MOSAIC TILE

Abstract

A mosaic tile, comprising a plurality of subunits (2a-2b) adhered to a backing material (3), wherein at least some of said subunits (2a-2b) comprise thermoplastic material, or, more particularly consist of heterogeneous PVC tile parts.

Claims

1. A mosaic tile comprising: a backing material sheet; and a plurality of subunits secured to the backing material sheet, wherein the plurality of subunits comprise: a plurality of plastic subunits; and a plurality of non-plastic subunits.

2. The mosaic tile of claim 1, wherein each of the plurality of plastic subunits are defined as thermoplastic subunits.

3. The mosaic tile of claim 2, wherein said thermoplastic subunits each comprise a heterogeneous polyvinylchloride material.

4. The mosaic tile of claim 3, wherein said thermoplastic subunits comprise a substrate layer having a printed decoration thereon.

5. The mosaic tile of claim 1, wherein each of the plurality of non-plastic subunits are defined as ceramic subunits.

6. The mosaic tile of claim 1, wherein each of the plurality of non-plastic subunits are defined as natural stone subunits.

7. The mosaic tile of claim 1, wherein: each of the plurality of plastic subunits are defined as thermoplastic subunits; and each of the plurality of non-plastic subunits are defined as ceramic subunits.

8. The mosaic tile of claim 7, wherein each of the plurality of plastic subunits has a first thickness, and each of the plurality of non-plastic subunits has a second thickness, and wherein the first thickness is at least substantially equal to the second thickness.

9. The mosaic tile of claim 7, wherein said thermoplastic subunits each comprise a heterogeneous polyvinylchloride material.

10. The mosaic tile of claim 1, wherein the backing material sheet comprises one of: a mat, a film, a mesh, a net, a scrim, or a maze.

11. The mosaic tile of claim 1, wherein the backing material sheet comprises an adhesive layer adhering the plurality of subunits onto the backing material sheet.

12. The mosaic tile of claim 1, wherein the plurality of subunits collectively define at least two opposing staggered edges configured to interleave with adjacent mosaic tiles.

13. A mosaic tile comprising: a plurality of tile subunits secured relative to one another, wherein the plurality of tile subunits comprise: a plurality of thermoplastic subunits; and a plurality of ceramic subunits.

14. The mosaic tile of claim 13, wherein said thermoplastic subunits each comprise a heterogeneous polyvinylchloride material.

15. The mosaic tile of claim 14, wherein said thermoplastic subunits comprise a substrate layer have a printed decoration thereon.

16. The mosaic tile of claim 15, wherein the substrate layer defines a plurality of decorative reliefs therein.

17. The mosaic tile of claim 13, wherein the plurality of subunits are secured to a common backing material sheet such that the plurality of subunits are secured relative to one another.

18. The mosaic tile of claim 13, wherein the plurality of subunits are disposed in a common receptor tray.

19. The mosaic tile of claim 13, wherein each of the plurality of thermoplastic subunits has a first thickness, and each of the plurality of non-plastic subunits has a second thickness, and wherein the first thickness is at least substantially equal to the second thickness.

20. The mosaic tile of claim 13, wherein the plurality of subunits collectively define at least two opposing staggered edges configured to interleave with adjacent mosaic tiles.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0028] Reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:

[0029] FIG. 1 represents an example of a mosaic tile with the characteristics of the invention;

[0030] FIG. 2 represent a cross-section along the line II-II indicated in FIG. 1;

[0031] FIG. 3 in a similar view as FIG. 2 represents a variant; and

[0032] FIG. 4 in a similar view as FIG. 1 represents a variant

DETAILED DESCRIPTION

[0033] The present disclosure more fully describes various embodiments with reference to the accompanying drawings. It should be understood that some, but not all embodiments are shown and described herein. Indeed, the embodiments may take many different forms, and accordingly this disclosure should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout.

[0034] FIG. 1 shows a mosaic tile 1 according to one embodiment. The tile 1 comprises a plurality of subunits, including plastic subunits 2a and nonplastic subunits 2b adhered to a backing material 3. In certain embodiments, the plastic subunits 2a comprise thermoplastic material 4 (e.g., PVC, PP, PE, PET, TPU), and/or the like, while the subunits 2b comprise ceramic tile parts. However, it should be understood that in certain embodiments, the plastic subunits 2a may comprise other plastic materials, such as thermoset plastics, and the nonplastic subunits 2b may comprise other nonplastic materials, such as natural stone, manufactured hard surfaces, and/or the like.

[0035] In the illustrated example embodiment of FIG. 2, the plastic subunits 2a comprise a thermoplastic material 4, specifically comprising (e.g., consisting of) heterogeneous PVC tile parts. The plastic subunits 2a comprise a substrate layer 5 upon which a printed decoration 6 is provided. In the illustrated embodiment, the printed decoration 6 resembles a wood grain, although it should be understood that other decorations, patterns, images, and/or the like may be provided. Moreover, the substrate layer 5 may include a reinforcement layer, such as a glass fiber layer (not shown in the figures).

[0036] Moreover, as shown in FIGS. 1-3, the nonplastic subunits 2b comprise ceramic subunits. The ceramic subunits may be preformed in the desired shape, for example, by forming and baking the ceramic material in the desired shape of the nonplastic subunits 2b. However, it should be understood that the nonplastic subunits 2b may be formed by cutting individual the nonplastic subunits 2b into a desired shape, for example, from a natural or manufactured stone or other hard surface material.

[0037] In certain embodiments, the thickness T of the plastic subunits 2a and nonplastic subunits 2b may be between 3 and 10 mm, for example, between 4 and 7 mm. According to the example of FIG. 2, the plastic subunits 2a have at least approximately the same thickness T as the nonplastic subunits 2b. According to the example of FIG. 3 the nonplastic subunits 2b (e.g., formed of ceramic tile parts) may have a larger thickness T than the plastic subunits 2a formed of thermoplastic material, or vice versa, such that a three-dimensional structure is obtained at the surface of the mosaic tile 1. The difference in thickness T between the plastic subunits 2a and the nonplastic subunits 2b may be slight, for example the difference in thickness may be less than 5 millimeters such as less than 3 millimeters or less than 2 millimeters.

[0038] The subunits making up the mosaic tiles of FIGS. 1-3 may be secured (e.g., adhered) to a backing material 3 using a glue 7 or other adhesive, such as an epoxy adhesive, a thermoplastic adhesive, a thermoset adhesive, a water-based adhesive, and/or the like. The backing material 3 may comprise a mat, film, mesh, net, scrim, maze and/or the like and may comprise a fiberglass material, a plastic material (e.g., a plastic fiber material), a natural fiber material, and/or the like. In the illustrated embodiments, the backing material 3 defines an at least substantially continuous sheet, such that a plurality of subunits (e.g., plastic subunits 2a and/or nonplastic subunits 2b) secured relative to a single backing material 3 sheet are secured relative to one another.

[0039] As represented, the backing material 3 at its rear side 8 has self-adhering properties due to an adhesive layer 9 (e.g., comprising a pressure sensitive adhesive) present at said rear side 8 or the side opposite the subunits. The adhesive layer 9 is covered with a removable protective layer 10. The adhesive layer 9 may be a separate layer, such as an adhesive film, an adhesive spray, and/or the like that may secured relative to the backing material 3. In other embodiments, the backing material 3 itself may comprise adhesive properties, at least on a backside of the backing material 3.

[0040] In the illustrated example of FIG. 1, the subunits 2a-2b may all be hexagon shaped, for example, having the same size and arranged in a honeycomb pattern. However it should be understood that the subunits 2a-2b may have any of a variety of shapes. The distribution of the subunits of differing material is random in the example, but may be showing a predetermined motif as well.

[0041] As shown in FIG. 1, the hexagon shape of the subunits 2a-2b may create a staggered edge profile surrounding at least a portion of the perimeter of the mosaic tile. The staggered edge profile may be complementary with other tiles placed adjacent to the mosaic tile, such that the staggered edges of adjacent tiles interleave with one another to visually providing the look of a continuous mosaic tile encompassing subunits disposed within a plurality of individual mosaic tiles having the configuration described herein. In certain embodiments, individual subunits 2a, 2b defining the staggered edge profile may be secured relative to the backing material 3, and may extend beyond edges of the backing material 3 to enable the staggered edges of adjacent tiles to be interleaved with one another, such that the individual subunits 2a, 2b at the perimeter of adjacent mosaic tiles may be spaced at a distance at least substantially equal to the spacing distance between subunits 2a, 2b of a single mosaic tile. By enabling consistent spacing both between subunits 2a, 2b on a single mosaic tile as well as between adjacent mosaic tiles, the mosaic tile configuration may provide the visual look of a continuous mosaic tile comprising a plurality of subunits 2a, 2b disposed within individual mosaic tiles.

[0042] FIG. 1 also shows the printed decoration 6 may show varying orientations of the wood grain pattern, e.g., for some of the plastic subunits 2a aligned to the main directions of the mosaic tile 1 and some not aligned.

[0043] The nonplastic subunits 2b may be free from patterns, and may comprise a top surface formed from a uniformly colored glaze 11.

[0044] The subunits 2a-2b may be spaced apart on the backing material 3. The spacing 12 may serve to accommodate a grouting material.

[0045] FIG. 4 illustrates another example of a mosaic tile in accordance with the invention. Herein the subunits 2a-2b comprise elongated rectangular parts. The plastic subunits 2a may comprise heterogeneous PVC tile parts, and the nonplastic subunits 2b may comprise ceramic tile parts. Although other materials may be utilized, as noted with respect to FIG. 1, above.

[0046] The subunits 2a-2b shown in the example of FIG. 4 are only minimally spaced apart, e.g., the spacing is less than half, or even less than a third of the thickness of the subunits 2a formed from thermoplastic material.

[0047] The embodiment shown in FIG. 4 is such that the boundary of the subunits 2a-2b comprises two opposing staggered edges 13-14, which are complementary to each other. The protruding parts 15 of one of said edges 13-14 can enter the spaces 16 formed at the opposing one of said edges 13-14.

CONCLUSION

[0048] Many modifications and other embodiments will come to mind to one skilled in the art to which this disclosure pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the disclosure is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.