Articles and methods for laying ceramic tile floor

• US 9,003,741 B2
• Filed: 05/08/2012
• Issued: 04/14/2015
• Est. Priority Date: 06/15/2010
• Status: Active Grant

• Current Assignee: Nue Tile Patent Co. LLC
• Original Assignee: Joseph D. D'Agostino
• Inventors: D'Agostino, Joseph D.
• Primary Examiner(s): Fox, Charles A
• Assistant Examiner(s): MAESTRI, PATRICK J
• Application Number:
  US13/466,649
• Publication Number:
  US 20120279655A1
• Time in Patent Office: 1,071 Days
• Field of Search: 523/093, 521/77, 523/84, 523/85, 527/031, 156/63, 156/81, 156/297, 156/299
• US Class Current: 52/747.11
• CPC Class Codes: B32B 15/20 comprising aluminium or copper B32B15/016 and B32B15/017 take precedence
• CPC Class Codes: B32B 2419/04 Tiles for floors or walls tiles for roofs B32B2419/06
• CPC Class Codes: B32B 3/14 characterised by a face layer formed of separate pieces of material which are juxtaposed side-by-side B32B5/02 takes precedence
• CPC Class Codes: B32B 7/12 using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: B32B 9/005 comprising one layer of ceramic material, e.g. porcelain, ceramic tile layered products with at least two ceramic layers composed mainly of ceramic B32B18/00
• CPC Class Codes: B32B 9/041 of metal
• CPC Class Codes: E04F 15/08 only of stone or stone-like material, e.g. ceramics, concrete; of glass or with a top layer of stone or stone-like material, e.g. ceramics, concrete or glass E04F15/02005 takes precedence
• CPC Class Codes: E04F 15/16 Flooring, e.g. parquet on flexible web, laid as flexible webs; Webs specially adapted for use as flooring; Parquet on flexible webresiliently-mounted floors, e.g. sprung floors, E04F15/22; linoleum D06N; carpets A47G27/00
• CPC Class Codes: Y10T 156/10 Methods of surface bonding and/or assembly therefor

Abstract

Ceramic floors and methods of making thereof such that the ceramic tiles are quickly and easily removable from the floor substrate and replaceable at a future date.

A ceramic tile floor is laid by releasably adhering a sheet to a floor substrate and bonding at least one ceramic tile to the sheet.

A plurality of pre-fabricated articles each comprising a sheet and one or more ceramic tiles bonded to the sheet are laid onto the floor substrate with sheet edges abutting, and the sheets are releasably adhered to the floor substrate. The tile edges are set inwardly from the sheet edges so that a tile of one article is spaced from a tile of another article when the articles are laid. A non-Portland cement grout, preferably urethane grout, is provided between adjacent tiles.

Claims

1. A method of laying ceramic tile onto a substrate comprising the steps of (a) releasably adhering a sheet to the substrate, and (b) bonding at least one ceramic tile to the sheet, wherein the step of bonding the ceramic tile to the sheet includes applying a mortar to the sheet and laying the ceramic tile in the mortar, and wherein the step of releasably adhering a sheet to the substrate comprises selecting the sheet to have a thickness of up to 1/32 inch and to be composed of paper with a plastic film bonded or laminated thereto.

2. A method according to claim 1 wherein the step of releasably adhering the sheet comprises applying to the floor substrate adhesive tape comprising the sheet and a releasable adhesive.

3. A method according to claim 1 wherein the sheet has a width which is at least about 22 inches.

4. A method according to claim 1 wherein the sub-step of applying a mortar to the sheet comprises applying a latex modified thinset mortar to the sheet.

5. A method according to claim 1 wherein the step of releasably adhering a sheet to the substrate comprises releasably adhering a sheet to a floor substrate.

6. A method for laying of ceramic tile onto a substrate comprising providing a plurality of articles each including a sheet having a thickness of up to 1/32 inch and composed of paper with a plastic film bonded or laminated thereto, at least one ceramic tile bonded to one side of the sheet with a mortar, and a releasable adhesive on an other side of the sheet for releasably adhering the sheet to a substrate, the method further comprising laying the articles so that edges of the sheets of adjacent ones of the articles abut, and releasably adhering the sheets to the substrate.

7. A method according to claim 6 further comprising applying grout between adjacent ones of the tiles including applying the grout between a ceramic tile of one of the articles and a ceramic tile of another of the articles which is adjacent thereto.

8. A method according to claim 7 further comprising selecting the grout to be urethane grout.

9. A method according to claim 6 wherein said mortar is a latex modified thinset mortar.

10. An article for applying to a substrate for laying of ceramic tile onto the substrate, the article comprising a prefabricated combination of a sheet, a releasable adhesive applied to one side of said sheet for bonding said sheet to the substrate, and a mortar bonding said at least one tile to an other side of said sheet, wherein said sheet has a thickness of up to 1/32 inch and is composed of paper with a plastic film bonded or laminated thereto.

11. An article according to claim 10 further comprising means for forming a gap between a tile on one of the article and an adjacent said tile on an adjoining one of the article as said sheets thereof are laid edge-to-edge.

12. An article according to claim 10 further comprising means for preventing grout applied between an edge of said at least one tile of one of the article and an edge of said at least one tile of an other of the article from contacting the floor substrate.

13. An article according to claim 10 comprising at least two of said at least one tile bonded to said sheet, the article further comprising grout between said at least two tiles.

14. An article according to claim 10 wherein said grout is a urethane grout.

15. An article according to claim 10 wherein the article is laid with others of the article on a substrate with said sheets of adjoining ones of the articles abutting, and grout between adjacent ones of said tile.

16. An article according to claim 15 wherein said grout is a urethane grout.

17. An article according to claim 10 wherein said mortar is a latex modified thinset mortar.

18. An article according to claim 15 wherein the substrate is a floor substrate.