AU2016100663A4 - A decorative tile and its manufacturing method - Google Patents

Abstract

Abstract A decorative tile is described. It includes a first glass layer comprising a plurality of glass elements and a second glass powder layer wherein the first and second glass layers are fused together, further backed by a porcelain layer for easy installation and support. A method of manufacturing a decorative tile is also described. The method can extend to include arranging a plurality of glass elements into a layer so that edges of adjacent shapes abut or interlock, or to any suitable lay out fusing the glass elements together to form a single layer of fused glass elements.

Description

FIELD OF INVENTION

[001] The Invention relates to a decorative tile and method of manufacturing a tile of the kind that is mounted to a wall or ceiling by adhesive. The invention in some embodiments include a decorative tile mounting a plurality of smaller components or tesserae, preferably in irregular shapes, to form a decorative tile that beside special aesthetic characteristics still allows ease of application to a surface.

BACKGROUD OF THE INVENTION

[002] General Glass mosaic tiles are popular and are widely used in many different ways. However, general glass mosaic, no matter face mounted or mesh mounted, request the tile tesserae to be flat either at the back or front side or at its sides so as to facilitate a grid patterned mould assembly. Irregular shape glass chips cannot be mounted together by rear mesh or face film because the bonding strength to either the rear mesh or face film is not enough due to the limited contact area.

[003] The present invention provides a means to manufacture a new decorative tile.

[004] In this specification, where a document, act or item of knowledge is referred to or discussed, this reference or discussion is not an admission that these documents, act or item of knowledge or any combination thereof was the priority date: A. part of common general knowledge; or B. known to be relevant to an attempt to solve any problem with which this specification is concerned.

SUMMARY OF THE INVENTION

[005] According to one broad form of the invention there is provided a decorative tile including: a first glass layer comprising a plurality of small to large glass elements (irregular or regular shape glass chips) a second glass layer comprising a plurality of fine glass elements (fine glass chips to powder glass) wherein the first and the second glass layers are fused together a third backing solid layer comprising of a thin porcelain tile sheet, or any other suitable materials, wherein the backing solid layer is bonded to the fused first and second glass layers by adhesive.

[006] Preferably different colour body glass elements, chips and powders are being used for the first layer and the second layer to achieve the decoration purpose, while presenting an aesthetic effect with different colours.

[007] The second glass layer is typically a fusion bed for bonding the first layer large glass chips.

[008] The third layer of porcelain is typically a solid layer of porcelain for further supporting and ease of installation.

[009] In some arrangement glass elements of the first and the second layer will be mixed together [010] In some arrangements glass elements of the first and the second layer may be fused with other glass elements of both the first and the second layers.

[011] The second glass layer is made from suitable glass powder and small glass chips [from here on called - glass powder]. Preferably glass powder and chips are in the range of l-2mm, in any suitable shape, size or mixed sizes for better fusion purpose. In preferred embodiments, the glass powder is arranged to form a layer of thickness of about 5-8mm suitable to accommodate the first glass layer during the fusing stage.

[012] The first glass layer elements may consist of glass chips of any shapes including any irregular, as well as planar or curved shapes, including but not limited to pebble shapes, narrow strips, wavy lines, square, round or oval and the like, as well as any irregular random shapes, with interlocking or random layout. Preferable, however, each glass element of the plurality of glass elements of the first glass layer is of irregular shapes. In preferred embodiments each glass piece comprises a range of irregular shapes in the range of 5mm to 20mm, with sizes varying from small to large. Glass powder and chips for the second layer may also be used in the first layer.

[013] Further, in preferred embodiments, it is contemplated that a plurality of such shapes, of varying colours and sizes are laid out randomly, overlapping or alongside, abutting or interlocking with one another in a plane so that a layer of randomly arranged or arranged as pattern form the first glass layer.

[014] Preferably a third layer is provided at the lower surface of the second layer of glass.

[015] Preferably the third layer is in the form of a tile of porcelain or any suitable material including glass, stone, plastic, cement or resin this to protect the newly formed fused glass layers from breaking and improve the finished tile adhesion during installation, additionally by preventing view of a substrate onto which the tile is applied.

[016] Preferably the third layer is bonded to the lower surface of the second layer by dedicate adhesive suitable for both interior and exterior application. Preferably an epoxy adhesive suitable for adhering glass and porcelain or any other suitable backing substrate is being used.

[017] According to another broad form of the invention there is provided a method of manufacturing a decorative tile, the method including the steps of: • Arranging a plurality of glass powder on a flat bottom tray so as to build-up a bedding for the large glass elements. • Arranging a plurality of glass elements of selected shapes, sizes and colours into the layer of the glass powder bedding, so that glass tiles can be laid out randomly or in any suitable layout design. • Fusing the first layer of glass elements with the second layer of glass powder to form a solid layer of glass. • Preferably the method includes the step of fusing as one glass elements by firing all components in a high temperature kiln. • The method further includes the bonding the fused solid glass element to a porcelain tiles. • Preferably the method includes a further step of being able to cut the assembled tile to form a different design shape or pattern.

Brief Description of the drawings

The invention will now be further explained and illustrated by reference to the accompanying drawings in which:

Figure 1 is a plan view of a tile in accordance with one preferred embodiment of the present invention.

Figure 2 is a section view of a tile in accordance with a preferred embodiment of the present invention, the section view along the cut lines A-A shown in Figure 1:

Figure 3 is a plan view of a tile in accordance with one preferred embodiment of the present invention:

Figure 4 is a picture showing the plan view of a sample tile of this invention:

Detail description of a preferred embodiment.

Referring to the drawings there is a shown a decorative tile in accordance with a preferred embodiment of the present invention generally indicated at 7. There is shown a decorative tile 7 which includes a first glass layer 1 comprising a plurality of glass elements 4; and a second layer 2 made from glass powder 5; a third layer 3 comprising a solid porcelain tile 6.

The glass elements 4 of the layer 1 and the glass powder 5 of the layer 2 are fused together to form a single solid glass layer. The solid porcelain tile 6 is laminated to the back of the solid glass layer by adhesive 7.

Preferably the fused glass elements 5 is composed of tiny glass elements and powder. In preferred embodiments, it is contemplated that a plurality of glass powder are laid out flatly on a plan to form a flat solid bottom face as well as a bedding for the large glass chips 4.

Preferably the fused glass elements 4 are in form of random irregular shapes of varying sizes. In preferred embodiments, it is contemplated that a plurality of glass shapes of varying colours and shapes are laid out randomly on the bedding of glass powder 5. In the arrangements the glass elements 4 will touch one another and/or the elements 5.

Preferably Colour glaze powder may also be combined into the first and/or the second layer of the decorative tile 7 to form specific designed pattern.

Glass powder element 5 may also be combined into the first layer of elements 4 in some designed pattern.

These elements are then fired at high temperature until all components are fused together. A supportive layer is then provided, indicated at 3 in a form of solid porcelain tiles or other suitable material, glued to the lower surface of the solid layer of glass 2. The layer 3 is to be used as strengthening and supporting the glass tile created by fusing layer 1 with layer 2; to improve the tile adhesion during installation as well as inhibiting any view of the substrate onto which the tile is applied.

To manufacture the tile 7, glass powder 5 is poured/ spread evenly on a moulding tray, forming the base and sitting bed of the glass element 4. Glass elements 4 are then arranged as a layer on top of the glass powder; glass elements can be arranged in any suitable shape or layout. Additional glass powder 5 is spread onto the glass elements 4 to fill any excessive or unwanted gaps between the large glass chips.

The glass element 4 and glass powder 5 are then fused together in a high temperature kiln at a suitable temperature. Temperatures of about 760°C have been found to be suitable for this purpose, however, other temperatures, say between 700°C to 800°C and the like may also be of use.

The supportive layer, preferably in solid porcelain or other suitable material form, is then applied to the lower face of second layer with suitable adhesive.

Thus, the tile 7 is formed.

The word 'comprising' and forms of the word 'comprising' as used in this description do not limit the invention claimed to exclude any variants or additions.

Any modification and improvements to the invention can be easily be noted to any person skilled in the art. Such modifications and improvements are intended to be within the scope of this invention.

Claims (6)

1. The claims defining the invention are as follows:

   1. A decorative tile including A first glass layer comprising a plurality of glass elements; and a second glass layer comprising a plurality of glass powder and chips; wherein the first and second glass layers are fused together in high temperature.
2. 2. The decorative tile in accordance with claim 1 wherein a layer or multiple layers or coating of colours is disposed on a face of at least some of the glass elements.
3. 3. The decorative tile in accordance with claim 1 where each glass element of the second glass layer comprising the plurality of glass elements is of any suitable size powder or chips for building a flat base.
4. 4. The decorative tile in accordance with claim 1 where in each glass element of the first glass layer comprising the plurality of glass elements is of any suitable shape or size design with random shape, planar or curve shape.
5. 5. The decorative tile in accordance with any of claims 1-4 wherein the first glass layer comprises a plurality of regular or irregular shapes of varying colours laid out alongside or stack one another in a plane.
6. 6. A method of manufacturing a decorative tile, the method including the steps of a. Arranging a plurality of glass powder into a mould tray to form a layer so to build a flat bottom base and bedding means for the glass elements b. Arranging a plurality of glass elements into a layer on a glass powder bedding so that edges of adjacent shapes abut or interlock; or form any suitable layout, c. Fusing all the large glass elements together with the glass powder backing to form a single solid layer of fused glass elements. d. Adhering a layer of porcelain or other suitable material to support the fused glass tile from broken.