Abstract:
A surface-covering article used to produce surface coverings is described. The surface-covering article includes a plurality of tiles disposed adjacent to each other. A first layer made of a first type of resin is applied to one side of the plurality of tiles. A second layer made of a second type of resin is applied to and around another side of the plurality of tiles and into any gap between adjacent tiles to enclose the plurality of tiles within the first and second layers of resin. The second type of resin of the second layer of resin bonds with the first type of resin of the first layer to join the resin layers permanently to each other and to the enclosed plurality of tiles, thereby producing a seamless surface-covering article made of multiple encapsulated tiles and having a continuous surface of resin that seals said any gap between adjacent tiles.

Description:
RELATED APPLICATION  
       [0001]     This application is a continuation application claiming the benefit of the filing date of co-pending U.S. patent application Ser. No. 10/856,070, filed May 28, 2004, titled “Surface-Covering Article and Methods of Installing the Same,” the entirety of which U.S. patent application is hereby incorporated by reference. 
     
    
     FIELD OF THE INVENTION  
       [0002]     The invention relates to surface coverings. More specifically, the invention relates to a surface-covering article used to produce a seamless surface covering.  
       BACKGROUND OF THE INVENTION  
       [0003]     A variety of surface covering products (e.g., tiles, sheets, planks, and the like) are widely used in the building industry. Surface covering products are either natural (e.g., stone, wood, ceramic, and mineral bodies) or man-made (e.g., laminates and plastics). The man-made surface coverings are often fabricated to appear like a natural material. For example, vinyl tiles can include a pattern that imitates the look of marble or wood.  
         [0004]     Although some man-made surface coverings can be resilient under foot, they typically are not designed with weight distribution in mind. As such, some man-made surface coverings tend to warp or displace when a load force is applied to the surface. The warping and displacement results in an unlevel surface. Natural tiles share in these disadvantages and are traditionally brittle and tend to crack or break during manufacturing, shipping, and installation. Although wood is strong and flexible, it rots, warps, and discolors as it weathers.  
         [0005]     Installation of some of the present surface coverings requires the use of special installation techniques. Also, some installations require subsequent applications of an adhesive, filling of the joints with grout, or chemically bonding and heat welding seams that results from the installation of multiple sections (e.g., tiles or sheets) of the surface covering. Such procedures are substantially more costly and labor intensive, and are not always aesthetically, structurally, or functionally satisfactory, over an extended period of time. For example, a typical tile installation consists of 6% or more porous grout area. The grout area is easily stained and readily promotes bacteria, fungal, and mold growth. It requires labor intensive buffing or polishing, to maintain the top finish and, after an extended period of time, it also becomes necessary to re-grout most areas surrounding the tiles due to discoloration and sanitary concerns.  
       SUMMARY  
       [0006]     In one aspect, the invention features a surface-covering article having a plurality of tiles disposed adjacent to each other. A first layer made of a first type of resin is applied to one side of the plurality of tiles. A second layer made of a second type of resin is applied to and around another side of the plurality of tiles and into any gap between adjacent tiles to enclose the plurality of tiles within the first and second layers of resin. The second type of resin of the second layer of resin bonds with the first type of resin of the first layer to join the resin layers permanently to each other and to the enclosed plurality of tiles, thereby producing a seamless surface-covering article made of multiple encapsulated tiles and having a continuous surface of resin that seals said any gap between adjacent tiles.  
         [0007]     In another aspect, the invention features a surface covering having a resin-based slurry layer disposed on a surface and a surface-covering article set in the slurry layer. The surface-covering article includes a plurality of tiles disposed adjacent to each other, a first layer of resin applied to one side of the plurality of tiles, and a second layer of resin applied to and around another side of the plurality of tiles and into any gap between adjacent tiles to enclose the plurality of tiles within the first and second layers of resin. The second layer of resin bonds with the first type of resin of the first layer to join the resin layers permanently to each other and to the enclosed plurality of tiles.  
         [0008]     In another aspect, the invention features a surface-covering article including a plurality of tiles disposed adjacent to each other, a first layer of resin applied to one side of the plurality of tiles, and a second layer of resin applied to and around another side of the plurality of tiles and into any gap between adjacent tiles to enclose the plurality of tiles within the first and second layers of resin. The second layer of resin bonds with the first type of resin of the first layer to join the resin layers permanently to each other and to the enclosed plurality of tiles. A resin-based top coat is applied to the surface-covering article. The top coat bonds to and encapsulates the surface-covering article. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0009]     The above and further advantages of this invention may be better understood by referring to the following description in conjunction with the accompanying drawings, in which like numerals indicate like structural elements and features in various figures. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention.  
         [0010]      FIG. 1  is an exploded view of an embodiment of a surface-covering article constructed according to principles of the invention.  
         [0011]      FIG. 2  is a side view of another embodiment of a surface-covering article constructed according to principles of the invention.  
         [0012]      FIG. 3  is a flow chart depicting one embodiment of a method of constructing a surface covering according to principles of the invention.  
         [0013]      FIG. 4  is a flow chart depicting another embodiment of a method of constructing a surface covering according to principles of the invention.  
         [0014]      FIG. 5  is a section view of an embodiment of an installation of a surface covering system according to principles of the invention.  
         [0015]      FIG. 6  is a flow chart of an embodiment of a method of installing the surface covering system according to principles of the invention. 
     
    
     DETAILED DESCRIPTION  
       [0016]     As general overview, surface-covering articles and a seamless flooring system are described. Surface-covering articles (e.g., tiles and sheets) are constructed of various resin and intermediate layers. The surface-covering articles include a reinforcing material encapsulated within the resin to provide dimensional stability for the surface-covering articles.  
         [0017]     Installation of the surface-covering articles includes applying to a substrate an undercoat of a similar or of the same resin base used to manufacture the surface-covering articles. A technician sets the surface-covering articles within the resin layer and then applies a top coat of the resin. The undercoat and top coat encapsulate the surface-covering articles. The top surface is seamless because the resins used for the undercoat, top coat, and surface-covering articles are chosen such that they bond, adhere, or chemically bond with one another. The term seamless, as used herein, refers to a surface that is void of penetrable surface area. As such, water or other contaminates are not able to erode the surface-covering articles or layers of material used to install the surface-covering articles.  
         [0018]     With reference to  FIG. 1 , one embodiment of a surface-covering article  10  of the surface covering system includes a top layer  14 , a bottom layer  18 , a first intermediate layer  22 A, and a second intermediate layer  22 B, disposed between the top layer  14  and the bottom layer  18 . In one embodiment, the first intermediate layer  22 A is a decorative layer and the second intermediate layer  22 B is a reinforcing layer. The top layer  14  and the bottom layer  18  sandwiches and encapsulate the intermediate layers  22 A,  22 B.  
         [0019]     In one embodiment, the top layer  14  is a liquid curable resin. Examples of liquid curable resins include but are not limited to, compositions such as phenols, saturated polyesters, unsaturated polyesters, polymers, methylmethacrylates, acrylics, bisphenols, isophthatics, orthophthalics, terephalics, thrixotropics, non-thrixotropics, bisphenol fumerates, urethanes, thermoplastics, and epoxy. In one embodiment, the top layer  14  is degedur or degement, which are methylmethacrylate based resin products, sold by Degussa/Rohm America, LLC of Piscataway, N.J. This resin is a “self-leveling” resin. Using a self-leveling resin ensures the top surface of the surface-covering article is level. The top layer  14  varies in thickness depending on the application and desired aesthetics features of the surface-covering article  10 . The top layer  14  can be transparent or pigmented depending on the application and desired aesthetic qualities of the surface-covering article  10 . The top layer  14  can be smooth or have protrusions therefrom to provide slip resistance.  
         [0020]     Similarly, the bottom layer  18  is a liquid curable resin. In one embodiment, the bottom layer  18  is the same resin as the top layer  14 . In another embodiment, the bottom layer  18  is a different resin than the top layer  14 . The resins used for each of the bottom layer  18  and the top layer  14  are chosen based on their chemical properties such that when the resins cure a bond is formed. The bottom layer  18  can be smooth or have protrusions therefrom to provide increased adhesion. The surface-covering article  10  is similar in composition through its thickness, with the exception of the intermediate layers  22 A,  22 B. In one embodiment, a chemical bond is formed between the bottom layer  18  and the top layer  14 .  
         [0021]     The first intermediate layer  22 A is a decorative layer. In one embodiment, the decorative layer is porous. This allows the resin of the bottom layer  18  to bond with the resin of the top layer  14 . The bonding of the resins sandwiches the first intermediate layer  22 A between the top layer  14  and the bottom layer  18 . Also, the resins encapsulate (i.e., surround) the first intermediate layer  22 A to suspended the first intermediate layer  22 A within the surface-covering article  10 . In one embodiment, the first intermediate layer  22 A is constructed of fabric and includes a pattern (e.g., mosaic) printed thereon. The printed pattern is seen through the top layer  14  to provide an aesthetic feature for the surface-covering article  10 . Other materials can be used at the decorative layer  22 A. For example, natural materials such as fabric, leaves, metallic particles, gold leaf, resin beads, mica, stone chips, and flakes can be used.  
         [0022]     In one embodiment, the second intermediate layer  22 B is a reinforcing layer. Similar to the first intermediate layer  22 A, the second intermediate layer  22 B can be porous to allow the resins of the top layer  14  and the bottom layer  18  to seep through the second intermediate layer  22 B. As such, both the first intermediate layer  22 A and the second intermediate layer  22 B are sandwiched and encapsulated between the top layer  14  and the bottom layer  18 . In one embodiment, the second intermediate layer  22 B is a fiberglass material, such as a fine spun fiberglass material. The fine spun fiberglass material can be TEXTUREGLAS sold by Roos International Ltd of Deerfield Beach, Fla.  
         [0023]     The second intermediate layer  22 B provides a weight distribution property for the surface-covering article  10 . The fine spun fiberglass material prevents warping of the surface-covering article after installation. Forces applied to the surface-covering article  10  are dispersed through the second intermediate layer  22 B. Additionally, the fine spun fiberglass material provides dimensional stability and strength to the surface-covering article  10 . This prevents cracking of the surface-covering article  10 .  
         [0024]      FIG. 2  depicts a side view of an embodiment of a surface-covering article  10 ′ that is constructed as a tile. As shown, the top layer  14  and bottom layer  18  encapsulate a single intermediate layer  22 ′. In this embodiment, a pattern is printed on a fine spun fiberglass layer, which is disposed between the transparent top layer  14  and the bottom layer  18 . Alternatively, the top layer  14  is pigmented and no pattern is printed on the intermediate layer  22 ′. Although shown as having only a single intermediate layer  22 ′, the tile can have any number of intermediate layers.  
         [0025]     Although shown as a tile, the surface-covering article  10 ′ can be constructed in various shapes (e.g., a sheet, plank, or some other shape) depending on the intended application. Additionally, because the surface-covering article  10 ′ is resin-based it can be thermoformed into a variety of shapes after it is initially formed. This allows the surface-covering article to be custom fitted around corners and other irregularities if needed. In one exemplary embodiment, the surface-covering article  10 ′ is a tile of dimensions one foot in length, one foot in width, and on-half inch thick.  
         [0026]      FIG. 3  depicts one embodiment of a method of fabricating the surface-covering article  10  according to principles of the invention. A human or a machine adds (STEP  100 ) a resin that forms the bottom layer  18  to a cast or mold. The mold can have a wide variety of shapes and sizes. In one embodiment, the mold is shaped like a square to create a tile type surface-covering article  10 ′. The mold typically is lined with rubber to prevent the resin from adhering to the sides and bottom of the mold. As the resin cures, the machine or human adds (STEP  110 ) the second intermediate layer (e.g., the fiberglass layer). The first intermediate layer  22 A (i.e., decorative layer) is added (STEP  120 ) next. In one embodiment, a thin layer of resin is placed between the first intermediate layer  22 A and the second intermediate layer  22 B. To fabricate the surface covering article  10 ′ of  FIG. 2 , only a single intermediate layer  22 ′ is added during the fabrication process.  
         [0027]     After the desired number of intermediate layers is in place, the top layer  14  is added by pouring (STEP  130 ) resin into the mold. The top layer  14  can be the same resin as the bottom layer  18  or a different resin. Preferably, the resin chosen for the top layer  14  is a self-leveling resin. Using a self-leveling resin ensures that the top surface of the surface-covering article  10  is smooth and level. After adding the resin for the top layer  14  to the mold, the resin in the mold is cured to create the surface-covering article  10 . Curing can take place naturally or be activated by a curing source such as ultra-violet light. The type of resin used determines the curing process.  
         [0028]      FIG. 4  shows another embodiment of a method for making a surface-covering article according to principles of the invention. In one embodiment, a transparent top layer  14  is formed by curing resin into a desired shape. Alternatively, the top layer  14  can be a commercial available transparent resin based tile such as a VARIA panel sold by 3Form Corporation of Salt Lake City, Utah. In such an embodiment, the bottom surface and/or the top surface of the tile may need to be scored (STEP  140 ) or “roughed-up” (e.g., using sand paper) to create a bonding surface. The first intermediate layer  22 A is applied (STEP  150 ) to the one of the scored surfaces. The second intermediate layer  22 B (e.g., the reinforcing layer) is applied (STEP  160 ) after the first intermediate layer  22 A. Resin is applied (STEP  170 ) to the second intermediate layer  22 B. The resin makes contact with one of the scored surfaces of the top layer  14 . As the applied resin cures (STEP  180 ), it bonds to the scored surface of the top layer  14  because the top layer  14  is constructed of a resin based composition. After curing, the applied resin forms the bottom layer  18  of the surface-covering article.  
         [0029]      FIG. 5  depicts a sectional view of a surface covering system  90  using the surface-covering articles  10  constructed according to principles of the invention. In one embodiment, the system  90  includes various layers of resin applied to a substrate and surface-covering articles  10 . The resin layers encapsulate the surface-covering articles  10  and create a seamless and continuous surface.  
         [0030]     As shown, a substrate  26  (e.g., a sub-floor or table top) has an uneven top surface  30 . A first layer  34  of self-leveling resin is applied to the top surface  30  of the substrate  26 . When the first layer  34  of self-leveling resin cures, a substantially level top surface  38  exists. In an alternative embodiment, the substrate  26  has a level top surface  30  which does not require the first layer of resin  34 . A slurry layer  42  covers the top surface  38 . The slurry layer  42  is another layer of resin that is applied to the top surface  38 . The slurry layer  42  can also be self-leveling. A plurality of surface-covering articles  10  are set into the slurry layer  42  before the slurry layer  42  cures completely. Once the surface covering articles  10  are set in place, the slurry layer  42  can be allowed to cure.  
         [0031]     The surface-covering articles  10  can be abutted against one another or spaced apart from each other, as shown. When the surface-covering articles  10  are spaced from each other a void  46  exists between the surface-covering articles  10 . A portion of the slurry layer  42  is displaced into the void  46 . After setting the surface-covering articles  10 , a top coat  50  is applied. The top coat  50  is also a resin of similar chemical composition to the slurry layer  42 , and the resins of the top surface  14  and bottom surface  18  of the surface-covering articles  10 . The top coat  50  may fill any remain space within the void  46 . This creates a level seamless top surface of similar chemical composition as the underlying layers  34 ,  42 , top coat  50 , and surface-covering articles  10 . In an alternate embodiment, the top coat  50  only partial fills the remaining space with the void  46 . As such, the top coat  50  appears to have “grout-lines,” although the top surface  50  is seamless. As the top coat  50  and slurry layer  42  cure, a bond forms between the layers  34 ,  42 , the top coat  50 , and the surface-covering articles  10 . In one embodiment a chemical bond is formed between the layers  34 ,  42 ,  50  and the surface covering articles  10 .  
         [0032]     In one embodiment, a self-leveling resin forms the top coat  50 . Using a resin provides a system  90  that has a resistance to water, fluids, stains, germs, bacteria, acid, thermal shock, and fading by ultraviolet light because of the chemical properties of the resin. Also the top surface  50  is renewable and repairable, because an additional layer of self-leveling resin can be applied directly to the top coat  50 .  
         [0033]      FIG. 6  depicts an embodiment of a method of installing a seamless surface covering system  90  according to principles of the invention. In one embodiment, the substrate  26  is not level. As such, a technician prepares the substrate  26  by applying (STEP  200 ) a layer  34  of self-leveling resin to the substrate  26 . As the leveling layer  34  cures (STEP  210 ), the leveling layer  34  creates the level top surface  38 . Once a level top surface  38  exists, the installation technician applies (STEP  220 ) the slurry layer  42 . As the slurry layer  42  cures, the installation technician sets (STEP  230 ) the surface-covering articles  10  into the slurry layer  42 . The curing time of the slurry layer determines the number of surface-covering articles that can be applied. Application (STEP  240 ) of the top coat  50  begins after the desired number of surface-covering articles  10  is in place. The slurry layer  42  and top coat  50  cure (STEP  250 ). Curing creates a bond between the slurry layer  42  and the leveling layer  34 . Additionally, a bond forms between the slurry layer  42 , the surface-covering articles  10 , and the top coat  50 . After curing, the surface-covering articles  10  are suspended and encapsulated between the layers  42 ,  50 .  
         [0034]     Using a resin of similar chemical composition through the surface-covering article fabrication and installation process obviates the need for adhesive, mastic, grout, chemical and heat welded seams. Additionally, the combination of encapsulated installation layers also serves to seal the joints between the surface-covering articles  10 . This creates a vapor barrier and eliminates dirt, debris, and moisture contamination for sanitary and aesthetic purposes. Also, using a resin to form the top surface  50  provides the appearance of one continuous surface covering.  
         [0035]     The system  90  allows the surface-covering articles  10  to be used in a variety of applications. For example, the surface-covering articles  10  can be directly applied onto a porous or nonporous surface. The system  90  transitions around curbs, corners, and imperfections. The surface-covering articles can be installed horizontally and vertically. The system can be used for both exterior and interior applications. The system  90  can be used to cover lobby areas, corridors areas, mall and arena areas, restaurants surfaces, retail areas, pool and spa areas, locker rooms and bathing areas, cruise ships and other entertainment vessels, airport terminal areas, outdoor terrace areas, veranda areas, and walkway areas, counter tops, work stations and vanity areas.  
         [0036]     While the invention has been shown and described with reference to specific preferred embodiments, it should be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention as defined by the following claims. For example, the preceding surface-covering articles, method of creation and installation can be used to create table tops, end tables, counter tops, and any other article requiring a level top surface.