Abstract:
A building material comprising, in layers, a thin waterproof membrane base of rigid plastic such as PVC, a mortar bed, a layer of cement, a metal lath, and a layer of ceramic tile, brick-veneer, granite tile or marble tile, which provides a pre-fabricated panel adapted to be attached to any flat surface, such as a wall or counter.

Description:
BACKGROUND OF THE INVENTION 
     The invention relates to the installation of ceramic tile, brick-veneer, granite tile or marble tile. These building materials are commonly used in shower enclosures, bathroom, bathtub or kitchen walls and counters. 
     The usual method for installation of tile, and the like in locations such as bathrooms or kitchens, involves installing a membrane of roofing felt or polyethylene film over wood or metal studs. Then, galvanized or painted expanded metal lath is installed. Next, there is applied a scratch coat of a cement mixture which is then allowed to cure for a minimum of 20 hours at 70 degrees F or above. Next, a mortar bed is installed and it is also then allowed to cure for a minimum of 20 hours at 70 degrees F or above. 
     After all these steps have been accomplished, the tile is applied with dry-set or cement mortar as a bonding coat on the cured bed of mortar. The bond coat is allowed to cure for a minimum of 24 hours at 70 degrees F or above and then grout is applied with dry-set grout 
     For a shower enclosure, other preparations must be done, such as installing a waterproofing shower pan, by applying a hot mop (hot asphalt) on the shower floor and dam, or applying a shower pan liner membrane. The shower pan and drain fittings must be tested by filling with water and testing for leaks and waiting 24 hours before laying the tiles. This method requires at least two persons (tile installer and helper) and it usually takes at least four days to complete an average 60 to 100 square feet of tile installation and it is very, very messy work. 
     Another method of installing tile involves using cementitious backer board. This material can be applied over wood or metal studs and ceramic tile can be bonded to it with dry-set, latex, or cement. An average 60 square feet of bathtub walls can be completed in two days, a shower enclosure, three days. This is still very messy work. 
     In both methods described above, the tiles must be trimmed for every corner and surrounding plumbing fixtures, producing an enormous amount of waste. Tools and buckets must be washed constantly to get rid of dry-set, latex cement, and grout, all of which have a high alkali content, usually with no appropriate place to wash and discharge it. Thus, it is often discharged into the ground or sewer system. When a cement mixer is used, it must be washed constantly and polluted water is discharged, untreated, into the ground or the sewer system. Thus tile installation, as it is done today, is not only very, very messy work, but it produces enormous amounts of contaminants. 
     OBJECTS OF THE INVENTION 
     Accordingly, several objects and advantages of the invention are as follows: 
     to provide a simple and easy method to install tile type building materials which is environmentally favorable; 
     to provide a clean and fast way to install tile type building materials; 
     to provide a less expensive way to install tile type building materials; 
     to provide pre-fabricated tile type building material panels which are easily installed. 
     SUMMARY OF THE INVENTION 
     The invention comprises a pre-fabricted board or sheet of tile type building material adapted to be installed in a bathroom or kitchen, in panels, to make installation far faster and easier than the present method where the tiles are all individually installed at the site. The tile board or panel comprises, in layers, a thin waterproof membrane base of rigid plastic such as PVC, a mortar bed, a layer of cement, a metal lath, and a layer of ceramic tile, brick-veneer, granite tile or marble tile, which provides a pre-fabricated panel adapted to be attached to any flat surface, such as a wall or counter. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is front view of a tile board of this invention; 
     FIG. 1A is a perspective view thereof; 
     FIG. 1B is a cross-sectional view of FIG. 1; 
     FIG. 2 is a front view of a tile board for corners; 
     FIG. 2A is a perspective view thereof; 
     FIG. 2B is a cross-sectional view of FIG. 2; 
     FIG. 2C is a is cross-sectional view of a tile board over another tile board; 
     FIG. 2D is an isometric exploded view of a tile board for wood or metal studs; 
     FIG. 2E an isometric exploded view of a tile board using a cementitious baker unit as a base; 
     FIG. 2F is an isometric exploded view of a tile board for gypsum board walls; 
     FIG. 3 is a perspective view of a shower enclosure; 
     FIG. 3A is a cross-sectional view of of a shower receptor pan; 
     FIG. 3B is a cross-sectional view showing a tile board over the shower pan; 
     FIG. 4 is front view of a tile board fastened over gypsum board; 
     FIG. 4A is a perspective view thereof; 
     FIG. 4B is a cross-sectional view of FIG. 4; 
     FIG. 5 is front view of a tile board for corners fastened over gypsum board; 
     FIG. 5A is a perspective view thereof; 
     FIG. 5B is a cross-sectional view of FIG. 5; 
     FIG. 6 is a perspective view of tile board installed on bathroom walls over gypsum board; 
     FIG. 6A is a cross-sectional view of tile board over a bathtub lip; 
     FIG. 6B through 6O are all perspective views showing a step by step installation of the tileboards of this invention in which; 
     FIG. 6B shows the first board installed; 
     FIG. 6C shows the second board installed; 
     FIG. 6D shows the screw holes covered with tile; 
     FIG. 6E shows the third board installed; 
     FIG. 6F shows the tile filled on the third board and the small leg fourth board; 
     FIG. 6G shows the small leg fourth board filled with tile; 
     FIG. 6H shows the fifth board installed; 
     FIG. 6I shows the tile filled on fifth board and the sixth board installed; 
     FIG. 6J shows the tile filled on the sixth board and the seventh board installed; 
     FIG. 6K shows the seventh board filled with tile and the eighth board installed; 
     FIG. 6L shows the ninth board installed; 
     FIG. 6M shows the eighth and ninth boards filled with tile; 
     FIG. 6N shows the tenth board installed; 
     FIG. 6O shows the tenth board filled with tile; 
     FIG. 7 is a cross-section of tile board over a counter top; and 
     FIG. 7A is a cross-section showing completion of the counter top. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring now to the drawings there is shown the multiple layers which comprise the pre-fabricated tile boards of the invention. The reference numerals refer to the base of the tile board or membrane 1, the reinforcement or metal lath 2, a first mortar bed 3, or scratch coat 3a, a thin bond coat 4, and the ceramic tile, brick veneer, granite tile or marble tile layer 5. In another embodiment there is a cementitious backer board underlayment 6 or a reinforced cementitious backer board underlayment 7. These layers are more fully explained below. 
     As is shown most specifically in FIG. 2D, a thin base of rigid plastic, such as PVC, forms the base 1. The plastic base has a honeycombed shaped bottom with punched walls on the top and bottom. A first scratch coat of mortar bed 3a fills the honeycomb shaped bottom of base 1. The mortar is commonly comprised of one part cement, one-half part lime, and four parts dry sand or five parts damp sand. It may also be composed of one part cement and three parts dry sand or four parts damp sand. The type of cement used may be any commonly available cement, such as portland cement. 
     A sheet of galvanized metal lath 2 is the next layer. This is usually 2.5 pounds per square yard. A second coat of mortar bed 3 is the next layer. It is composed of one part cement, one-half to one part lime and five to seven parts damp sand. It is normally cured for a minimum of 20 hours at 70 degrees F or above. 
     A thin coat of cement 4 is the next layer, which acts as a bond coat on mortar bed 3. Layer 4 can also be a thin coat of dry-set or latex cement mortar. The tile, brick veneer or other tile type building material is layer 5 which is the top layer. 
     An additional embodiment is shown in FIG. 2E, which comprises a cementitious backer board 6, the sheet of galvanized metal lath 2, a coat of mortar bed 3, a thin coat of cement 4, or dry-set or latex cement, as set forth above. 
     Another embodiment is shown in FIG. 2F, which comprises a reinforced cementitious rigid, non-flexible backer board underlayment 7, the thin coat of cement 4 or dry-set or latex cement, which is then cured for a minimum of 20 hours at 70 degrees F or above. 
     The tile board of this invention conforms with the nationally recognized standard Handbook for Ceramic Tile Installation by the Tile Council of America, for walls, exterior and interior, ceilings, bathtub walls, shower receptors and walls, and countertops. It also conforms to all building codes, ordinances, climatic conditions and trade practices. 
     The pre-installed and pre-grouted tile board of this invention is typically 16 inches to 24 inches high, 30 inches to 48 inches wide, and one-half inch to one and one-half inches thick. It is made of waterproof, rigid, non-flexible material. A board will weigh between 25 pounds to 70 pounds, a shower pan board between 60 pounds to 90 pounds. The boards are easily handled and installed by an adult person. 
     The boards have pre-drilled holes for screws for fastening and leveling the boards to the surface on which they are to be placed. The openings where the screw holes are placed may be easily covered with the same layered material. Openings for plumbing fixtures as well as recessed soap and shampoo boxes are pre-made at the manufacturing plant. 
     A complete installation of ceramic tile or marble in a shower enclosure, as shown in FIG. 3, can be completed in less than four hours by one experienced tile installer. A complete ceramic tile or marble installation on bathtub walls, as shown in FIG. 6B to 6O, can be completed in two hours by an experienced tile installer. 
     As can be seen by the method of pre-fabricated construction, using the tile board of this invention eliminates an enormous amount of contaminating waste and polluted trash. The tile board can have other shapes, such as triangular, trapezoidal, square or any other shape desired. It can come in other sizes than set forth above. 
     Having thus described the invention;