixed substantially parallel to the support member.

Suitably, the tiling unit further comprises a flexible sheet coupled to the tiles. Suitably, the flexible sheet is coupled to the support member. Preferably, the flexible sheet comprises a mesh coupled between the tiles and the support member.

According to a second aspect of the present invention, there is provided a support member as described in the first aspect of the invention, the support member having an adhesive surface for coupling first and second tiles to the support member.

Suitably, the adhesive is provided on a double-sided tape or sheet .

According to a third aspect of the present invention, there is provided a method of manufacturing a tiling unit, the method comprising the steps of (a) providing a self- supporting support member; (b) providing first and second tiles; and (c) coupling the tiles to the support member. Suitably, the step (c) comprises arranging the first and second tiles at the predetermined separation before coupling the tiles to the support member.

Suitably, the tiles provided at step (b) are coupled to a flexible sheet .

According to a fourth aspect of the present invention, there is provided the method of tiling comprising the steps of the method of the third aspect of the present invention, and further comprising the steps of: applying fixing material to one or both of a surface and the tiling unit; and fixing the tiling unit to the surface by means of the fixing material .

Brief Description of the Drawings

For a better understanding of the invention, and to show how embodiments of the same may be carried into effect, reference will now be made, by way of example, to the accompanying diagrammatic drawings in which:

Figure 1 is a front view of an example of a support member for use in preferred embodiments of the present invention;

Figure 2 is a cross-sectional view of a lattice member within the support member of Figure 1 ;

Figure 3A is a cross-sectional view of a lattice member within a support member of a second embodiment of the present invention, the lattice member comprising engagement members ; Figure 3B is a cross-sectional view of a lattice member within a support member of a third embodiment of the present invention, the lattice member comprising engagement members ;

Figure 4A is a front view of a lattice member comprising engagement members;

Figure 4B is a front view of an alternative lattice member comprising engagement members;

Figure 5 is a front perspective view of a tile for use with embodiments of the present invention;

Figure 6 is a front perspective view of a tiling unit according to an embodiment of the present invention;

Figure 7 is a front perspective view of a second tiling unit according to an embodiment of the present invention;

Figure 8 illustrates a method of assembling a tiling unit according to an embodiment of the present invention;

Figure 9 illustrates alternative method of assembling a tiling unit according to an embodiment of the present invention;

Figure 10 is a front view of a plurality of tiling units of Figure 6 fixed to a surface; Figure 11 is a front view of a plurality of tiling units of Figure 7 fixed to a surface;

Figure 12 is a front view of a second example support member for use in preferred embodiments of the present invention;

Figure 13 is a front view of a third example support member for use in preferred embodiments of the present invention; and

Figure 14 is a side view of a portion of the support member of Figure 13 looking in the direction X as shown in Figure 13.

Detailed Description of the Preferred Embodiments

Figure 1 shows a support member for use in preferred embodiments of the present invention. The support member comprises a lattice 1 used to improve the efficiency and accuracy of positioning tiles when fixing tiles to a surface .

The lattice 1 is self-supporting, and therefore maintains tiles coupled thereto at a predetermined relative separation. Relative sagging of tiles under gravity during tiling is eliminated for tiles coupled to the support member, leading to better alignment of tiles.

In contrast to a flexible sheet used to hold tiles attached thereto at a predetermined maximum separation, the use of a relatively inflexible, self-supporting support member means that even distribution of the tiles thereon is guaranteed. In practice, flexible sheets are difficult to use when fixing horizontal rows of tiles to a vertical surface, for example when fixing a mosaic tile border. When fixing a mosaic tile border, the tiles attached to a flexible sheet are pulled down by gravity, which can lead to the tiles being positioned closer to one another than the predetermined maximum separation in places .

The lattice 1 comprises a plurality of lattice members 10, each lattice member comprising a top end 11 and a bottom end 12. The lattice members 10 intersect with one another at nodes 3.

The lattice 1 is substantially square when viewed from the front. Other shapes, preferably polygonal and/or tessellating shapes can be used to accommodate a range of tile shapes, sizes and arrangements.

In the lattice 1 the angle 4 of intersection of the lattice members 10 at each of the nodes 3 is 90°. However, other angles of intersection are possible, e.g., 10°, 20°, 30°, 40°, ..., 170°, and can be chosen to improve the rigidity of the lattice or to accommodate a range of, sizes, shapes, etc., of tiles.

The lattice 1 comprises thirty-eight lattice members 10. The number and spatial density of lattice members 10 of Figure 1 is merely exemplary. Other arrangements of lattice members can be chosen to provide a desired rigidity of the lattice, or to accommodate a range of sizes, shapes, etc., of tiles. In the lattice 1 of Figure 1 each lattice member 10 is arranged at an equal distance from its immediately- neighbouring lattice member (s). Each lattice member is substantially parallel to its immediate neighbours. This regular arrangement of lattice members is merely exemplary and irregular arrangements are possible, e.g., every second or third lattice member further displaced or not parallel, to improve the rigidity of the lattice or to accommodate a range of sizes, shapes, etc., of tiles.

Figures 12 and 13 show second and third example support members comprising a lattice 1. The lattice 1 of Figures 12 and 13 comprises a frame 5 around its perimeter. The frame 5 serves to reinforce the lattice 1, and to prevent the ends 11,12 of the lattice -members 10 from being damaged.

The lattice 1 of Figure 13 comprises built in lines of weakness 6. The lines of weakness 6 run across the lattice 1 from edge to edge. The lines of weakness 6 are substantially parallel to an edge of the lattice 1. The lines of weakness may conveniently comprise sections of reduced cross sectional thickness, as shown in Figure 14. In example embodiments, the lines of weakness are of similar rigidity to the rest of the lattice 1, but are brittle so that the lattice 1 can be easily divided. The lattice 1 may comprise a plurality of lines of weakness 6, arranged spaced apart on the lattice 1 at regular or irregular distances.

Figure 2 shows a lattice member 10 in cross section. In cross section the lattice member 10 comprises a polygon 18. The polygon 18 comprises an upper portion 13, side portions 14 and a base portion 15.

The upper portion 13 makes it easy for the lattice member 10 to cut into a fixing material (not shown) when a tiling unit including the lattice member is fixed to a surface. The upper portion 13 and side portions 14 comprise a fixing region to in use engage the fixing material . The base portion 15 provides a coupling region to facilitate coupling of the lattice member 10 to a tile.

The lattice member 10 has a height 16 selected based on factors including: intended depth of fixing material; intended tile thickness; desired surface area of side portions 14; and a desired rigidity of the lattice member 10. The lattice 1 can comprise individual lattice members 10 that are of a uniform height 16 or of a non-uniform height 16 across the lattice member 10. Each of the plurality of lattice members 10 has a uniform height 16 across the lattice member 10. The height 16 of each of the plurality of lattice members 10 can be uniform or nonuniform relative to other lattice members 10 of the lattice 1.

The lattice member 10 has a width 17 selected based on factors including: intended tile size; and desired rigidity of the lattice member 10. The lattice 1 can have lattice members 10 of uniform width or of non-uniform width across the lattice.

In Figure 2 the polygon 18 is a triangle. Other regular and irregular shapes are possible, including reentrant shapes . Figures 3A and 3B show lattice members 10 from lattices for use in second and third embodiments of the present invention. In Figures 3A and 3B the lattice members 10 shown comprise a plurality of engagement members 20. The engagement members 20 increase the number of surfaces of lattice members 10, which increases the number of surfaces to in use engage and key with a fixing material. The engagement members 20 can also improve rigidity and self-supporting nature of the support member

1.

In Figure 3A engagement members 20 are triangles in cross section.

In Figure 3B the engagement members 20 are hexagons in cross section.

Other shapes of engagement members are possible, and the lattice members 10 may comprise engagement members 20 of different shapes, including recesses rather than proj ections .

Figures 3A and 3B show two engagement members 20, but other numbers of engagement members 20 can be used on each lattice member 10.

Figures 4A and 4B show the engagement members 20 of the lattice members 10 running the length of the lattice member 10. Figure 4A shows engagement members 20 running continuously, whereas Figure 4B shows engagement members

20 running discontinuously . The support member can be made from a range of materials including, plastics materials.

The support member can be manufactured by casting, moulding, extrusion, etc. as appropriate to the material being worked.

Figure 5 shows a tile 30 comprising a front section 31 and rear section 32. In use, the front section 31 is the decorative side for display and the rear section 32 is fixed to support surface with a fixing material. The tile 30 is a substantially square mosaic tile of approximately 25mm x 25mm, with a thickness in the range 3 -5mm.

Figure 5 shows a square tile 30, but any regular or irregular shape could be used in a tiling unit according to the present invention. Commonly used polygonal tile shapes include triangles, quadrilaterals, pentagons, hexagons, etc. Other shapes such as pebbles, petals, circles, teardrops, etc. can also be used.

Figure 6 shows a first embodiment of a tiling unit 40. The tiling unit 40 of Figure 6 comprises a support member in the form of a lattice 1 and a plurality of tiles 30 coupled to the lattice 1 in a square arrangement.

Figure 7 is a second embodiment of a tiling unit 40. The tiling unit 40 of Figure 7 comprises support member in the form of a lattice 1, and a plurality of tiles 30 coupled to the lattice 1 in a rectangular arrangement.

The tiling units 40 of Figures 6 and 7 comprise a double sided adhesive intermediary layer at least on one side to hold the tiles 30 on the lattice 1. The adhesive intermediary layer may for example comprise a perforated double-sided adhesive sheet, or double sided adhesive tape. Alternatively, glue or another fixing material can be used to hold the tiles 30 on the lattice 1.

Figure 8 depicts a method of assembling the tiling unit 40. The method could be part of a manufacturing process or the method could be part of a process undertaken by a user at the tiling site. The method comprises providing a lattice 1 of appropriate shape and configuration; providing tiles 30; then coupling the tiles 30 to the lattice 1. The lattice and/or tiles may be supplied with adhesive or an adhesive intermediary layer applied thereto, or alternatively a user may perform the step of applying adhesive/an adhesive intermediary layer. The adhesive or double sided adhesive intermediary layer may be covered by a removable cover sheet, said sheet being removed to allow the lattice to be coupled to the tiles. In example embodiments the lattice may be provided with an adhesive or double sided adhesive intermediary layer on both sides thereof, and one or both sides may feature a removable cover sheet.

Figure 9 depicts an alternative method for assembling the tiling unit 40. The method comprises providing a lattice 1 of appropriate shape and configuration, a flexible mesh 50 of appropriate shape and configuration and tiles 30; then coupling the lattice 1, and flexible mesh 50 and tiles 30 accordingly. The tiles 30 may be supplied coupled to the flexible mesh 50, and a user may subsequently couple the tiles 30 and mesh 50 to the lattice 1. Figures 10 and 11 shows a tiled surface 60 comprising a plurality of tiling units 40. The lines 61 and 62 illustrate the boundaries between the tiling units 40. Although the lines 61 and 62 do not form part of the tiled surface, a guideline, spacers or similar means can be used to help with tiling unit positioning.

Figures 10 and 11 show a tiled surface 60 comprising tiling units 40. The tiling units 40 can be used in conjunction with one or more tiles not mounted to a support member .

When tiling units 40 are used in conjunction with a tile not mounted to a support member, the thickness of the lattice 1 can be chosen so that the thickness of the tiling units 40 matches the thickness of the tiles not mounted to a support member. Generally, smaller mosaic tiles are thinner than larger tiles, and can be built out using a suitable support member.

In Figures 10 and 11 the tiling units 40 are fixed to a support surface. The surface could be a ceiling, a floor, a wall, or an object such as a table top, etc. Typically, the surface is a wall. Tiling units 40 are fixed to the support surface using a fixing material . The fixing material passes through apertures in the support member and engages with the tiles 30 to hold them on the surface. Fixing of the tiles does not rely on the coupling between the tiles and the support member.

If, in use, tiling units are used that only comprise a flexible mesh 50 and not the lattice 1, the tiles mounted thereon are prone to sagging relative to one another during the fixing process, or during the time that it takes the fixing material to set. To overcome unevenness caused by sagging, only one horizontal row of tiles is typically fixed at a time.

Using a relatively rigid, self-supporting support member addresses the problem of relative sagging, because tiles attached to the support member do not move relative to one another. Thus horizontal rows of tiles can be fixed above one another quickly and easily without giving an uneven result.

Attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference.

All of the features disclosed in this specification

(including any accompanying claims, abstract and drawings) , and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive.

Each feature disclosed in this specification

(including any accompanying claims, abstract and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.

The invention is not restricted to the details of the foregoing embodiment (s) . The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

Claims

CLAIMS :

1. A tiling unit, the tiling unit comprising at least first and second tiles coupled to a support member, characterised in that the support member is self- supporting.

2. The tiling unit of claim 1, comprising more than two tiles.

3. The tiling unit of claim 1 or 2 , wherein the support member is substantially planar.

4. The tiling unit of any preceding claim, wherein the support member comprises a plurality of apertures.

5. The tiling unit of any preceding claim, wherein the support member comprises a lattice made up from a plurality of lattice members.

6. The tiling unit of any preceding claim, wherein the support member comprises a coupling region to which the tiles are directly or indirectly adhered, and a fixing region for in use engaging a surface and/or fixing material used to adhere the tiling unit to the surface.

7. The tiling unit of claim 6, wherein the fixing region comprises an engagement member extending from a surface of the fixing region to in use aid keying of the fixing region with fixing material .

8. The tiling unit of claim 6 or 7, wherein the tiles are coupled to the support member by adhesive.

9. The tiling unit of claim 8, wherein the tiles are coupled to the support member by a double sided adhesive intermediary.

10. The tiling unit of any preceding claim, wherein the tiles are coupled to the support member in a fixed predetermined position relative to one another.

11. The tiling unit of any preceding claim, further comprising a flexible sheet coupled to the tiles and the support member .

12. The tiling unit of any preceding claim, wherein the support member comprises one or more in-built lines of weakness .

13. A support member to which at least first and second tiles can be coupled, wherein the support member is self- supporting, characterised in that the support member has an adhesive surface for coupling the first and second tiles thereto.

14. A support member as described in any one of claims 1-12.

15. The support member of claim 13 or 14, wherein the adhesive is provided on a double-sided tape or sheet.

16. A method of manufacturing a tiling unit, the method comprising the steps of: (a) providing a self-supporting member; (b) providing first and second tiles; and (c) coupling the tiles to the support member.

17. The method of claim 16, wherein the step (c) comprises arranging the first and second tiles at the predetermined separation before coupling the tiles to the support member .

18. The method of claim 16 or 17, wherein the tiles provided at step (b) are coupled to a flexible sheet.

19. A method of tiling comprising the steps of (a) providing a self-supporting member; (b) providing first and second tiles; (c) coupling the tiles to the support member; (d) applying fixing material to one or both of a surface and the tiling unit; and (e) fixing the tiling unit to the surface by means of the fixing material .

20. The method of claim 16 or 19, wherein the self- supporting member provided in step (a) is as described in the support member according to any of claims 1-15.