| Surface-covering article used to produce seamless surface coverings -> Monitor Keywords |
|
|
 
Surface-covering article used to produce seamless surface coveringsRelated Patent Categories: Stock Material Or Miscellaneous Articles, Two Dimensionally Sectional LayerSurface-covering article used to produce seamless surface coverings description/claimsThe Patent Description & Claims data below is from USPTO Patent Application 20060210755, Surface-covering article used to produce seamless surface coverings. Brief Patent Description - Full Patent Description - Patent Application Claims
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 22A, and a second intermediate layer 22B, disposed between the top layer 14 and the bottom layer 18. In one embodiment, the first intermediate layer 22A is a decorative layer and the second intermediate layer 22B is a reinforcing layer. The top layer 14 and the bottom layer 18 sandwiches and encapsulate the intermediate layers 22A, 22B. Continue reading about Surface-covering article used to produce seamless surface coverings... Full patent description for Surface-covering article used to produce seamless surface coverings Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Surface-covering article used to produce seamless surface coverings patent application. ###  How KEYWORD MONITOR works... a FREE service from FreshPatents1. Sign up (takes 30 seconds). 2. Fill in the keywords to be monitored. 3. Each week you receive an email with patent applications related to your keywords. Start now! - Receive info on patent apps like Surface-covering article used to produce seamless surface coverings or other areas of interest. ### Previous Patent Application: Versatile label sheet and dispenser Next Patent Application: Audio video disc protector Industry Class: Stock material or miscellaneous articles ### FreshPatents.com Support Thank you for viewing the Surface-covering article used to produce seamless surface coverings patent info. IP-related news and info Results in 0.19898 seconds Other interesting Feshpatents.com categories: Accenture , Agouron Pharmaceuticals , Amgen , AT&T , Bausch & Lomb , Callaway Golf 174 |
 * Protect your Inventions * US Patent Office filing 
PATENT INFO |
|
