WO2008035202A1

WO2008035202A1 - Apparatus and method for manufacturing mosaic tiles sheets and mosaic tiles sheet produced by such an apparatus and method

Info

Publication number: WO2008035202A1
Application number: PCT/IB2007/002941
Authority: WO
Inventors: Fabio Bettazzi
Original assignee: Fabio Bettazzi
Priority date: 2006-09-18
Filing date: 2007-09-17
Publication date: 2008-03-27

Abstract

A mosaic tiled sheet, a mosaic tiling system and production method composed of a number of prefabricated tiled panels. Such a mosaic tiled sheet is used as a finishing layer on walls, floors, swimming pools, sanitary ware and any other similar surfaces. Each element is made of an array of small sized tiles (1) fixed on a self-adhesive flexible backing (2), not permeable to water. The installation on the surfaces can be simply done by applying the tiled elements (1) with no need of waterproofing treatment, glues or cement. The installation is simple and can be carried out by a relatively unskilled person. Benefits for builders and homeowners include shorter installation downtime and lower fitting costs. The disruption due to the presence of workers is kept to the minimum together with the amount of debris and waste materials.

Description

APPARATUS AND METHOD FOR MANUFACTURING MOSAIC TILES SHEETS AND MOSAIC TILES SHEET PRODUCED BY SUCH AN APPARATUS AND METHOD

Technical Field of the invention

This invention relates to the installation of small sized tiles on walls, floors, swimming pools, sanitary ware and any other similar surfaces. Prior Art

The installation of small sized tiles on surfaces is usually known as mosaic. Its invention dates back to the roman period when, the application of small pieces of marbles of different colors on surfaces was used to create decorative drawings and patterns. This was particularly- used on surfaces exposed to water where painting was not possible. The small pieces of tiles, called "tessere" or "tesserae" were applied one by one with cement on the surfaces. In the bizantine period the use of mosaic was extended to other materials especially glass of various colors. The use of mosaic tiles has not changed till the 20th century when began the use of pre-mount the tiles on paper or nylon nets, usually in arrays of size 1' by 1' . The factory production of the so called mosaic tiles is now done by first producing the tessere in the finishing materials, then placing them with the finished face downward in positioning grilles and finally gluing the net to the rough face. This method resulted in the installer being able to fix the tessere to the surfaces in panels of size similar to the normal tiles. The installation downtime decreased but the timing and the installation sequence is still similar to the installation of ceramic tiles. The installation method for tiles hasn't changed for several centuries. There has been a strong evolution in the materials and the aesthetic qualities due to changing fashion and tastes but the installation process is substantially similar. As of today the installation sequence is: a) application of waterproofing in moisture sensible spaces, with possible preliminary use of "primer" in order to enhance bonding and provide support for joints subject to dilatation; b) preparation of glue or cement, in the quantity necessary for about half hour tiling work.

This corresponds to the glue drying time; c) start to apply the glue to the surface, and applying the tiles on the glue, taking care to level the tiles one by one and interposing spacers to keep a constant width between the tiles. Once the opposite corner is reached the last row of tiles is cut one by one, d) wait till the glue is completely dried and then the joints are filled up. Common sizes for tiles are 200X200 mm or 12"X12". These measures are considered optimal for the efficiency of the tiling process: using smaller tiles increase the number of panels that need laying and increases the number tiles cut around the corners, bigger tiles increase the installation time as more accurate leveling is required, tile waste is also increased. Several tests has been made recently to develop a different method for installing tiles, to reduce the cost, installation time and subsequent disruption - for example U.S. Pat. No. 5,816,005 by Han and U.S. Pat. No. 6,330,774 by Weinstein. These methods try to enhance the installation method by- installing the tiles on rigid panels and then applying the panels to the surface with fasteners.

These methods had limited results because of the difficulty in predetermining the dimensions of the panels and in cutting large panels on site.

The large increment of work in the workshop for designing and preassembling the panels and the increased logistical problems to transport and store the panels is also a problem. Today, most tile installations are performed on site, requiring skilled, experienced professionals. In addition to being costly and time consuming, the installation involves the use of different materials, usually creating disruption. Waterproofing, when needed, may increase the stages in the installation process rising costs.

Description of the Invention

The system and its relative production method is described for the realization of finishing claddings composed of small tiles in many materials.

The main element of the system is a background flexible support, a flexible sheet, preferably made of a waterproofing material.

On one side is applied a layer of glue in order to make the panel self-adhesive, on the other side the array of tiles are glued.

The tiles are preferably of small dimensions. The installation on the surfaces can be done simply by applying the tiled panels, with no need of previous waterproofing treatment and without the use of glues or cements.

The installation sequence is simple and can be carried out by a relatively unskilled person.

Benefits for builders and homeowners includes shorter installation downtime, less installation costs for the use of relatively unskilled installers, less intrusion of workers, lower rubbish and waste materials.

This is a particular advantage during renovations allowing for better scheduling in construction process.

A further advantage of the invention consists in the possibility of applying the panels over existing tiles or directly on metal panels, with benefits in renovations and in yachts and ships installations.

It is clear that the present invention overcomes the limitations of the previous methodologies and constitutes an improved tiling system. Another object of the invention is to provide a production method for the flexible tiled panels where, in a opposite way to the normal production method, the finishing material is firstly applied on the flexible support in large elements and then cut in smaller tiles arrays.

The advantage is in having a faster and simpler construction process as the tiles are not cut from finishing materials, positioned in grilles and then glued to the support. The tiles are directly cut on the support.

Still another object of this invention is to provide tiled flexible sheets that can be glued to the surface using many types of fixing glues. As example either bi component glues or hot melting glues can be used.

Applying the panel to the surface can be done, for example, in case of the two components glues by applying one of the components to the surface to be finished, the other can be applied in the factory to the panel. The contact of the two components will fix the sheets to the surface.

Still as example, if hot melting glues are applied in the factory on the tiled panel, the bonding to the surface can be achieved by simply positioning the sheet on the surface and heating it.

Another object of this invention is to provide a construction system made of basic tiled sheets having an array of tiles assembled on a adhesive background support and auxiliary elements made of tiles disposed in strips of different width or made of tiles of different shape.

The installation in corners or the filling of eventual gaps can be this way achieved.

An example could be installations around piping or fixed sanitary ware. Another additional element is a self adhesive tape to restore waterproofing on the joint between adjacent elements .

Other objects of this invention will in part be apparent and in part will be pointed out hereinafter. With these ends in view, the invention finds embodiment in certain combinations of elements and arrangements of parts by which the aforementioned objects and certain other objects are hereinafter attained, as more fully described with reference to the accompanying drawings and the scope of which is more particularly pointed out and indicated in the appended claims.

In the accompanying drawings, in which are shown an exemplary embodiments of the invention:

- FIG. 1 is a partial perspective view of the basic element of this invention illustrating the tiles, the support sheet and the paper that protects the adhesive side. This paper would be removed before the installation.

- FIG. 2 is a perspective view of the basic object of the invention during its application to the surface. This picture also shows details of the installation method.

- FIG. 3 are partial plan views of a additional element of the invention composed of an array of tiles of different shapes that is used to restore the mosaic pattern for example around piping. - FIG.4 is a partial plan view of a supplementary element of the invention composed of an array of tiles disposed in strips of different sizes. This would be used for installations in corners avoiding the cut of the tiles in the basic elements. - FIGS. 5-6 are elevation views that shows how, in an embodiment of this invention, elements with tiles of different shapes and sizes are used to fill the gaps around piping.

- FIG. 7 is a partial perspective view of the corner between two surfaces that would be covered and shows how a strip cut from the sheet with strips of different width is used.

- FIG. 8 is a perspective view showing an embodiment of the production method of this invention and the phases in an automated production line.

- FIG. 9 is a sectional view taken along line 1-1 of FIG. 10 detailing how the tiles are cut directly on the flexible support sheet after being glued on this.

FIG. 10 is a schematic perspective view showing an embodiment for the production method for this invention.

With specific reference now to the details in the figures, it is stressed that the particulars shown are by way of example and for the purposes of illustrative discussion of the preferred embodiments of the present invention only and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the invention. In this regard, no attempt has been made to show aspects of the invention in more detail than is necessary for a fundamental understanding of the invention, the description taken together with the drawings should make it apparent to those skilled in the art how the several forms of the invention may be embodied in practice. Referring now in detail to FIG. 1 of the drawings, there is shown the basic panel of this invention.

The tiles 1 can be made of any material as marble, gres, ceramic, metal, wood.

Dimension of the tiles can vary but are preferable small dimensions as 20X20mm or 1"Xl". Tiles are glued on the background support sheet 2.

The support sheet is made of a continuous flexible material, preferably with waterproofing properties. Many types of materials can be used as PE, PVC or elastomeric bitumen. Elastomeric bitumen or Polymer Modified Bitumen (PMB) is particularly suitable for this usage and its application as support for mosaic tesserae is another object of the present invention. This material, composed by bitumen and various types of polymers as Styrene Butadiene Styrene (SBS) or Atactic Polypropylene (APP) , overcomes the limitations of other flexible supports, in fact it is self adhesive, it can be used with fibreglass or other reinforcements for dimensional stability and can plastically adapt itself to the roughness of the surface to be bonded to. Furthermore it is more economical than other similar supports. Being self adhesive, in an embodiment of this invention, the finishing material of the tesserae can be sticked on the support with no need of other glue, in the same way, on the opposite side, no other glue must be applied for the installation of the mosaic tile at the surface to be covered. Alternatively, with other types of supports, or still with same polymer modified bitumens if advantageous for the production process, many type of glues can be used, such as PVC glues, polyurethane resins, epoxy resins, hot melts, etc. The adhesive face of the support sheet to be applied to the surface to be covered is preferably protected till installation by a protecting sheet made of silicone covered paper, PE or any other easily detachable material. As shown the support sheet can extend beyond the tiled surface to allow overlapping of waterproofing on the joints of contiguous elements.

In an alternate embodiment the background support is big as the tiled area and waterproofing of the borders can be done with a waterproofing tape applied to the surface to be covered, in the position of the joints, before installation, or simply applying a liquid waterproofing by brush. Referring next to FIG. 2, there is shown in perspective view of a preferred realization of the application of a tiled panel of this invention in a corner of two walls 4.

The element is firstly aligned to the corner, the adhesive protective sheet 3 is then removed from the corner toward the opposite edge and at the same time the element is pressed toward the walls allowing adhesion.

The support sheet, extending in this case beyond the tiled area, is bended at the corners between wall and wall and between wall and floor.

These strips can be fixed only after the sticking of the tiled area as the adhesive protecting sheet is precut along the tiled area borders.

On surfaces of certain materials, especially if friable, may be necessary to apply a fixative primer before installation to facilitate adhesion. In an alternative embodiment of this invention the adhesive applied on the supporting sheet is one of the two components of a two component glue as epoxy resin.

The other component is applied with brush or airbrush to the surface to be covered. The positioning of the tiled sheets on the surface to be covered will induce the two components to catalyze fixing the panels.

Yet still in another embodiment of this invention the adhesive used is an hot melting glue. Fixing of the tiled elements is obtained positioning the element in place over the surface and heating it with electrical resistances or other methods.

It is also within the scope of this invention to provide a construction system for tiled surfaces that doesn't need to cut the tiles during installation.

The advantage is that no special tools are needed on site and that installation can be done by unskilled workers.

Referring now to FIG. 3 that shows partial plan views of preferred forms of supplementary elements of the invention and referring also to FIG. 5 and FIG. 6 that shows the application of these ancillary elements.

In particular FIG. 3 shows a partial view of a tiled sheet where the tiles are cut following two orthogonal directions 5 and one angled direction 6. The distance between each parallel cut in the orthogonal directions is the same as in the basic tiled element of the invention. This element can be done without support sheet as the tiles are to be used one by one, the glue can be applied directly on the tiles and the elements are kept together by the adhesive protecting sheet.

The so cut adhesive tiles assume a variety o triangular and trapezoidal sizes that, as further showed in FIGS. 5-6 can be used to fill gaps around piping or fixed sanitary-ware or along borders not aligned to the direction of the tiles. As example in FIGS. 5-6 is showed how these tiles can be used to fill the gaps around piping. FIG. 5 represent a tiled basic element of this invention installed over piping coming out from a wall 7. The tiles of this panel that interfere with the piping can be entirely removed.

In case that hot melting glue has been used to bond the tiles to the support sheet it can be done simply heating the tiles. The space left free from tiles can be filled simply sticking on the support the triangular and trapezoidal tiles of appropriate size 8.

In the same way can be surrounded any curved shape or border not aligned to tiles direction. Referring now to FIG. 4 it shows plan view another ancillary element of an embodiment of the invention. This element is a sheet made of an array tiles fixed on adhesive flexible support, tiles are cut in two orthogonal directions 9. The distance between each parallel cut in one direction is the same as in the basic tiled element of the invention 10. The distance between each parallel cut in the other direction 11 vary with a small increment from the minimum value of about 3-4 mm, till the maximum value slightly lower of the dimension of the tiles in the basic tiled sheet of the invention.

Referring now to FIG. 7 it is shown how a self-adhesive strip of the appropriate width 12, cut from this ancillary element, can be used to fill the gaps in the corners avoiding to cut the tiles of the basic element of the system.

The cutting of the tiles on site during installation is difficult to do especially on certain materials as marble, gres or glass, it must be done by expert workers and need appropriate cutting tools. It is also within the scope of this invention to provide a manufacturing method for the aforementioned tiled panels, although it can be produced with the same procedure as the standard mosaic tiles assembled on net. In the normal production process of mosaic tiles, the tiles are first of all cut from the base material and then are inserted into grilles to keep them in position with the polished face downward, at this point the net to keep them assembled is glued on the back of the tiles. Referring now to FIG. 10, there is shown in a schematic perspective view an embodiment for the production method still part of this invention.

It consists in a multidisk saw 13 with a belt conveyor on bottom 14. The material for the tiles, in slabs or large tiles of the dimension of the tiled area to be produced, is first glued on the flexible support 2, then inserted in the multidisk saw in one direction cutting it into strips 15, so is inserted in an orthogonal direction cutting the strips into rectangular or square tiles 1. Making not orthogonal cuts the tiles can be done also of rhomboidal, triangular or trapezoidal shape.

Alignment guides, not shown in figure, can be placed to keep the material aligned with the disks.

FIG. 9 is a sectional view taken along line 1-1 of FIG. 10 detailing the cutting of the strips into tiles.

The multidisk saw have a micrometric adjustment of the height of the disks to avoid the cutting of the flexible support sheet.

Referring next to FIG. 8, there is shown a schematic perspective view of an embodiment of the production method of this invention.

It consists in an automated production line on two conveyors 14 disposed in two orthogonal directions.

At the beginning of the line the flexible support material 2 is disposed on the belt conveyor 14, on this is disposed the glue 16, an automated charging system 17 with suction cups takes the material of the tiles and dispose it on the glue.

Material of the tiles is then cut in strips by the first multidisk saw 13, an automatic cutter 18 provides then to cut the flexible support material.

At this point the elements are shifted on the orthogonal conveyor where is situated a second bridge saw to cut the strips of the finishing material into tiles. If the material has been cut with water for refrigerating the disks, it can pass through hairdryers 19 or through ovens 20.

At this point the elements are ready to be packed.

It should be seen that there is provided a tiling system which achieves the various objects of this invention and which is well adapted to meet conditions of practical use.

Since various possible realizations might be made of the present invention or modifications might be made to the sample realizations above set forth, it is to be understood that all materials shown and described in the accompanying drawings are to be interpreted as illustrative and not in a limiting sense.

Claims

1. Apparatus for manufacturing of mosaics tiles sheets (24), comprising: a first conveyor (14), a supplying unit (21) of a flexible continuous support (2), located at one end of said conveyor (14), means (16) to provide an adhesive layer on predetermined portions (22) of said support (2), a loading and positioning unit (17) of tiles (23) on said portions (22), a first multi-disk cutting unit (13) arranged at a vertical height so that it interferes at least partially with a thickness of said tiles when the latter are moving along said conveyor in a direction (Dl) while it does not interfere with the support (2) of the tiles, a severing unit (18) arranged to cut in transverse direction to (Dl) said support (2), and to define from said tiles (22) modular panels (24) having predetermined dimensions .

2. Apparatus according claim 1,, wherein downward said cutter (18) it comprises: a guide element (25) arranged to move said panels (24) onto a second conveyor (14 ') in a direction (D2) which is not parallel to direction (Dl) ; a second cutting unit (26) arranged at a vertical height so that it interferes at least partially with a thickness of said tiles when the latter are moving along said second conveyor, while it does not interfere with the support (2) of the tiles.

3. Apparatus according to one of the preceding claims, further comprising a washing unit (19) of said panels (24) .

4. Apparatus according to one of the preceding claims, further comprising a drying unit (20) of said panels (24) .

5. Apparatus according to one of the preceding claims, wherein at least one of said cutting units (13, (26) comprises a plurality of cutters arranged in array to facilitate the removal of material from said tiles (23) .

6. Apparatus according to one of the preceding claims, further comprising a packaging unit arranged at the downward end of the apparatus to wrap the modular panels manufactured.

7. Apparatus according to one of the preceding claims, further comprising further guide elements to keep said tiles aligned (23) on said conveyors (14, 14').

8. Method for the manufacturing of mosaics tiles sheets (24), comprising: supplying a support (2), fixing at least a tile (23) on said support (2), cutting said tile (23) in at least one predetermined direction (Dl) by at least one multiblade cutting unit (13) in order to obtain smaller tesserae from said tile (23) .

9. Method according to claim 8 comprising: supplying a continuous flexible support (2) on a first conveyor (14) , applying a glue on predetermined portions (22) of said support (2) , position at least a tile (23) on a corresponding portion (22) of said support (2), at least partially cutting the thickness of said tile (23) in a predetermined direction (Dl) by a first cutting unit (13), without cutting said support (2), severing said support (2) transversally to direction (Dl), defining modular panels (24).

10. Method according claim 8 further comprising the step of: moving said panels (24) on a second conveyor (14¹), at least partially cutting the thickness of said tile (23) in a predetermined direction (D2) by a second cutting unit (26), without cutting said support (2), direction (D2) being not parallel to direction (Dl) .

11. Method according to any of claims 8-10 further comprising a step of washing said tiles, after said step of cutting.

12. Method according claim 11 further comprising a step of drying said panels (24) .

13. Method according to any of claims 8-12 further comprising a step of packaging of one or more panels (24) on line with the manufacturing steps.

14. Mosaic tiled sheets ready to be installed, comprising a continuous flexible support sheet, on one side of which sheet an array of tiles is arranged, the other side being prepared with the glue for the fixation to a surface to be covered.

15. Mosaic tiled sheets as claimed in claim 14 wherein the flexible support sheet have waterproofing properties.

16. Mosaic tiled sheets as claimed in claim 14 wherein the glue used for the fixation to the surface to be covered has self-adhesive properties and is protected till installation by an adhesion protecting sheet.

17. Mosaic tiled sheets as claimed in claim 14 wherein the glue used for the fixation to the surface to be covered is a two component glue, one of the two components being applied in the factory on the face of the panel, the other one being applied on the surface to be covered before installation.

18. Mosaic tiled sheets as claimed in claim 14 wherein the glue used for the fixation to the surface to be covered is activated by heating the tiled elements during the installation.

19. Mosaic tiled sheets as claimed in claim 14 wherein said sheets are used together with supplementary tiled sheets composed of an array of tiles of different shapes and sizes, said tiles being used to restore the mosaic pattern around curved shapes or along borders not aligned to the directions of the tiles.

20. Mosaic tiled sheets as claimed in claim 14 wherein said sheets are used together with supplementary panels constituted by an array of tiles to be cut in strips of different width, said strips are used in the borders and the corners during installation to adjust the tiled area to the dimensions of the surface to be covered.

21. Mosaic tiled sheets as claimed in claim 14 wherein said sheets are made with a production method characterized by the fact that the material from which the tiles are made is first assembled in large tiles or slabs on the supporting sheet and then cut into an array of tiles of smaller dimensions .

21. Mosaic tiled sheets as claimed in claim 14 wherein said sheet is made of a material having self adhesive properties, with no need of other glue for the fixation on the tesserae or to apply the sheet to the surface to be covered.

22. Mosaic tiled sheets as claimed in claim 14 wherein said sheet is made of polymer modified bitumen, wherein said polymer can be styrene butadiene styrene or atactic polypropylene or any other type of polymer.