Patent Publication Number: US-2022213692-A1

Title: Prefabricated Tile Strip

Description:
This application is a continuation of U.S. Ser. No. 16/549,771, filed Aug. 23, 2019, which claims the benefit of U.S. Provisional Application 62/722,011 filed Aug. 23, 2018. 
    
    
     BACKGROUND OF THE INVENTION 
     Prefabricated tile boards are known in prior patents but are not in widespread use in remodeling and new construction. 
     U.S. Pat. No. 6,330,774 describes tile panels with edge regions free for applying fasteners to mount the panels to framing studs. Each panel is fabricated using a flat rigid base member to which tiles are adhered with an adhesive and grouted. After the panels are fastened in the tile free regions, joints of adjoining panels are taped and then the tile-free edge regions are tiled over and grouted, concealing the fasteners. 
     U.S. Pat. No. 3,362,119 describes a prefabricated tile panel having a rigid base sheet of cement board, tiles adhesively mounted on the sheet, and grouted between tiles, and a deformable backing material composed of moisture proof foam board, over the back of the base sheet. Some tiles are left off to allow fastening adjacent panels to studs and then these locations are tiled over. 
     U.S. Pat. No. 8,887,462 describes a pre-fabricated tile system including modular extruded plastic backing boards including male/female edges for mating with an adjacent boards. Flat backing boards are not disclosed. 
     The present inventor has recognized that it would be desirable to provide a prefabricated tile strip that was durable, crack resistant, efficiently installed, and cost effectively manufactured. 
     SUMMARY 
     The exemplary embodiment of the invention provides a prefabricated tile strip that enhances installation, provides an improved aesthetic appearance and is cost effectively manufactured and installed. 
     The embodiment includes a preassembled strip of backing board, a tile region having plural tiles and grout. The grout can be composed of a resin/polymer-based grout that allows for superior water resistance, stain resistance, crack resistance and is transportable without breaking. The strip can have up to 5 layers of moisture protection. The strip includes an edge region or flange on either side of the tiles to allow for simple screw in and glue on assembly; not even a wall is necessary; the strip can be attached directly to the studs. 
     A step over/under water resistant edge can go directly onto a bathtub or shower ledge or onto the wet area of a tile floor (not separate ledge), allowing it to go straight down to the bottom of a shower floor, or it can step right over a thin plastic flange on a tub or shower base. 
     The strip is advantageously used with flat surface panels such as countertops, shower panels or tub wall panels. The tiles can be color coordinated with these flat surface panels. The use of ⅜ inch thick tiles, such as mosaic tile of real glass and stone, can allow for stronger support when transporting, and more practical when handling. The strip can have a water proof “step over” edge, allowing for the backing board to go over obstructions. 
     An aluminum tile edger can surround the tile region and can be used to avoid any unfinished perimeter, or to transition between substrates or panels. 
     A waterproof membrane can be used to cover the backing board. Adhesion promoters can be used on edges for construction adhesives (not just standard mortar). Antimicrobial protection can also be applied. 
     The membrane can cover all sides, can be thin and gives unique level of water resistance and mold protection, even letting the tile sit directly over a wet ledge and still avoid “wicking”, where the tile backing board draws in water. These edges have a water resistant coating as well as an adhesion promoter that binds not only to mortar, but also common types of construction adhesives. 
     An antimicrobial agent for fighting mold and bacteria can be added to the backing board. Alternatively, the strips can be factory cut and finished with an anodized aluminum edge, which can be decorative and/or functional. Where necessary, a decorative tile edger can be used to avoid/minimize any unfinished perimeter. 
     The backing board can include a fiberglass-based front, making it resistant to moisture and mold. The backing board can be stiffer and stronger than conventional cement board. 
     The edge design is different in multiple ways, which affects both application options and an easier or more practical handling/installation. 
     Resin/polymer based grout, minimizes porosity, for maximum water, mold and stain resistance. Fluoro-chemical grout and stone sealant gives an added layer of moisture and stain protection. 
     Numerous other advantages and features of the present invention will be become readily apparent from the following detailed description of the invention and the embodiments thereof, and from the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a fragmentary elevation view of an installation of an exemplary embodiment of the invention; 
         FIG. 2  is a sectional view taken generally along line  2 - 2  of  FIG. 1 ; 
         FIG. 3  is an enlarged sectional view of the exemplary embodiment taken from  FIG. 2 ; 
         FIG. 4  is a fragmentary sectional view taken generally along line  4 - 4  of  FIG. 1  illustrating a step over edge; and 
         FIG. 5  is a fragmentary sectional view comparable to  FIG. 4  but with a step under edge; 
         FIG. 6  is an elevational view of the exemplary embodiment of  FIG. 1 . 
     
    
    
     DETAILED DESCRIPTION 
     While this invention is susceptible of embodiment in many different forms, there are shown in the drawings, and will be described herein in detail, specific embodiments thereof with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the invention to the specific embodiments illustrated. 
     This application incorporates by reference U.S. Ser. No. 16/549,771, filed Aug. 23, 2019, and U.S. Provisional Application 62/722,011 filed Aug. 23, 2018 in their entireties. 
       FIG. 1  illustrates a wall assembly  10  mounted onto a bath or shower base  54 . The assembly  10  includes a shower panel  20  and a shower panel  28  installed on either side of a tile panel  16 . The panel  16  includes backing board  22  that carries a tiled region  24  on a front face thereof. The region  24  includes tiles  25  adhesively secured onto the backing board  22  and having grout  26  surrounding each tile  25 . The grout can be a urethane based grout and then sealed with a group sealer. Even though only some tiles  25  are shown in the region  24 , it should be understood that the entire region  24  can be substantially covered with tiles  25  and grout  26 . An aluminum tile edger or frame  27  can be used around the tile region  24  to avoid any unfinished perimeter, or to transition between substrates or panels. 
     As shown in  FIG. 2 , the backing board  22  can be fastened to studs  31  by nails  33  or other fasteners, and/or adhesive. Alternatively the backing board  22  can be adhesively secured to wall boards or green boards, not shown. 
     The tiles  25  advantageously have a thickness T 1  of about ⅜ inch corresponding to a thickness of the shower panels  20 ,  28  to provide a continuous flush surface over the shower panels  20 ,  28  and the region  24 . The backing board  22  can have a thickness T 2  equal to adjacent wall boards  14 . 
     As shown in  FIG. 3  the board  22  includes a base board  40 , such as a DENSSHIELD Tile Backer, from Georgia-Pacific that is substantially covered by a sealing layer  44 . The sealing layer  44  is composed of one thickly brushed-on layer of REDGARD waterproofing membrane, available from Custom Building Products Corporation of Seal Beach Calif. The tiles  25  (not drawn to scale) in the region  24  can be secured by an adhesive layer  48  to the backing board  22 . The board  22  includes exposed side regions  32 ,  36 , also covered by the layer  44  that provide edge regions or flanges for receiving the overlapping shower panels, or tiles or other coverings. The shower panels  20 ,  28  can be adhesively secured and sealed to the regions  32 ,  36 . 
     The entire panel  16  can be factory preassembled with base board  40 , sealing layer  44 , adhesive  48 , tiles  25 , frame  27 , grout  26  and grout sealer to be delivered to the job site for installation onto the studs or other structure. 
       FIG. 4  illustrates the panel  16  mounted to a shelf  58  of a shower or tub base  54 . The shelf  58  includes a vertical edge or rim  60 . The backing panel  22  includes a rear step  66  that has a height and width sufficient to step over the vertical rim  60 . With the step  66 , the tile region  24  can be set down onto the shelf  58  or set closely to the shelf  58 . The step  66  can be applied to only the bottom or to both the top and bottom as shown in  FIG. 6 . This allows for a top step over as needed. 
       FIG. 5  illustrates an alternate embodiment panel  16 ′ mounted to a shelf  58  of a shower or tub base  54 . The shelf  58  includes a vertical edge or rim  60 . The backing panel  22 ′ includes a front step  66 ′ that has a height and width sufficient to step under the vertical rim  60 . With the step  66 ′, the tile region  24  can be set down onto the rim  60  or close to the rim  60  and a bottom of the board  22  can be set onto an underlying structure  70 . The step  66  can be applied to only the bottom or to both the top and bottom as shown in  FIG. 6 . This allows for a top step under or over as needed. 
     From the foregoing, it will be observed that numerous variations and modifications may be effected without departing from the spirit and scope of the invention. It is to be understood that no limitation with respect to the specific apparatus illustrated herein is intended or should be inferred. 
     All references, including publications, patent applications, and patents, cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein, to the extent that the references are not contrary to the present disclosure.