WO2009075906A2 - Installation comprising a polymeric grout for bonding tiles to each other and an underlayment to produce a floor and method of manufacture - Google Patents

Abstract

A floor tile installation and method of manufacturing the tile Installation are provided. The floor tile installation contains tiles bonded together with a polymeric grout on an underlayment. The tile installation provides for a fast and economic method installing a tile floor over an existing floor. The floor tile installation can be either a floating floor or a non-floating floor.

Description

INSTALLAllON COMPRISING A POLYMERIC GROUT FOR BONDlN(^ TILRS TO BACH OTHER AND AN UNDHRLA YMENT TO PRODUCE A FlXX)R AND

MFfHOD OF MANUFACTURE

CROSS-KEFERεNCF; TO RELATED APPLICATIONS

This application is a eo&tinuation-m-part of international Application No. FCT/US2uG?/fJH6758, filed December 7, 2007, which claims priority to U.S. Application No. 1 1/639,338, filed December 1.5, 2006, the contents of which are incorporated herein by reieresee.

TECHNICAL FIELD

[0001 ] The present disclosure relates to a floor lite installation comprising Hies bonded together with polymeric grout on an usiαerlayment. The tile installation provides for a iloor, such as a ceramic tile and/or stone floor covering, over an existing floor. The disclosure also re-latc-s Io a method of manufacturing the tile installation. The tile installation provides for a fast and economical method of manufacturing a floor covering over an cxisdng door,

BACKGROUND

10002] Conventionally, floor tiles axe installed by mortaring iik directly onto a wood or ceuie.nl Ooor and then grouting the tik with, a oemeutatious grout In many applications, a cemenvadous backer-board is first applied to the floor followed by mortaring the tik to me cemerstaυous backer-board. This conventional process of laying floor tik is time- consutYimg and labor intensive. As a result, conventional tile floors are expensive to install owing to high labor costs. In addition, water-based cementations mortars and grouts can not be used with flooring and tiles dial are adversely affecLcd by moisture For example, flooring made of waver sweϋable materials such as particle board can not be easily used with water-based cements, ϊn addition, certain types of colored marble files swell when exposed to water and would rsot be usable with a water-based mortar or grout. [0003 ] The pjescm disclosure relates to a lloor die installation and a method of manufacturing the tile installation. The tik installation comprises at least two tiles bonded together with a polymeric grout on an uudedayment. The present disclosure also relates in a method of manufacturing the tile installation. The method comprises placing an underkyn-sent over an existing floor stxf placing at least two tiles separated by a apace on The underpayment. Next an ur> cured polymeric grout is applied in the space between the iiles and the uncured polymeric grout is then struck to contour arid then the polymeric grout is allowed to cure so form the UIe installation.

[0004] The floor ille Insinuation is simple, fast and economical compared to conventional hie installations, for example, the tile installation can be walked on within 2 to 6 hours depending upon the polymeric grout used. This is much faster than using conventional technique? which can take days before the tile can. be put into service. The tile installation can he manufactured where water-based installation methods are prohibited, hi addition, the tile installation can be completely waterproof. The polymeric grout of the disclosed tile installation has much higher strength and flexibility man conventions! cement grout. This provides for less unwanted cracking by isolating the floating tile floor from suhiloofs with high load movement.

(00051 Other modes and various advantages of the present disclosure will become readily apparent by those skilled in the art from the following detailed description, where it is shown and described only in the preferred embodiments, simply by way of illustration of the best mode, Λs will be realrxeά, the disclosure is capable of other and different embodiments ajul as several details are capable of modifications in various obvious respects, without departing from the disclosure. Accordingly, the description is to be regarded a^ illustrative in. nature and not as restrictive in seυpe,

BRIEF DRSCR.rπOJN QF THE PRA WI KGS

10006] Figure 1 - Picture showing particle board flooring used to simulate existing flooring in the ex. ample. [000?] Figure 2 ~ Picture showing particle board covered with 4 mil LDPE tiexihb water proof plastic sheet as an tωderlayment. Picture also shows optional pressure sensitive patches -used to bold the ides in place during Installation,

10008 j Figure 3 ~ Picture showing optional tape used to expedite oiears-up alter applying the polymeric grout between the tiles,

[0(H)SJ] Figure 4 - Pievure showing optional decorative particles (sand) applied (o nnenred polymeric grout.

10010j Figure 5 - Picture showing finished glazed porcelain OoonJfe installation with decorative sand giving the appearance of cernetaisous grout.

!^"00 ! i ] Figure 6 ~ Picture showing elose-irp view of decorative sand applied to polymeric grout to g.ive the appearance of cementations grout.

[0012] Figures 7 and 8 - Pictures showing the top

bottom finished UIe installation standing up illustrating the overall strength of the tile installation.

[00 Oj Figures 9 and. 10- Picture showing I IvJ glass tiles with pearl escsmt decorative particles.

[0014] Figures 1 1 and 12- Picture showing 3 x 3 in glazed ceramic tile with color shifting custom paint rl&ke.

(00!S] Figure 13- Picture showing 6 x 6 in engineered sione tiles with decorative sand (001 (i^"j Figure 14- Picture showing 6 x 6 in natural slate tile with decorative sand.

1001 ?] Figure 15- Picture showing ύ x 6 in natural marble UIe with peadcscent decorative particles.

[0018] Figure 16 -Figure illustrating one embodiment with the reladonship between the surfaces of the tile material, the release layer and the grout area.

I)ETAI LED DESCRIPTION ANB VARIOUS MODES

[001 Q] The tile installation comprises at least two tiles bonded with 3 pc-lynienc grout and aa undcriaymeπt -which together form a ϋoor covering. The isnderiayineut cau be aτ5y snatcriai that can be placed between an existing floor and a tik material Typically, the underiaymsrst can be a rigid mater ud, a flexible material or &rs adhesive material When the imderiayment is a rigid or flexible material the tile installation would be a Heating floor When the underlaymer-i is an adhesive, the file installation is not a floating floor. Mure typically, (he undedaymem is a moisture barrier. Optionally., the tϋeβ may be bonded to the underpayment with an adhesive or an adhesive tape. Arry tile material usable for flooring may be utilized in the tile installation,

100201 The polymeric srout used to bond the tiles can be anv tvoe of curable; polymeric material thai can be applied between the spaces of the tiles. Typically, the polymeric grout has higher strength, as measured by pounds uf flex at the yield point using ASTM OSSO, than conventional grout For example, the polymeric grout has from about 1 ,000 to about 3,000 pounds of Ilex at the yieki point compared to standard grouts which have ilexurai strengths of about 400 to about 6(K) pounds of flex at the yield point. More typically, the polymeric grout, has from about 1.500 to about 2500 pounds of ilex a* the yield point Typieaϋy, the polymeric grout is non-porous, waier-prooh .mildew resistant, susin .resist am and mold resistant.

[0021] Non-hmϊtmg examples of the uαdcrlayment include plywood, wood particle board, wood planking, cement, cork, synthetic cork, recycled rubber, a foam sheet a liber glass sheet, plastic sheet, a metal sheet a composite sheet arsd an adhesive layer. Smaller sections of uisderiaymeπi ean be utilized and joined together to form a larger section, 1 he anderiayrrserst may be chosen to provide acoustical protection to the Ooormg system.

[0022 j Typical plastic sheets include polyethylene (PB) sheet polypropylene (FF) sheet, PH/PP sheet, nylon sheet, polyester sheet, mylar sheet, styrenie sheet, polycarbonate sheet, acryiii,: slteei, acetal sheet OdrbeO^ sheet, Lexatv® sheet, LueueΦ sheet, Miearta® sheet, FεrspexΦ sheet, Plexigias® sheet, AcryiiteOl; sheet, PET sheets, ABS sheet, PVC sheet, PTfK sheet, HIPS sheet, FVOII sheet, PP/EVOH sheet and Tyvek®.

(0023^"| Typical composite sheets include a polymeric resin and a Obrous material. The polymeric resin typically includes polyester resin, epoxy resin, urc-thane resin, poiysuHorse resin, polypheny I su Li one resin, polyether suifone resin, polyphalarmcle resin, ^■poiyphenylene sulfide resin, aromatic polyketone resin, poiyamide-iBUde resin. polycarbonate resin, styrenie resin, ABS resin, acrylic resin, FET resin and combinations thereof.

[0024] The fibrous material utilized in the composite sheets typically includes synthetic fibers stseh as bus not limited to ilber-glass, carbon liber., polyethylene fiber, polypropylene fiber, nylon fiber, polyester fiber, and polyarnide fiber and natural libers such as but not limited to bcmp, cotton fiber, linen liber, woo! liber, and combinations synthetic and natural libers thereof.

[00251 in addition to polymeric rcsin/ilbrous materia! composites, eernentafious material/fibrous material composites can be utilized. The oerrsentaiious materials can be any type of material containing cement in the formulation. The fibrous materials ears be any of those listed above for the polymeric resin/fibrous materia! composites.

|0026] The underlaynieut may also include an adhesive materia) laid down on the existing floor as a layer. The adhesive material typically includes PiioseslΦ, epoxies and urethanes, In this embodiment, the floor tile installation is not a floating floor tile installation because the tile is bonded to the subiioor by the adhesive underlayrnenL

10027] The floor tile installaUoT? co.ntains tiles which typically include ceramic tile (Figures 5, 6, 1 1 and 12}, porcelain tile, term eotta tile, marble tile (^'Figure IS s, concrete tile, slate tile (Figure 14), granite tile, wood tile, glass tile (Figures 9 and 10), metal tile, plastic tde, engineered stone tile (Figure 1 3) or combinations there*,;!. Typically, the floor tile installation contains a rigid tile as opposed to flexible plastic tiles, such as vinyl tiles.

100281 The polymeric grout used to bond the tiles of the floating Ooor tile installation is not limited and includes any structural adhesive that provides sufficient strength to ihe tile installation. Typically, the polymeric grout provides strength as measured by pounds of flex at me yield point as measured by A_.STN1C-580- Typically, the polymeric grout provides about 1,000 to about 3,000 pounds of flex at the yldd point, and more typically _: about 1500 to about 2500 pounds of flex at the yield point. The polymeric grout is typically non-porous, water-proof, mildew resistant;, stain resistant and mold resistant |002v] The polymeric grout typically contains a oroihane, as cpoxy, a. polyester, an acrylic and combinations thereof, In embodi.nie.nte of the invention, the polymeric grout comprises a two component ureiiurne structural adhesive.

[0030] The polymeric grout may be applied by a mix bag or a static mixer, typically when a two component adhesive, such as a two component urethane structural adhesive, is used. The mix bag is typically a ilexibie divided pouch which contains measured amounts of ihe adhesive components. The components are mixed as they are dispenses from the mix hag. Suppliers of mix bag systems include Merlin Packaging Technologies and AFS&> • Adhesive Packaging Specialties Inc. The static mixer is not limited, and can be any type of static mixer αseful ior applying at least a two component polymeric grout, such as static mixers available from FAM Industries.

|0031 j The tile installation optionally contains decorative particles covering and bonded to the polymeric groni or dispersed into the polymeric grout. The de-corative particles cars be any type of material that can be used in flooring. The decorative particle is applied to the uneureu polymeric grout and is bonded to the grout after the grout is cured. The decorative panicles typically include natural materials such as sand, minerals, crushed stone, crushed shell, metal flake, titanium dioxide and natural pigments and synthetic materials such as ceramic and ceram.ic coated particles, crushed glass, synthetic pigments and cured resώ particulates such as polyester flake, and combinations of natural and synthetic materials thereof

[0032] The floor tile installation is typically manufactured by placing an underpayment over an existing floor then placing at least two tiles separated hy a space on the ursderkyment. Next, a polymeric grout is applied into the space between tiles and the polymeric grout is optionally struck and then allowed to cure producing the tile installation as a floating Door. The dies may be optionally placed onto th& αnderlayment ^■with a spacer io insure uniform snaeir-s- between the tiles, in addition, the tiles may he bonded to the underlaymcnt with an adhesive or adhesive tape prior io applying the polymeric grout. Decorative particles may also he applied to the polymeric grout after applying the grout into spaces between the dies. The particles are applied before the grout completely cures. The particles are then bonded to ihe polymeric grout alter the groin cures.

10033] In order to expedite clean-up, the tiles may be protected with a tape or film prior to applying the polymeric grout into the space between the dies. I he tape or Him is men removed before or after the polymeric grout cures leaving a cleat finish. An alternative method to ease ciean-up is to protect the tile surface with a release agent prior to applying the polymeric groin. After the polymeric grout has partially cured, excess grout may be peeled from the surface of the tile and the tile cleaned with a suitable solvent to rerøove the release agenL Alternatively, the release agent can be applied as a water-based coating on to the tile surface prior to applying the imeured polymer grout, then allowing the water to evaporate to provide a tack-free protective coaling and then peeling off the coaling with a scraper abler the polymeric grout is cured. f 0034 J Figure 16 illustrates one embodiment utilizing the release agerst in order to achieve a clean grout line on Ihe tile installation. The release layer can be applied as a tape, film, coating or agent. The relationship between the surfaces of ihe tlie material, the release layer and the grout area is illustrated hi Figure 16. One typical method tor applying ihe release layer is by applying a water based composition before the polymeric grout is applied. Alter ihe polymeric grout is applied and cured, the release layer is washed off the tile leaving a clean grout line.

[0035] A further embodiment concerns a tile structure comprising at least two tiles bonded together with polymeric grout. This tile structure may comprise or be incorporated into a flooring material, but may also comprise other structural devices such as a device that hangs on a wall, like a back splash, shower and/or tub walk a decorative wall hangings a decorative waterfall backing and the like. The polymeric grout may be any of the grout materials discussed herein, including a two component methane structural adhesive. The decorative particles as described herein may also be included. Likewise the tiles and any other aspects of the tile installation as described herein may be incorporated into the life structure. Backing material ancl/or an underlayment may be used, !?^'}036] The following examples are i\n illustration purposes only aαcl arc not intended to limit ihe scope of she claims.

[0037] A floating type iiie floor installation was manidaetured using a plastic sheet moisture barrier as an underlayrneut and a structural adhesive as a polymeric grout First, ?to approximately 16 FT^" section of panicle board nailed to 2 x 4" studs was constructed 0%ure 1 X NexS_v the particle board was covered with a water proof plastic 4 ■ nil !,DPH sheet as a vvater proof underlay moot. PtIOSEΛL 3" rubber splice tape pressure sensitive patches were fliers applied io the plastic sheet io hold the tiles m place (Figure 2). Prior to placement on the underpayment, the tiles were taped with protective, removable tape to aid in clean up after the polymeric grout is applied. Next, 16 - ! FT elated ceramic tiles were placed onto the undedayment with a space between the tiles using ihe pressure sensitive tape to hold the tile in place (Figure 3). Next, a 2-<omporsern ore-thane adhesive φolymeric grout) was mixed and applied between (he tiles using a disposable plastic grout bag. Alternative methods of application include dispensing the polymeric grυui trom a cartridge, such as a cartridge equipped with a static mixer, υsirsg a dispensing gun or floating the pot v.merie grout into the space between the tiles as with oemematious grout and cleaning the tile surface with art appropriate solvent. (This method w^'as used io produce ihe tile installations in Figures ^cλ 10, 1 1 arid \ 2Λ The 2- coo-porierst uretfcuie polymeric grout was ibrmulated as shown in ^'Fable 1 . The polymeric grout was then, struck and decorative sand zircon sand, lake sand or silica sand i was applied to the uticured polymeric grout (Figure 4), Before the polymeric gram completely cured, the tape was removed. After 4 hours, the polymeric grout cured sufficiently to remove excess decorative- sand and the tile could then be walked on {Figure 5 κ The decorative sand gives the appearance of cemεαtaucms grout (Figure 6). The finished tile installation is strong enough us support itself in a vertical position (Figures ? arsd S), With the high strength of the finished tde systmu preformed tile sections can be prepared aαd installed as if they were individual dies using fee method described. 1 able 1. PoUnscr grαut

uretha.ne) formulation used in the trample

Prepoh mer Curative

100.00

[00381 TIv k'rro "α^nπslng" ;3.nd its gmmmatica) varialk>rϊs) as u^ed btTda !?■ used in ihc inclusive ^cnse of "hax'ing" or "including" and not in the exclusive ^en^e αf

ooh ot". The LCΠB "a^" miά "Ihc" as used hetem arc understood so encompass the pUnul as vx'cU as she singular.

1003*⁾] The lore-going tk'serlptiou illustrates and describes flse present disciosurc. Λ Jd?tie>«aiK\ the diseSosuR' shows and describes only the preferred e-mhodimcnis of the disclosure, h«s, us mcπύoned

it is to be uudersiood thai It h capable of changes or snoditkations within ihe scope of tile concept as expressed herein commensnrate w-Uh the uhi've teachings and/or skill or knc>u'l«ige of the reiev;ϋ-!f art. The embodiments dcscdbed hercsnabove uiv further intended to explain best modes known of prseύesng the ύn-efuion and io cπαbie others ski HeU in the art to luiii/e the disclosure m sυeh. ur other, i.-rnbodimems and xvi.h the various modification required by the partscah-tr applications or uses disclosed herein. Accordingly, the description is not intended ι- ϊmv.t she inveniϊon to the form disdosed heroin Also, it is intended thai the appended claims be construed to include allernαuve embodiments.

(004Gj All public aύons, patents and patent applications cited in this specilkaύon are herein ineorp^taicd b>" reiereuce, αod lor any and all purposes, as; if each individual pubhecαion. potesu or patent application vsere spceiilealiy and Individually indicated k> be incorporated by refereϊϊee. In the case of inconsistencies, ihe- present disclosure will ϋrevau.

Claims

We Claim:

1 A die installation comprising an underlayrrserst and at least two flies bonded with a polymeric grout to produce a floor.

2. The tile installation as claimed in claim U wherein the underlayment is a rigid material a ilexible material or an adhesive material and wherein the tmderlavment b optionally a moisture barrier.

3. The hie Installation as claimed in claim K wherein the tile installation iorms a floating floor.

4. The tils installation as claimed in claim I, wherein the imderiayrucnt is an adhesive materia! and the die installation is bonded directly to a subOoor and the tik installation forms a noiv floating floor.

5. The. tile installation as claimed in claim I . wherein the at least two dies bonded with a polymeric grout are bonded to the underlayment with a polymeric grout an adhesive or an adhesive tape,

6. The tik installation as claimed in claim K wherein the at least two tiles bonded with a polymeric grout are not bonded to the irnderkryment.

7. The die installation as chimed in claim 1. wherein the polymeric grout is noα- porous.

miickw resistant stain resistant and mold resistant.

S. The tile installation as claimed in claim 1«, wherein the polymeric grout is at least one selected tY«n the group consisting of a urcthane grout., an epoxy grout, a pub/ester grant or an acrylic grout.

V. T he iik insudianon as claimed in claim 1 , wherein the at least two tiles arc selected from the group consisting of ceramic tiles, poreeiaio tile, terra eoUα tile, marble

n tiles, concrete tile, metal tile, plastic tile, granite tile, slate UIe, wood tile, glass tile, engineered stone use and combinations thereof.

10 The tile installation as claimed m claim 1. wherein the onderlaymersi ss at least one selected from the iU'Oim eonsistiiiu of plywood, wood øartick- board, wood plankiue, cork, synthetic cork, recycled rubber, a metal sheet, cement, a fiber glass sheet a plastic sheet, a Io ant sheet, a composts sheet and combinations thereof

1 1 , 1 he tile i spallation as claimed in claim 10, wherein the underlayrnent is a composite comprising a polymeric resin, and a fibrous materia!,

12, The tile installation as claimed iu claim 1 ! , wherein the polymeric resin is at least one selected from die group consisting of polyester resin, cpoxy reβin, αreihane resirs, pαlysaHbne resin, polypheny lsulfone resin, polyeihcvsulibne resin, polyphthalaniiϋo resin, polyaryiamtde resin, polsphenylene sulfide resin, aromatic polykctαne resin, poiyamide-unkk. resin, polycarbonate resin, styrenic resin, ΛBS resiα, acrylic resin and PET resin.

13, The Uh' installation as claimed in claim 1 1 , wherein the Obrous material is at leitst one selected iron^ the group consisting of synthetic libers such as hut not limited m ihScr- gluss, carbon fiber, polyethylene fiber, polypropylene fiber, nylon fiber, polyester fiber, and polyarnide fiber &s\ά natural fibers such as but not limited to kmp, cotton fiber, linen fiber, wool fiber, and combinations synthetic and natural fibers thereol,

14, The iile installation as chimed in claim 1 _> wherein the imderlayroent is a composite comprising a cement material and a fibrous material,

15, The die installation as claimed in dasro L further cormmsmg a dccoradvc particle covering arsd bonded to or dispersed in to the polymeric grout.

16. The tile .installation as claimed ϊn claim IS, wherein the decorative particle Is at leas? one selected from the group consisting of natural materials such as sand, minerals, crushed stone, crushed shell, metal Oakc, titanium dioxide and natural pigments and synthetic materials such as ceramic and ceramic coated particles, crushed glass, synthetic pigments and cured resin particulates such as polyester Hake, and combinations of natural and synthetic materials thereof.

17. The tile inspiration as claimed in claim 2, wherein the underlaynieat is as adhesive and the adhesive is at least one selected from the group consisting oi PliosealΦ.. urethaπe adhesives and epoxy adhosives,

18. Λ method of manufacturing the tile installation as claimed in claim I, comprising: placing an urideriayment over an existing floor; placing at least two tiles separated by a space on the underlayment: applying an unciu'ed polymeric grout in the space between the at ie&at two tiles; optionally striking the polymeric grout to give a desired contour So the grout and allowing the uncured polymeric grout to cure to produce the tile installation as a floating floor,

19. The method oi^"' manufacturing the tile installation as claimed in elahn 18, wherein a spacer is utilized to provide the space separating the at least two tiles.

30. The method of manufacturing, the tile installation as claimed in claim 1 S, further comprising hondmg the at least two tiles to the undedavment prior to applying the polymeric grout.

21, The method of manufacturing the die installation as claimed in claim I E, wherein the underiaymeut and the at least two tiles are not bonded together.

22. The method of manufacturing the tile installation as claimed m claim 18, further comprising applying a decorative particle to the uneureα polymeric grout In the space between the a! least rwo dies wherein the decorative particle is bonded to ihe polymeric groin stler curing.

23. The method of .manαfaemriug the tile installation as claimed in claim 1 S, further comprising taping or applying a. flexible film to the surface of at least ι.wo dies prior to applying ihe uπ cured polymeric grout and removing the tape or fihrs after .he polymeric grout is applied into the space between the at least two tiles before the polymeric groυi cures,

24. The method of manufacturing the tile installation as claimed in claim I 8, further comprising application of a release agent to ihe tile surface prior to applying the unewed polymeric grout and lhen removing ihe excess partially cured polymeric grout horn the surface of the tile followed by removal of the release agent alier the polymeric grout is completely cured.

25 The method of manufacturing Ihe life installation as claimed in claim 1 , comprising; placing &i\ underpayment over an yxisiirsg floor; placing a( leasi two tiles separated by a space on ihe undc-riaymeni; applying a release layer on the at least two tiles; applying an unoured polymeric grout in the spa.ee between the at least two tiles; optionally striking the polymeric grout to give a desired contour to the grout; and allowing the uneured polymer grout lo cure and removing ihe release layer along with excess cured polymeric grout giving a giooi line wuh a clean edge to produce the tile installation as a floor,

^'2$. The method of manufacturing the tile installation as claimed in claim 25, wherein ihe release layer is a water based composition, and the water based composition is removed by washing to give a grout line with a clean edge.

) 4

27. The method, of mauuføoturirsg the ϋ Ie installation as claimed in claim 1 S, further comprising utilising preformed tile sections manufactured according Jo the method in claim IS.

28. The method of manufacturing the tile installation, as claimed in claim 24, wherein ihe release agent is a water-based ooatirsg that is allowed to άry Io provide a lack free protective coating release agent.

29. The method of manufacturing the tile installation as claimed in daim 18, wherein (he unoured polymeric grout is applied by a mix hag or a static mixer.

30. A ti Ie structure comprising at least two tiles bonded with a polymeric grout. 3 } . The tile structure of claim 30 wherem the polymeric grout comprises a two component structural adhesive. 32. The tile structure of claim 30 further comprising decorative particles applied to the polymeπe groin.

The tile structure of claim 30 further comprising an imdeilayrnent ot a backirsg materia!