1. Field of the Invention
The present invention relates generally to the field of floor and other building surface coverings. More specifically the present invention relates to a tile including a flexible and resilient backing layer having a rearward face for securing to a building surface such as a floor and a forward face covered with a flexible cement layer. The rearward face is preferably covered with a mounting adhesive and peal off paper. The flexible cement layer is preferably textured to have aesthetically appealing surface irregularities and is preferably colored and shaded with any of a wide variety of pigments. The resulting appearance, feel and durability substantially duplicate those of far more expensive poured cement surfaces.
The backing layer is preferably a square of laminate, peg board, formica, wood or other suitable sheet material. The flexible cement layer is preferably formed of a fine aggregate cement mixture combined with an acrylic resin, a water-based paint, waterproof rubber material and water-based sealer.
A process of manufacturing the tile includes the steps of sanding or grinding the forward face of the backing layer to develop grooves and to de-gloss the surface; mixing a fine aggregate cement with an acrylic resin and waiting until a false set is reached; mixing into the fine aggregate cement and acrylic resin mixture a waterproof rubber material and a water-based paint and water-based sealer; adding adhesive as needed to reach a suitable consistency; spreading the mixture over the forward face of the backing layer; coloring the mixture; texturing the mixture with a trowel or machine trowel while the mixture is wet or semi-wet, or with a machine trowel when the mixture is dry; permitting the mixture to dry completely; and then adding color as little or as much as desired; then sealing the dry mixture with a suitable sealer such as a xylene or water-based sealing coat. If the xylene-based sealer is used, one quart of boiled linseed oil may be added to a quantity of one to five gallons of xylene-based sealer to create a shiny top coat.
2. Description of the Prior Art
There have long been building surface coverings such as URO-TILE.TM. for creating a decorative and durable surface, which may be prepared to appear in many different styles and colors. URO-TILE.TM. includes an approximately one-eighth to one-quarter inch thick layer of pigmented cement mix. The mix surface is textured with a towel and randomly grooved to simulate interfitted stones or bricks. Grout is optionally troweled into the grooves to further enhance the separate stone or brick visual effect. A problem with the URO-TILE.TM. method is that it is very expensive and requires skilled and experienced labor on site to install, so that installation by a typical homeowner is not feasible.
The URO-TILE.TM. is disclosed in detail in U.S. Pat. No. 4,349,588, issued on Sep. 14, 1982 to Schiffer. Several other prior patents teach forming a cement slab with a colored surface by pouring colored mortar into a form, and then optionally pouring non-colored cement on top of the colored mortar to create a unified slab. These methods present many of the problems of Schiffer.
Spencer, U.S. Pat. No. 1,204,378, issued on Nov. 7, 1916, discloses a process for marbleizing cement. A coloring compound is prepared including Portland cement and mineral coloring. Then a layer of surface mixture of white Portland cement and water is produced, perhaps one quarter inch thick, and the coloring compound is stirred with paddles into the surface mixture to create streaks resembling marble. This composition is poured into a mold having a polished bottom wall to form a smooth upper slab surface. Then, while this composition is still in a fluid state, it is jarred or vibrated to fill voids and increase surface density. The form is thereafter filled to the top with non-colored backing mix, permitted to harden, removed from the form and inverted.
Wohl, U.S. Pat. No. 2,305,126, issued on Dec. 15, 1942, reveals a process of molding imitation terrazzo tile. In Wohl a mix is once again poured into a form having a polished bottom wall. The bottom wall is waxed and painted, and spotted or grained with the desired arrangement of slab surface coloring. Dry Portland cement is poured into the form and spread uniformly over the polished bottom wall to about one-quarter inch thickness. A damp mix of cement and sand is added. Next the form is placed in a press, such as a hydraulic power press, and pressure is applied to cause the paint to impregnate the hydrated thin layer of cement to a depth sufficient to cause retention of the intended ornamentation on the face of the finished piece. Placement of dry cement over the paint in the form is intended to insure that the paint is attracted to the cement particles prior to hydration.
Jennens, U.S. Pat. No. 1,568,070, issued Jan. 5, 1926, reveals a method of making artificial stone. Coloring matter of the consistency of thick paint is applied to a greased bottom wall of a form. A string or cord is immersed in the coloring matter and distributed over the form bottom wall in a haphazard manner. Then small particles or nodules are sprinkled into the form. A gas forming material, such as bicarbonate of soda, is sifted over the surface. Finally, cementitious material is spread over this deposited composition and a dry material is applied to take up excess moisture. The mix is permitted to cure, and the form is removed and the resulting slab is inverted to an upright position.
Ewen, U.S. Pat. No. 1,596,482, issued on Aug. 17, 1926, teaches a method of producing cement tiles, slabs, and like products. Ewen is much like Spencer, except that there is an additional step of using a grid to separate a colored layer into squares or other shapes. Then alternating shapes are removed and replaced with matching shapes of another color. Denivelle, U.S. Pat. No. 1,233,265, issued on Jul. 10, 1917 is also much like Spencer.
Other references teach coloring an upper surface without need of inverted molding in a form. Phillips, Sr., U.S. Pat. No. 5,441,677, issued Aug. 15, 1995, discloses a method of making high gloss, hardened concrete floors. A non-colored cement mix is poured into a form to within about one-half inch of the full level. Then a dry shake is applied, troweled or otherwise floated, and then another dry shake is applied, and again floated, until the cement in the form reaches a full level. This mix cures into a unified concrete slab having a colored upper layer. A problem with Phillips, Sr. is that the dry shake requires several applications and floatings to create a colored layer. See Phillips column 3, lines 54-66.
Lowe, U.S. Pat. No. 5,320,790, issued on Jun. 14, 1994, discloses a method for producing a durable tactile warning surface. A first method is provided for forming a tactile warning surface on an existing sidewalk, which includes the steps of making a pigmented cement and spreading it over the sidewalk surface and then stamping the wet surface with a patterned tool.
Lowe provides a second method for forming a complete sidewalk slab where none existed before. This second method includes the steps of preparing a cementitious mortar, pouring the cementitious mortar into a form, leveling the mortar to a substantially even thickness of about four inches, applying pigmented hardener to the surface of the mortar to a depth of about one quarter inch to become "an integral part therewith", applying a hydrophobic release agent to the resulting surface, and stamping the surface with a patterned tool. See bottom of Lowe column 4 and top of column 5.
It is thus an object of the present invention to provide a building tile which presents a textured cement surface convincingly simulating brick, stone or ceramic tile, and alternatively presents a textured cement decorative surface.
It is another object of the present invention to provide a building tile which is thin, light weight and flexible.
It is still another object of the present invention to provide such a tile which is formed and textured at the manufacturing plant, so that an ordinary home-owner can simply fit and bond it into place.
It is a further another object of the present invention to provide such a tile which is installed rapidly and with no drying time, and which may be replaced quickly and neatly in selective areas, and which can cover and fully conceal structural cracks.
It is finally an object of the present invention to provide such a tile which is highly durable, will withstand many years of wear and resists denting, is relatively light weight to transport, and is inexpensive to manufacture and thus affordable.