Abstract:
An apparatus and method for creating mosaic structures, generally comprises the steps of providing a frame comprising spaces for individual pieces of a mosaic tile. Each of the individual pieces are spaced from each other and positioned in each space and are circumscribed by a peripheral ridge surrounding each piece.  
     Grout is poured into the spaces between the pieces. The grout is then permitted to dry and the resulting tile is removed from the frame.

Description:
FIELD OF THE INVENTION  
         [0001]    The present invention relates to creating mosaic structures, for instance, mosaic tiles comprised of numerous pieces held together.  
         BACKGROUND OF THE INVENTION  
         [0002]    Mosaic designs for use in images, walls, tiles, etc., have been known for centuries—indeed millennia. Of particular beauty are the mosaics in the city of Ravenna, Italy, which are known all over the world.  
           [0003]    Tiles comprised of pieces of stone, glass or other material are highly desirable for baths and other areas of a home or apartment. Such tiles are typically 12 inches by 12 inches in dimension, with each of the stones being approximately ⅜ of an inch square.  
           [0004]    A traditional method of creating such tiles is depicted, for example, in FIG. 1, which shows the steps of providing a netting (FIG. 1 a ), applying adhesive thereto (FIG. 1 b ), arranging individual small constituent pieces (“tile pieces”) of the overall tile (FIG. 1 c ) with the top side up—that is, the side to be viewed (or stepped on if for a floor) is facing up. The pieces are arranged with gaps between successive pieces to create a “mosaic” effect.  
           [0005]    Grout is then poured (FIG. 1 c ) onto the tile pieces and moved (by hand, using a tool or by the flowable nature of the grout if mixed with sufficient liquid) into the gaps between the tile pieces. For the grout between the tile pieces to be relatively level, it must be:  
           [0006]    (a) in a sufficiently “runny condition;” or  
           [0007]    (b) accurately smoothed by hand or a tool; or  
           [0008]    (c) of a sufficient amount that it is fairly level with the top surface of the tile pieces.  
           [0009]    Regardless of the above method however, the top surfaces of the tile pieces must be cleaned of the group—a labor intensive task.  
           [0010]    The above method of creating mosaic tiles is extremely labor intensive and make the tiles difficult to assemble. Further, when a tile is cut, chipping of the individual stones could occur. Chipping can be a more significant problem with particular types of stones such as slate as sheeted segments of which can easily detach across parallel planes. Angular cutting of the pieces is particularly difficult because the flexible nature of the netting allows the tile pieces to move substantially when subject to vibration or nudging.  
           [0011]    An additional problem with the traditional method of creating mosaic tiles is that the top surface of the tile is often uneven, specially when the individual tile pieces are of different heights.  
           [0012]    Even placing “spacers” (FIG. 1 c ) between adjacent pieces to assure uniform spacing between tile pieces can be difficult and labor intensive by the traditional method.  
           [0013]    A further problem occurs when using metallic tile pieces because under the traditional method a filled, solid metal piece (which is heavy and costly to produce) must be used in order to lay flat on the netting prior to the pouring of the grout.  
           [0014]    A still further problem with the traditional method of laying mosaics is that grooves on adjacent tiles do not line up well—particularly when installing mosaic tiles on walls.  
           [0015]    A further problem with the traditional method is that smaller dimensional pieces such as ⅜″ cannot be easily laid as the height may not be sufficient to create significant contract by the grout between such adjacent pieces.  
           [0016]    It is therefore a object of the present invention to provide a method and apparatus of creating mosaic structures which is less labor intensive than conventional methods.  
           [0017]    Another object of the invention is to provide a method and apparatus for the creation of mosaic structures in which the structures may be more easily cut, without the pieces easily chipping and breaking.  
           [0018]    A further object of the invention is to provide a method and apparatus for creating mosaic structures in which the grout lines can be substantially uniform, while lying below the plane of the top surface of the tile pieces and in which corresponding grout lines of adjacent tiles line up.  
           [0019]    A yet further object of the invention is to provide a method and apparatus for laying grout in which the top surfaces of the tile pieces are on a substantially flat plane, even if the heights of the tile pieces are quite different.  
           [0020]    Additionally, an object of the invention is to provide a method and apparatus for creating mosaic structures in which tile pieces made of stamped metal may be used in place of solid filled metal pieces.  
         SUMMARY OF THE INVENTION  
         [0021]    These and other aspects of the invention, which shall become apparent hereafter, are achieved by a method and apparatus for creating mosaic works, comprising the steps of providing a template or frame for the positioning of mosaic pieces therein with gaps between adjacent pieces. The gaps are created by the existence a low wall circumscribing each of position for the insertion of each tile piece. The height of the parametric wall does not extend beyond the height of each tile piece.  
           [0022]    The tile pieces are positioned into the frame so that the “top” side of the pieces face downward. The next step is optionally applying adhesive onto the tile pieces and then optionally placing a mesh or other securing and flexible mechanism to hold the pieces together. The next step is the pouring of sufficient “grout” or other cement/adhesive—like product onto the bottom side of the pieces so that grout runs into the spaces between the pieces and covers the top planar surfaces of the positional parametric walls. Sufficient grout must be poured so as not only to fill the spaces between individual tile pieces, but also to provide a sufficiently thick grout layer on the tile pieces to hold the pieces together as a single tile once the tile is removed from the template after the drying of the grout.  
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0023]    The invention will be better understood by the Detailed Description of the Preferred Embodiment, with reference to the drawing in which:  
         [0024]    FIGS.  1 ( a )-( c ) depict a prior art method of creating mosaic structures;  
         [0025]    [0025]FIG. 2 is a cross sectional view of a tile showing grout between the tile pieces taken across the direction of line  2 - 2  of FIG. 1-( c );  
         [0026]    [0026]FIG. 3 is a perspective view of a template containing individual small mosaic pieces within its frame; and  
         [0027]    [0027]FIG. 4 is a cross sectional view of a stamped metallic tile piece in a position of the template frame. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0028]    Referring now to the drawings, wherein like numerals reflect like elements throughout the various views, a the traditional method of creating mosaic structures is depicted in FIGS.  1 ( a )- 1 ( c ) and comprises the steps of providing a netting  10 , applying an adhesive (see FIG. 1( b ))  20  thereon and positioning tile pieces  30  thereon (see FIG. 1( c )).  
         [0029]    In order to obtain uniform spacing between adjacent tile pieces  30  and maintain straight rows and columns, spacers  31  maybe used. Of course, even the positioning of spacers  31  consumes much time. Alternatively, the tile pieces  30  may be painstakingly positioned by “eyeballing” them in an effort to obtain uniform spacing.  
         [0030]    Once the adhesive  20  dries and the tile pieces are secured, the next step is the pouring of a second adhesive compound, typically known as “grout”  50  (see FIG. 1( c )), to fill the spaces in the gaps between individual adjacent tile pieces. After pouring the grout  50 , the top surface  32  of the pieces  30  must be cleaned to remove excess grout thereon so that grout remains primarily only in the spaces  40  between individual tile pieces  30 .  
         [0031]    This prior art method unfortunately had a number of drawbacks in that the cutting of the tile  60  could be difficult and could cause individual pieces  30  to chip, fracture and break. Chipping can be a more significant problem with particular types of stones, such as slate, sheeted segments of which easily detach across parallel planes. Angular cutting of the pieces is particularly difficult because, as explained, the flexible nature the netting allows the pieces to move when subject to vibration or nudging.  
         [0032]    Further, as explained, the laying of spacers  31  is extremely time consuming. Additionally, the height of the grout  50  within the spaces  40  was difficult to maintain uniform, unless the grout  50  is poured such that it fills the spaces completely. In other words, having grout filled at an intermediate height (i.e. below the level of the surface of the tile pieces  30 ) between all of the tile pieces  30  can be difficult to achieve uniformly.  
         [0033]    A further problem with the traditional method is that smaller dimensional pieces such as ⅜″ could not be easily laid as the height may not be sufficient to create significant contract by the grout between such adjacent pieces.  
         [0034]    The inventive apparatus and method for creating mosaic structures generally comprises providing a template frame  70  which, in this case, is rectangular, although it may be of any shape. The template frame  70  generally includes a circumferential outer wall  80  and has tile piece positions  71  for individual tile pieces  30 . Each position  71  includes a base  72  extending under the pieces  30  (see FIG. 3) so that the pieces do not fall through the frame  70 . Individual pieces  30  are also circumscribed by positioned parametric walls  73  which do not extend above the surface or depth of each piece  30 .  
         [0035]    Once the pieces  30  are inserted into the frame in a respective position, a netting (not shown) may optionally be placed over preferably all of the pieces  30 .  
         [0036]    Subsequently, grout  120  is poured onto the bottom surfaces  33  of the pieces  30  (which are inserted face down in frame  70 ) until the grout  120  completely fills the spaces  40  between the individual tiles  30  and covers top planar surfaces  74  of the positional parametric walls  73 . Sufficient grout  120  is poured so that not only the spaces  40  between individual tile pieces filled, but also to provide sufficient grout layer thickness covering the bottom surfaces  33  of the tile pieces  30  to hold secure all of the pieces together as a single tile  60  once the tile  60  is removed. The grouting is then allowed to dry and the final product—a solid piece of mosaic tile, is removed from the frame.  
         [0037]    This method overcomes many of the problems associated with the traditional method of laying tile. Some of the advantages which overcome problems with the prior art method are:  
         [0038]    (1) the level of the grout is uniform and defined by the top planar surfaces  74  of the positional parametric walls  73 ;  
         [0039]    (2) the laying of spacers is eliminated by the existence of the positional parametric walls  73 ;  
         [0040]    (3) since the tile pieces  30  are positioned top side down, the base  72  ensures that the top surfaces of the tile pieces  30  will be relatively flush virtually regardless of the height of individual tile pieces  30 ;  
         [0041]    (4) chipping is reduced as the grouted tiles are formed with a thickness of grout  120  underneath the tile pieces  30 ; the tiles can thus be easily cut—even at an angle; and  
         [0042]    (5) the cost of metal or other punchable pieces are greatly reduced because the invention facilitates the use of “punched,” open ended rectangular shaped metal pieces which can be formed from metal sheets (decreasing substantially the volume of metal necessary over using filled metal pieces).  
         [0043]    While the preferred embodiment of the invention has been depicted in detail, modifications and adaptations maybe made thereto without departing from the spirit and scope of the invention as delineated in the following claims: