Patent Publication Number: US-2009229206-A1

Title: Decorative holographic tile

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates generally to decorative tile elements and, more particularly, to a decorative holographic tile that includes a glass-inlaid holographic film. 
     The use of ornate but functional construction materials such as tile in bathroom and shower areas and in flooring is well-known. Such tiles can take many forms and can be constructed of aesthetically pleasing materials and/or include decorative designs thereon. For example, stone or marble tiling is commonly found in flooring or in bathroom décor to enhance the appearance of these structures. Additionally, tiles can include decorative and ornate characteristics, such as floral patterns, that are contained within a laminate structured tile. 
     While a myriad of tile designs are currently available, there is an ever-present demand for new tile structures that incorporate designs or materials not currently used. Ornate tiles incorporating expensive materials are desired to further enhance the appearance of existing tile structures and can be used in combination with existing tiles to create unique, decorative patterns. When incorporating these “decorative tiles,” it is desired that such tiles be visually distinct from the surrounding tiles. Thus, decorative tiles that can make use of ambient light from the surrounding environment to brighten the interior of a shower stall while still presenting a decorative pattern thereon are highly desirable. 
     Other considerations are also present in constructing decorative tiles. That is, bathroom and shower areas are subject to high humidity at various periods of time. For decorative tiles incorporating materials sensitive to such humidity, it is necessary to protect those materials from the surrounding humid environment. For laminate tiles having humidity sensitive decorative materials included therein, sealing must be provided to prevent moisture from creeping in between laminate layers in the tile. 
     Therefore, it would be desirable to design a visually distinct decorative tile that is configured to make use of ambient light from the surrounding environment and that presents a decorative pattern. It would also be desirable for such a decorative tile to be constructed such that it is suitable for use in a high humidity environment, such as a bathroom or shower stall. 
     BRIEF DESCRIPTION OF THE INVENTION 
     The present invention is directed to a decorative holographic tile for use as a shower tile, a floor tile, a wall tile, or a backsplash tile. 
     In accordance with one aspect of the invention, a decorative tile element includes a tile substrate, a first resin layer affixed to the tile substrate, and a holographic film element attached to the first resin layer and configured to receive ambient light and diffract the ambient light. A second resin layer is affixed to the holographic film element and a cover element is attached to the second resin layer and configured to allow the passage of the ambient light therethrough. 
     In accordance with another aspect of the invention, a holographic tile for use as a decorative element includes a metalized polyethylene terephthalate (PET) film having a front side and a back side. The front side of the PET film is configured to diffract light received thereby to produce a holographic image. The holographic tile also includes a resin applied to each of the front and back sides of the metalized PET film, a transparent surface element bonded to the resin and adjacent to the front side of the metalized PET film, and a substrate bonded to the resin and adjacent to the back side of the metalized PET film. 
     In accordance with yet another aspect of the invention, a method of constructing a decorative tile includes the steps of affixing a back surface of a holographic film element to a tile substrate and applying a transparent resin to a front surface of the holographic film element, the front surface of the holographic film element configured to receive and diffract ambient light. The method also includes the step of securing a cover element to the transparent resin applied to the front surface of the holographic film element, wherein the cover element is configured to allow the passage of the ambient light therethrough. 
     Various other features and advantages of the present invention will be made apparent from the following detailed description and the drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The drawings illustrate preferred embodiments presently contemplated for carrying out the invention. 
       In the drawings: 
         FIG. 1  is a pictorial view of a shower stall and decorative tile arrangement. 
         FIG. 2  is a cross-sectional view of a holographic tile according to an embodiment of the present invention. 
         FIG. 3  is a cross-sectional view of a holographic tile according to another embodiment of the present invention. 
         FIG. 4  is a top view of a holographic film element according to an embodiment of the present invention. 
         FIG. 5  is a cross-sectional view of a holographic film element according to another embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The present invention is directed to a decorative holographic tile that is configured to be used as a shower tile, a floor tile, a wall tile, or a backsplash tile. 
     Referring to  FIG. 1 , a decorative tile element  10  is shown included in a shower stall  12 . A plurality of decorative tile elements  10  are positioned at varying locations in shower stall  12  and are mixed with stone or ceramic tiles  14  that typically make up a majority of the walls in shower stall  12 . A smaller number of decorative tile elements  10  are mixed with the stone/ceramic tiles  14  to provide decorative accents in shower stall  12 . 
     Each of decorative tile elements  10  comprises a holographic tile that that is configured to diffract light received thereby to produce a holographic image. That is, the holographic tiles  10  receive ambient light from the surrounding environment and are configured to diffract that light to produce a holographic image or pattern. Such holographic images/patterns on the holographic tiles  10  makes those tiles visually distinct from the surrounding tiles, thus enhancing the appearance of shower stall  12 . Additionally, by making use of ambient light from the surrounding environment and diffracting that light to produce rainbow colored images/patterns, holographic tiles  10  serve to brighten the interior of shower stall  12 . 
     While shown as being included in a shower stall  12 , it is also envisioned that decorative tile elements  10  can also be used as floor tiles, wall tiles, or backsplash tiles. Dependent on the desired usage, decorative tile elements  10  can be sized and shaped accordingly. That is, floor tiles may be sized larger than shower tiles or backsplash tiles, and it is recognized that the decorative tile elements  10  of the present invention are not limited by their specific size or shape. 
     Referring now to  FIG. 2 , a detailed view of a holographic tile  10  is shown. Holographic tile  10  includes therein a tile substrate  16  that forms a back surface of the tile  10 . That is, tile substrate  16  serves as the surface of holographic tile  10  that is mounted to a wall or floor surface for affixing the tile within a shower stall, floor, wall, or backsplash. Positioned adjacent to tile substrate  16  is a holographic film element  18 . In one embodiment, holographic film element  18  is comprised of a metalized polyethylene terephthalate (PET) film, although it is also envisioned that other suitable holographic materials could also be substituted for the PET film. Also included in holographic tile  10  is a cover element  20  is placed on top of holographic film element  18 . The cover element  20  is comprised on a transparent substance, so as to allow for ambient light to pass therethrough and be received by a front surface  22  of holographic film element  18 . In one embodiment, cover element  20  comprises a ¼″ thick glass cover, although it is also envisioned that the cover element could be formed from an acrylic cast clear plastic or other suitable material. In the embodiment shown in  FIG. 2 , an anti-reflective film  24  is deposited on an outer surface of cover element  20 . Anti-reflective film  24  allows for a greater amount of ambient light to be received through cover element  20  and strike holographic film element  18 , thus providing a brighter holographic display on holographic tile  10 . Anti-reflective film  24  can comprise, for example, a single layer coating (e.g., magnesium fluoride) or a silica-based multi-layer coating, although other anti-reflective films/coatings are also envisioned. 
     For securing holographic film element  18  to each of the tile substrate  16  and cover element  20 , an adhesive or resin is included in holographic tile  10 . A first resin layer  26  is deposited between tile substrate  16  and a back surface  28  of holographic film element  18 . A second resin layer  30  is deposited between the front surface  22  of holographic film element  18  and cover element  20 . In one embodiment, first and second resin layers  26 ,  30  are composed of polyvinyl butyral (PVB), which provides optimal binding and optical clarity properties (i.e., a transparent resin). It is also envisioned, however, that other resins or adhesives could also be used the exhibit desirable adhesion, optical clarity, toughness, and flexibility properties. Additionally, while both the first and second resin layers  26 ,  30  are described above as being comprised of PVB, it is further envisioned that second resin layer  30  be comprised of a non-transparent resin or adhesive. That is, as it is not necessary for any ambient light to pass through second resin layer  30 , it is recognized that second resin layer  30  could be comprised of either a transparent or non-transparent resin. 
     In constructing holographic tile  10 , the cover element  20  is cast in a mold to a desired thickness and shaped typically with a flat planar surface on each side and beveled or curved edges on one side. Second resin layer  30  is applied and coated over a back side  31  of cover element  20 . The front surface  22  of holographic film element  18  is then pressed firmly against the second resin layer  30  with a roller or other similar mechanism so that bubbles are removed that would otherwise impede the visual appearance of the holographic element  18 . First resin layer  26  is then applied to a front surface  33  of tile substrate  16 , and the tile substrate  16  is pressed against back surface  28  of holographic film element  18 . Once the resins  26 ,  30  have hardened, the holographic tile  10  can be affixed to a wall surface or bathroom shower vertical surface through conventional adhesives. 
     When first and second resin layers  26 ,  30  are comprised of polyvinyl butyral, heat and pressure is applied to holographic tile  10  at regulated speeds to ensure a bond between tile substrate  16 , holographic film element  18 , and cover element  20 . In one embodiment, holographic tile  10  is loaded into an autoclave, which employs high pressure and heat to ensure a stronger bond between each of the tile substrate  16 , holographic film element  18 , and glass cover element  20 , and the PVB resin layers  26 ,  30 . The stronger, tighter bonds created by such a process helps to protect holographic film element  18  from the humidity and moisture typically found in a bathroom environment. 
     Referring now to  FIG. 3 , in another embodiment of the invention, a holographic tile  32  is further protected from humid environmental conditions by sealing a perimeter of the tile. That is, a cover element  34  is formed so as to protrude down from a front edge  36  of holographic tile  32 . Cover element  34  extends downward past a holographic film element  38  included in holographic tile  32  and comes in contact with a tile substrate  40  that forms a back edge of holographic tile  32 . To seal holographic film element  38  from the ambient environment, cover element  34  can be bonded to tile substrate  40  during an annealing process of the cover element. (i.e., edge slumping). The bonded perimeter formed by the joining of cover element  34  and tile substrate  40  thus provides a moisture resistant barrier that protects holographic film element  38 . 
     It is recognized that the holographic film element included in holographic tile  10 ,  32  can include any of a variety of patterns holographic patterns thereon. An example of such a pattern formed on holographic film element  42  is shown in  FIG. 4 . In one embodiment, the pattern  44  is formed on holographic film element  42  by way of an embossing process. The embossed pattern  44  allows for holographic film element  42  to selectively diffract light of two or more wavelengths to produce a holographic image. It is also envisioned, however, that other processes can also be used to form a holographic pattern, such as by depositing a hologram sensitive material sensitive to green and red light in a patterned manner on a PET substrate of holographic film element  42 . Such a patterned deposition also allows for the selective diffraction of light of two or more wavelengths to produce a holographic image. 
     While the holographic tile  10 ,  32  in  FIGS. 2 and 3  is shown as including a single holographic film element  18 ,  38 , it is envisioned that the holographic film can be comprised of multiple layers that are adhered together. Referring to  FIG. 5 , a holographic film element  46  is shown having a first holographic layer  48  and a second holographic layer  50 , which as set forth above, can each be comprised of a metalized PET film. The first and second holographic layers  48 ,  50  are adhered together via a transparent resin layer  52 , such as polyvinyl butyral (PVB), to provide optimal binding and optical clarity properties. While being shown as including only first and second holographic layers  48 ,  50 , it is also envisioned that holographic film element  46  could be comprised of additional holographic layers (e.g., 3 or 4 layers), with a layer of transparent resin included in between each of those layers. The plurality of holographic layers included in holographic film element  46 , along with any embossed/etched pattern (see  FIG. 4 ) formed thereon, achieves the visual effect of depth in a resulting holographic image. That is, the multiple holographic layers create a three-dimensional (3D) image visual effect that can further enhance the decorative qualities of the holographic tile. The multi-layer holographic film element  46  can be incorporated into either of the holographic tiles  10 ,  32  shown in  FIGS. 2 and 3 , to provide a further visually distinct holographic tile. 
     Therefore, according to one embodiment of the present invention, a decorative tile element includes a tile substrate, a first resin layer affixed to the tile substrate, and a holographic film element attached to the first resin layer and configured to receive ambient light and diffract the ambient light. A second resin layer is affixed to the holographic film element and a cover element is attached to the second resin layer and configured to allow the passage of the ambient light therethrough. 
     According to another embodiment of the present invention, a holographic tile for use as a decorative element includes a metalized polyethylene terephthalate (PET) film having a front side and a back side. The front side of the PET film is configured to diffract light received thereby to produce a holographic image. The holographic tile also includes a resin applied to each of the front and back sides of the metalized PET film, a transparent surface element bonded to the resin and adjacent to the front side of the metalized PET film, and a substrate bonded to the resin and adjacent to the back side of the metalized PET film. 
     According to yet another embodiment of the present invention, a method of constructing a decorative tile includes the steps of affixing a back surface of a holographic film element to a tile substrate and applying a transparent resin to a front surface of the holographic film element, the front surface of the holographic film element configured to receive and diffract ambient light. The method also includes the step of securing a cover element to the transparent resin applied to the front surface of the holographic film element, wherein the cover element is configured to allow the passage of the ambient light therethrough. 
     The present invention has been described in terms of the preferred embodiment, and it is recognized that equivalents, alternatives, and modifications, aside from those expressly stated, are possible and within the scope of the appending claims.