Patent ID: 9636942
Date: 2017-05-02
CPC Classifications: B44C,Y10T

Claim:
1. A method of making pre-grouted mosaic panels, wherein each panel is formed from a plurality of mosaic tiles each having an upper surface and a lower surface, comprising the steps of: a) laying said tiles over a substantially horizontal support base in mutually spaced positions, to define a plurality of grooves; b) placing, after said step of laying said tiles, a first polymeric thermoformable sheet element on an upper surface of said mosaic tiles; c) thermoforming said first sheet element placed on said tiles, for said first thermoformed sheet element to at least partially fill each of said grooves to provide an intermediate product that comprises said tiles held together by said first polymeric thermoformed sheet element; d) turning said intermediate product upside-down and placing said intermediate product on a laying base to enable access to said grooves from outside; and e) distributing a filling resin in pasty or semisolid state into said grooves to form a plurality of jointing beads, wherein thermoforming said first sheet element comprises causing portions of the first thermoformed sheet element that at least partially fill the grooves to be convex toward the support base, and wherein distributing the filling resin in the pasty or semisolid state into the grooves comprises causing the filling resin to cover the convex portions of the first thermoformed sheet element, such that after curing of the filling resin, the convex portions provide an upper surface of a mosaic panel with concave jointing beads.