Abstract:
A method for creating personalized tile that includes creating a tile base, attaching borders to the tile base through the process of scoring and slipping the tile base and the borders to create a tile, and placing mosaics onto the tile.

Description:
CLAIM OF PRIORITY 
     The present application claims the benefit of the U.S. provisional patent application filed on Jul. 21, 2006 by Oliver Justin McGee for METHOD AND APPARATUS FOR CREATING PERSONALIZED TILE (Ser. No. 60/807,955), the entire disclosure of which is hereby incorporated by reference herein. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to tile and, more particularly, to a method and apparatus for making personalized tile. 
     BACKGROUND OF THE INVENTION 
     Home improvement has steadily grown into an important and popular market. Tile is often used for flooring, countertops, and even on walls as backsplashes, showers, and decoration. Tiles can also be used in pools, as coasters, or as borders for hardwood floors. In addition, manufacturers have begun producing synthetic substitutions of these materials for the same uses. While both the synthetic and natural products may vary greatly with respect to color and design, consumers are constrained by the styles manufacturers choose to mass produce. 
     SUMMARY OF THE INVENTIONS 
     The present invention recognizes and addresses the foregoing considerations, and others, of prior art construction and methods. 
     In this regard, one aspect of the invention provides a method for creating personalized tile comprising the steps of flattening a first section of clay to create at least one slab of clay, tracing at least one outline of a first template into the slab to create at least one tile, cutting a first border from the slab, scoring a first edge of a bottom of the tile, slipping the edge, aligning the border with the edge, and placing the border on the tile. 
     According to another aspect, the present invention also provides a method for creating personalized tile comprising the steps of forming a tile from clay corresponding to a desired set of dimensions, creating a plurality of smaller mosaics from at least one larger mosaic, and attaching the smaller mosaics to the tile&#39;s top. 
     A further aspect of the present invention provides a method for creating personalized tile comprising the steps of forming a tile from a slab of clay, cutting four borders from the slab, attaching the borders to the tile, and attaching a mosaic to the tile. 
     The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate one or more embodiments of the invention and, together with the description, serve to explain the principles of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       A full and enabling disclosure of the present invention, including the best mode thereof directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended drawings, in which: 
         FIG. 1   a  is a perspective view of a bag of clay that may be used in accordance with an embodiment the present invention; 
         FIG. 1   b  is a perspective view of several blocks of clay removed from the bag of clay of  FIG. 1  in accordance with an embodiment of the present invention; 
         FIG. 2   a  is a perspective view of a slab roller to be used in accordance with an embodiment of the present invention; 
         FIG. 2   b  is a perspective view illustrating a use of the slab roller of  FIG. 2   a  in accordance with an embodiment of the present invention; 
         FIG. 3  is a perspective view of clay slabs in accordance with an embodiment of the present invention; 
         FIG. 4  is a perspective view illustrating a use of a template to be used in accordance with an embodiment of the present invention; 
         FIG. 5  is a perspective view of a trimming tool to be used in accordance with an embodiment of the present invention; 
         FIG. 6  is a perspective view of clay tiles in accordance with an embodiment of the present invention; 
         FIG. 7  is a perspective view illustrating a use of a sea sponge in accordance with an embodiment of the present invention; 
         FIG. 8  is a perspective view of the sea sponge of  FIG. 7  in accordance with an embodiment of the present invention; 
         FIGS. 9 through 11  are perspective views illustrating a use of the trimming tool of  FIG. 5  in accordance with an embodiment of the present invention; 
         FIG. 12  is a perspective view illustrating a use of slip and a paintbrush tool in accordance with an embodiment of the present invention; 
         FIG. 13  is a perspective view of a paintbrush tool of  FIG. 12 ; 
         FIG. 14  is a perspective view illustrating a use of the trimming tool of  FIG. 5  in accordance with an embodiment of the present invention; 
         FIG. 15  is a perspective view of a clay tile with tile borders in accordance with an embodiment of the present invention; 
         FIG. 16  is a perspective view of the smoothing of the clay tile of  FIG. 15 ; 
         FIG. 16   b  is a perspective view of several clay tiles in accordance with an embodiment of the present invention; 
         FIG. 17  is a perspective view of a clean-up tool to be used in accordance with an embodiment of the present invention; 
         FIG. 18  is a perspective view of a ribbon tool to be used in accordance with an embodiment of the present invention; 
         FIG. 19   a  is a side view of a clay tile illustrating a use of the ribbon tool of  FIG. 18  in accordance with an embodiment of the present invention; 
         FIG. 19   b  is a side view of the clay tile of  FIG. 19   a  in accordance with an embodiment of the present invention; 
         FIG. 20   a  is a side view of a clay tile illustrating a use of the clean-up tool of  FIG. 17  in accordance with an embodiment of the present invention; 
         FIG. 20   b  is a side view of a clay tile in accordance with an embodiment of the present invention; 
         FIG. 21  is a side view illustrating a use of sandpaper in accordance with an embodiment of the present invention; 
         FIG. 22  is a top view of a tile nipper to be used in accordance with an embodiment of the present invention; and 
         FIG. 23  is a perspective view of an application of mosaics to a clay tile in accordance with an embodiment of the present invention. 
     
    
    
     Repeat use of reference characters in the present specification and drawings is intended to represent same or analogous features or elements of the invention. 
     DETAILED DESCRIPTION 
     Reference will now be made in detail to presently preferred embodiments of the invention, one or more examples of which are illustrated in the accompanying drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that modifications and variations can be made in the present invention without departing from the scope or spirit thereof. For instance, features illustrated or described as part of one embodiment may be used on another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents. 
     Referring to  FIGS. 1   a  and  1   b , raw clay  10  of a suitable type is purchased from a supplier and is transported in a plastic bag, such as bag  12 . Clay  10  is removed from bag  12  and separated into equivalent sections, such as sections  13 ,  14 ,  15 , and  16 . It should be important to note that the size and amount of clay in each section is not of major importance because each section will be rolled out and cut to other lengths. 
     Referring to  FIGS. 2   a  and  2   b , each section of clay is placed between two pieces of material  17  such as burlap, which provide the clay sections with texture allowing for suction when used as flooring, countertops, etc. It should be understood that burlap is known in the art and that other materials capable of providing clay sections with a sufficient amount of texture may be used. 
       FIGS. 2   a  and  2   b  illustrate a slab-roller  26  to be used in accordance with an embodiment of the present invention. In this case, slab-roller  26  is a table comprising a rolling pin  18  situated horizontally across the table and attached to wheel  19 . Slab-rollers should be known by those of ordinary skill in the art and are, therefore, not discussed in further detail. Any such slab-roller may be used, such as the STANDARD SLAB ROLLER manufactured by North Star Equipment, Inc. (Cheney, Wash.). 
     In operation, the user determines the desired thickness of the clay by vertically raising or lowering rolling pin  18  so that a space exists between the pin and the table&#39;s flat surface  20  corresponding to the desired thickness. In the depicted example, clay section  15  is placed between two burlap pieces  17  and fed through slab-roller  26  by turning wheel  19 , which flattens clay section  15  to the desired thickness. 
     In an exemplary embodiment as shown in  FIG. 3 , a section of clay has been rolled into three (3) slabs  28 ,  30 , and  32  having a thickness of approximately a quarter inch (¼″) and three (3) slabs  34 ,  36 , and  38  having a thickness of three-sixteenths of an inch ( 3/16″). Each slab  28 ,  30 ,  32 ,  34 ,  36 , and  38  may be about two feet (2′) long. Slabs  34 ,  36 , and  38  will be later cut and used as borders as described below, while  28 ,  30 , and  32  will be used as tile bases. It should be understood by one of ordinary skill in the art that clay shrinks when fired in a kiln and that different types of clay shrink different amounts. The user decides the size of the borders and bases according to type of clay and its intended application as he or she desires. This determination will impact the size of the slabs made as described above. 
     Slabs  28 ,  30 ,  32 ,  34 ,  36 , and  38  are placed on a two foot by two foot (2′×2′) plywood square  40 , which may be covered with plastic bag  12  to minimize the loss of moisture that occurs when the clay sections come in contact with square  40 . If the clay needs to be transported or stored at this point, plywood square  40 , plastic bag  12 , and slabs  28 ,  30 ,  32 ,  34 ,  36 , and  38  may be placed in another plastic bag. Slabs  28 ,  30 ,  32 ,  34 ,  36 , and  38  are then misted with water, and the additional plastic bag is sealed to prevent any additional moisture loss. 
     If slabs  28 ,  30 ,  32 ,  34 ,  36 , and  38  have been previously sealed in an additional plastic bag, these slabs, plywood square  40 , and plastic bag  12 , are removed from the bag. Slabs  28 ,  30 ,  32 ,  34 ,  36 , and  38  are then transported to a work area as shown in  FIG. 4 . The slabs are again preferably misted with water. Any cracks, impressions, or irregularities in thickness created from the splitting, rolling, or handling of the slabs may be removed by extensively rubbing the slabs with one&#39;s fingertips. 
     Template  46  is placed on top of slab  28 , and its outline is preferably traced into slab  28  using trimming tool  48 . Template  46  can be a piece of tile, marble, cardboard, or any other useful material that is representative of the final product&#39;s dimensions as desired by the user. It should be understood by one of ordinary skill in the art that trimming tool  48  is also known as a pointed shaping tool, a cutting tool, and also as a needle tool.  FIG. 5  displays another view of trimming tool  48  in greater detail. The above process is repeated until no more tiles of similar dimensions can be outlined from slab  28  using template  46 . It should be noted that templates of different sizes and shapes may be used to outline tiles from slab  28 . 
     As shown in  FIG. 6 , outlined tiles  50 ,  52 ,  54 , and  55  have been removed from slab  28 . The leftover portion of slab  28  is placed in a bucket containing water. When leftover portions of clay are combined with water, they become what&#39;s known as “slip.” It should be known to one of ordinary skill in the art that slip has many uses including the ability to be recycled into additional clay. 
       FIG. 7  illustrates the use of a sea sponge  59  or the like, which has been wetted, to smooth out any imperfections or sharp edges from the top and sides of the removed tiles, as shown with reference to tile  50 . The use of sea sponge  59  also ensures there are no height variations in the tiles&#39; sides. This step also gives texture to the surfaces of the tiles, which allows mosaics to adhere to each tile properly as described below.  FIG. 8  illustrates another view of sea sponge  59  in greater detail. 
     In an exemplary embodiment as shown in  FIGS. 9 and 10 , a slab preferably having a thickness of three sixteenths of an inch ( 3/16″), such as slab  36 , is cut into two borders  58  and  60  using trimming tool  48 . Preferably, border  58  is one eighth of an inch (⅛″) wide by twelve inches (12″) long and border  60  is a quarter inch (¼″) wide by twelve inches (12″) long. It should be understood that borders cut from slab  36  may consist of different shapes and sizes depending on the desired aesthetics of the personalized tile as described below. Using trimming tool  48  to divide slab  36  causes the widths of borders  58  and  60  to vary with a wavy appearance as shown in  FIGS. 9 and 10 . This is mainly for aesthetical value, giving the borders a custom-made appearance. It should be known that, if a uniform cut is desired, a straightedge or slicer can be used to create the borders. When cutting slab  36  into pieces, trimming tool  48  (or any other instrument used), is preferably held at an angle, such as a forty-five degree(45°) angle. As a result, one side of borders  58  and  60  will be straight, while the other will preferably be angled so that it tapers from the side&#39;s bottom to the side&#39;s top. Accordingly, the width of the base of borders  58  and  60  will be larger than the width of their tops as illustrated in  FIGS. 9 and 10 . This also allows the separated tile to appear as one piece when borders  58  and  60  are added to tiles  50 ,  52 ,  54 , or  55  as described below. 
     Referring to  FIG. 11 , trimming tool  48  is used to draw a line around the perimeter of tile  50  and also down the center of border  58  as denoted by numbers  62  and  64 , respectively. A number of hash marks (collectively denoted at  66 ) are drawn across lines  62  and  64  at an angle. This process is referred to as “scoring” and is important because it causes slip to act like glue when added to the base of tile  50  and border  58 . Referring to  FIG. 12 , slip  29  is then pasted over hash marks  66  on tile  50  and border  58  using a number four (#4) paintbrush  68  (shown in greater detail in  FIG. 13 ). This process is referred to as “slipping” and should be done quickly before slip  29  dries in order for it to act as an adhesive. It should be apparent that other suitable paintbrushes or devices suitable for applying slip may be used. 
     Referring to  FIGS. 14 and 15 , border  58  is then cut into segments  70 ,  72 ,  74 , and  76  having lengths that match the length of the sides of tile  50  and are placed on tile  50  such that hash marks  66  located on border  58  coalign with the hash marks located on a side of tile  50 , line  62  coaligns with line  64 , and the angled side of these segments face outward. The corners of segments  70 ,  72 ,  74 , and  76  are scored and slipped in the same manner as described above so that the segments adhere to one another at the corners as well as to tile  50 . The user mists his/her hands and runs fingers down the inside and outside of the sides of segments  70 ,  72 ,  74 , and  76  in order to assure these segments are flush with the sides of tile  50  as shown in  FIG. 16 . This step is repeated until all four sides of tile  50  have been lined up with segments  70 ,  72 ,  74 , and  76 . 
     Sea sponge  59  is wetted and used to gently apply light pressure to the tops of segments  70 ,  72 ,  74 , and  76  to assure that the slip applied between these segments and tile  50  is evenly distributed. An amount of pressure that can reshape or remodel segments  70 ,  72 ,  74 , and  76  should not be used. This process also blends the clay for aesthetics where segments  70 ,  72 ,  74 , and  76  have been added to each other and to tile  50 . Joints  78  are preferably rubbed with wetted sea sponge  59  to assure tile  50  looks like one piece. 
     Referring to  FIGS. 16 and 16   b , the inside portions of segments  70 ,  72 ,  74 , and  76 , collectively denoted by  80 , should be as close as possible to right angles (90°) so that they are perpendicular with respect to tile  50 , which will give the mosaics a support wall when applied to the tile as described below. The user may apply relatively gentle pressure to the sides of the tile, such as segment  74 , with his or her hands as illustrated in  FIG. 16 . The shaped tiles, such as tile  50 , are returned to plywood square  40  and allowed to dry for about an hour in order to stiffen. In another embodiment, tiles can be moved to a Rialto beige tile approximately sixteen inches (16″) in length and sixteen inches (16″) in width to finish drying. It should be apparent that the completed tiles may be placed on any sized surface made out of any material that will allow the tiles to finish drying without warping or adhering to the surface. The tiles (e.g., tile  50 ) are then allowed to dry for about twenty-four (24) hours. Ideally, the tiles should be checked every three to four hours to see if the corners have lifted while drying. If so, pressure should be applied to the corners to position them back on the drying surface for the remainder of the drying process. 
     After drying, the tiles are inspected for cracks, breakage, or serious flaws, and if found, the tiles are discarded into the bucket containing slip. The bottom and sides of each tile, such as tile  50 , may be scraped such as by using clean-up tool  84  and a ribbon tool  86 , examples of which are illustrated by  FIGS. 17 and 18 , respectively, to remove any sharp edges. Referring to  FIGS. 19   a ,  19   b ,  20   a , and  20   b , the edges of tile  50  should ideally be rounded (as denoted by  88 ) instead of squared (as denoted by  90 ). Clean-up tool  84  and ribbon tool  86  can be used repeatedly to scrape and smooth tile  50  until it exhibits the desired shape and finish. Tools  84  and  86  also can be used to smooth over the entire tile  50  and to remove any loose particles. Clean-up tool  84  and ribbon tool  86  should be known to one of ordinary skill in the art, and any such tools, like the clean-up tools and ribbon tools manufactured by Kemper Enterprises, Inc. (Chino, Calif.), may be used. 
     Referring to  FIG. 20   a , clean-up tool  84  is then used to ensure borders  70 ,  72 ,  74 , and  76  form as close to a right angle (90°) as possible with base  100  ( FIG. 16   b ) of tile  50 . This may be accomplished by pressing the flat part of tool  84  against the inside and outside of the borders of tile  50 , such as border  70 . If lines are visible showing where segments  70 ,  72 ,  74 , and  76  were attached to form tile  50 , wet sponge  59  is used to smooth these lines and form one continuous tile  50 . Referring to  FIG. 21 , tile  50  is then wiped extremely lightly with sandpaper  102 , which is preferably one hundred fifty (150) grit sandpaper, in order to remove any rough lines or marks from the scraping process. Sandpaper  150  should also be known to one of ordinary skill in the art. 
     The finished tiles are then fired in a kiln. One skilled in the art should understand that the process of firing tile is known in the art and can be done by a number of individuals, companies, or services. The tiles should be low fired if they are to be used as decoration on the wall or high fired if they are going to be used as flooring. The higher the heat or temperature during the firing process, the more the tiles will shrink and change color. The user must, therefore, consider the type of tile and/or clay to use based on the qualities and changes it will exhibit during firing as well as the temperature and time at which the tile will be fired. 
     In another embodiment, decorative mosaics are added to the tiles after they have been fired. Decorative mosaics should be known by one of ordinary skill in the art and can be purchased from Mosaic Art Supply (Atlanta, Ga.; www.mosaicartsupply.com). These mosaics are generally three-eights of an inch (⅜″) wide by three-eights of an inch (⅜″) long and one-eighth of an inch (⅛″) in height. While it is important to note that mosaics of other sizes may be used, the mosaics&#39; dimensions should allow them to be placed within borders  70 ,  72 ,  74 , and  76  of tile  50 , specifically so that no mosaic extends above the height of the plane created by the borders. 
     Referring to  FIGS. 22 and 23 , mosaics  106  can be cut with tool  104  commonly referred to as a tile nipper. Any suitable tile nipper, such as the MOSAIC GLASS CUTTER manufactured by Mosaic Art Supply (Atlanta, Ga.), may be used. Other pieces of decorative glass or material, such as that from old vases or other decorative tile, may be used as suitable mosaics as long as they do not extend above the height of the tile&#39;s borders  70 ,  72 ,  74 , and  76  because this may cause injury if used. Thus, mosaics  106  may be relatively uniform in height, and may be pieces of decorative glass or created by dividing a larger image, decoration, ornament, etc., as shown in  FIG. 23 . Mosaics  106  are then attached to tile  50  and to each other using a substantial glue, such as weldbond glue, which can also be purchased from Mosaic Art Supply. 
     While one or more preferred embodiments of the invention have been described above, it should be understood that any and all equivalent realizations of the present invention are included within the scope and spirit thereof. The embodiments depicted are presented by way of example only and are not intended as limitations upon the present invention. Thus, it should be understood by those of ordinary skill in this art that the present invention is not limited to these embodiments since modifications can be made. Therefore, it is contemplated that any and all such embodiments are included in the present invention as may fall within the scope and spirit thereof.