Patent Application
20150140270
Stone, ceramic tiles, and fused glass are used for covering floors, walls, back splashes, and for any other type of decorative application. Tiles take significant resources to manufacture and are relatively expensive. For example, stone tiles are fabricated from pieces of mined rock. Ceramic tiles are formed from pieces of clay, fired in a kiln, glazed, and then re-fired in the kiln.
Other less expensive decorative coverings exist. For example, decals and stickers with adhesive backings can be attached to walls, windows, mirrors, etc. The decals typically comprise a thin layer of plastic or paper but do not have the dimensional textured 3-dimension characteristics of stone, ceramic, fused glass, or any other natural organic material. Thus, decals and stickers may have a lower aesthetic appeal and provide a lower impression of quality than stone or ceramic tiles.
A fabricated decorative covering is dimensional and thus replicates some of the aesthetics provided by organic materials, such as stone, fused glass, ceramic, or any other three dimensional object. An ink layer forms an image on a vinyl sheet. One or more textured layers are applied to the sheet and create a three-dimensional (3-D) light effect that refracts light at different random angles. Another ink layer may be applied to a second vinyl sheet forming a second image. The two vinyl sheets may be laminated together to further accentuate the 3-D characteristics between the two images. The one or more vinyl sheets may provide high quality aesthetics and may be less expensive to manufacture, than organic and other 3-D materials.
Instead of grout and mortar, the fabricated coverings may include an adhesive for attaching to surfaces. The coverings may be installed more quickly and may require less skill for properly attaching to different surfaces.
In the example of
In one example, an adhesive is pre-applied at a factory to a bottom surface of tiles 100. A user may remove a paper cover from a back side of tile 100 and simply press the tile against a surface. After a few hours the adhesive bonds tile 100 to the surface.
A repositionable permanent adhesive may be used that allows tile 100 to be attached to a surface and then observed. If the installer does not like the original tile position, tile 100 can be removed and repositioned. After an acceptable position is obtained, the installer then applies additional pressure to the tile and leaves the tile in place on the surface for several hours. After several hours, the adhesive permanently bonds tile 100 to the surface.
In one example, the adhesive may be formed from an opaque material and hide the attached surface. For example, in
In one example, top sheet 140 may comprise a 3.0 mil high gloss UV overlaminating film manufactured on a vinyl roll. One example vinyl sheet 140 is part number 400-30 also manufactured by Interluxy Gmbh, Judenpfad 72, 50996 Cologne Germany. Top sheet 140 may include a transparent adhesive on a bottom surface.
Any type of film, plastic, vinyl, resin, or the like, with any type of thickness and/or manufactured form or size may be used for sheets 120 and 140. In one example, sheets 120 and 140 each include a bottom adhesive layer. In one example, the bottom of sheet 120 has a substantially opaque adhesive layer and the bottom of sheet 140 has a substantially transparent adhesive layer. As described above, an opaque adhesive layer on the bottom of sheet 120 may cover/hide whatever is attached behind tile 100. The transparent adhesive layer on the bottom of sheet 140 allows light to pass through sheet 140 and reflect and refract within bottom sheet 120 enabling viewing of images printed on sheet 120.
In one example, a first image 122 is printed onto sheet 120 and a second image 142 is printed onto sheet 140. In one example, images 122 and 142 may simulate different veins of materials running through a piece of stone, such as marble or granite. Of course, images 122 and 142 may comprise any combination of different shapes and colors. In one example, image 122 may be applied using a lithograph inking process and image 142 may be applied using an inkjet printing process. But again any type of printing or inking process may be used on sheets 120 and 140 for forming images 122 and 142, respectively.
One or more textured layers 130 are applied on sheet 120. Textured layer 130 may comprise a pattern of random or semi-random shaped bumps or protuberances 132. The bumps 132 may be arranged into different patterns on sheet 120. In one example, a screen printing process may be used for applying textured layer 130 and forming bumps 132. One example screen printing process for forming and applying textured layer 130 is described in U.S. Pat. No. 7,468,203, issued Dec. 23, 2008, entitled: Textured Window Film, which is herein incorporated by reference in its entirety. In another example, a flexographic printing process may be used for one or more of the ink or textured layers.
A transparent overprint clear layer may be applied over textured layer 130 (see
Image 142 is printed on top of sheet 140 and sheet 140 is laminated with sheet 120. For example, a roller may press the bottom of sheet 140 against the top of sheet 120 and the transparent adhesive on the bottom of sheet 140 laminates sheets 120 and 140 together. The laminated sheets 120 and 140 are then die-cut into different shapes, such as into the shape of tile 100. In one example, one or more drops of transparent liquid resin are poured onto the top of sheet 140. Gravity combined with a capillary action creates a smooth domed shaped layer 150 on the top surface of sheet 140.
In one example, tile 100 contains two or more images on two different laminated sheets thus providing a physical spacing and associated 3-D effect between image 142 on sheet 140 and image 122 on sheet 120. Textured layer 130 increases the 3-D effect between images 122 and 142 by refracting light at different angles and thus simulating non-uniform textures that may exist in some 3-D objects, such as in stones and other organic materials.
As also mentioned above, adhesive layer 160 may alternatively be transparent for use in other applications where the structure behind tile 100 does not need to be covered. For example, a transparent adhesive layer 160 may be used when tiles 100 are applied to windows so light may pass through the window and tile 100. Transparent adhesive layer 160 also may be used when tiles 100 are applied to mirrors and prevent a dark tile image from being reflected back out from the minor.
An ink layer 162 is applied on the top surface of sheet 120. As mentioned above, a lithograph printing process may be used for applying ink layer 162 and forming image 122. Any combination of colors may be used in ink layer 162 and may form any combination of images 122. Some of the colors may be more opaque and other colors may be more transparent or translucent.
Textured layer 130 is printed on top of ink layer 162. Textured layer 130 may comprise any transparent or translucent material that creates a non-even surface on sheet 120. As explained above, in one example textured layer 130 is formed by applying a transparent resin on sheet 120 through an emulsion screen. Opacitors may be used in the resin to reduce transparency. The emulsion screen includes a pattern that forms different protuberances or bumps that have different shapes and sizes. The bumps also may be formed into different patterns within different areas of sheet 120.
An overprint layer 164 may be formed on top of textured layer 130. Overprint layer 164 also may comprise resin, clear varnish, clear coat, or the like. In one example, the resin in overprint layer 164 may be less viscous than the resin used for forming textured layer 130.
The combination of image 122, textured layer 130, and overprint layer 164 promote prismatic characteristics on light that produce a 3-D effect. For example, the bumps formed in textured layer 130 may refract or bend incoming light while substantially flat areas within textured layer 130 may create little or no refraction of incoming light.
Optionally a second textured layer 170 may be formed on top of overprint layer 164. Two layers of bumps create more of a random bump characteristic. Textured layer 170 also may comprise a substantially transparent or translucent resin that provides another non-even surface on sheet 120. Textured layer 170 may be formed in a manner similar to textured layer 130 by applying a transparent resin through an emulsion screen. The emulsion screen used for textured layer 170 may form a pattern of bumps and the bumps also may have different shapes and sizes compared with the bumps in textured layer 130.
In one example, objects 172 may be mixed with the resin used for forming textured layer 170. In one example, at least some of objects 172 comprise a reflective glitter material that may provide additional visual contrast and depth variance relative to image 122. In one example, objects 172 may comprise a Micronic Jewles glitter having sizes of 0.004×0.004 inches (100 microns) manufactured by Meadowbrook Inventions, Inc., PO Box 960 Mine Brook Road, Bernardsville, N.J. 07924. However, any size, shape, and/or type of material may be used in objects 172. In another example, objects 172 alternatively, or in addition, may be mixed within textured layer 130.
As discussed above, sheet 120 with layers 160, 162, 130, 164, and 170 is laminated with sheet 140 in
Tiles 100 can provide a substantially limitless variety of different visual effects. For example, different textured patterns and images can be created that simulate visual effects that exist in stone, fused and/or textured glass, ceramics, wood, metal, or any other material.
Overprint layer 164 is printed on top of textured layer 130 and in one example fills in some of the spaces between bumps 132. Bumps 132 may create a rough undefined look. Overprint layer 164 creates a smooth clearer sealed layer over bumps 132 and provides a more visually refined aesthetic property to tile 100. Textured layer 170 is formed on top of overprint layer 164. In one example, textured layer 170 comprises a second set of bumps with a second set of shapes formed into a second pattern. Textured layer 170 creates additional 3-D effects in tile 100.
Adhesive layer 180 is applied to a bottom side of sheet 140 and an ink layer 182 forming image 142 (
Adhesive layer 180 also may fill in some of the spaces between bumps in textured layer 170 so the bumps may be less visible while still providing physical separation. Sheet 140 seals the second textured layer 170 and provides additional physical distance and dimension between ink layer 162 and ink layer 182. Sheet 140 also provides a relatively smooth top layer for receiving dome layer 150.
Spacing provided by sheets 120 and 140 increases light refraction between image 122 on ink layer 162 and image 142 on ink layer 182, respectively (
After lamination, a weeding process is performed where stamp 190 cuts pieces of laminated sheets 120 and 140 into tiles 100. In one example, stamp 190 cuts laminated sheets 120 and 140 while a paper backing (not shown) remains attached to adhesive layer 160 on the bottom surface of sheet 120. Portions of laminated sheets 120 and 140 between stamped tiles 100 are removed from the top of the paper backing forming spaces between tiles 100.
Drops of resin are applied to the top surface of the spaced apart tiles 100. Vertical sides of each spaced apart tile 100 extend perpendicularly up from a top horizontal surface of the paper backing. As explained above the combination of gravity and capillary action causes the drops of resin to spread over the top surface of each individual tile 100 and form domed layer 150.
The heterogeneous compositions and perpendicular orientations between the paper backing and the sides of tiles 100 create a capillary effect where the drops of resin spread out until reaching the edges of each tile 100. The resin then stops spreading and dome around the tile perimeter edges. The stamping process performed by stamp 190 cuts individual tiles 100 without cutting into the paper backing. The continuous non-cut paper backing maintains the heterogeneous boundary between the paper backing and the sides of tiles 100 preventing the resin in dome layer 150 from flowing over the edges of stamped tiles 100.
A screen is used for printing textured layers 130 and 170 on top of sheet 120. A pattern is formed in areas of the screen using a photosensitive emulsion that is applied as either a liquid coating or in sheet form. A pattern is applied over the emulsion and the emulsion is then exposed to light. The areas in the emulsion that were covered by the pattern remain soft and are washed out forming open areas. The areas not covered by the pattern remain blocked off with emulsion.
The screen is located over sheet 120 and a resin material is spread over the screen. Using a squeegee, the resin is spread through the unblocked areas in the screen and onto sheet 120 forming textured layer 130. In one example, the resin material is clear, but other degrees of opaqueness or color can be used.
The size and shape of the individual bumps 130 and areas within textured layer 130 can be relatively consistent or can vary in shape, size or spacing. If different areas of textured layer 130 have different shapes, the corresponding bumps 132 formed in the different areas also may have different shapes. It should also be noted that the variable size and shape of bumps 132 formed in textured layer 130 and the bumps formed in textured layer 170 help promote the random or semi-random refraction of light creating the 3-D visual aesthetic in tile 100.
In one example, the same systematic pattern of bumps 132 is repeated for multiple sections of sheet 120. Bumps 132 can be created in any repeating, random, or semi-random arrangement that refracts light in different directions. The bump patterns can then be used to form visual subpatterns that simulate different surfaces or materials. This is shown in more detail below in
In one example, the screens used for forming textured layer 130 and textured layer 170 have thread counts in the range of between 65-420 threads per inch and the thickness of the photosensitive emulsion used to coat the screens is anywhere between 1 mil-100 mils. But in other examples, the screens are coated with emulsion to a depth of about 6.0-8.5 mils. The range of 6.0-8.5 mils of emulsion produces a thickness for textured resin layer 130 of around 1.0-5.5 mils.
It should be understood that the dimensions and composition of tile 100, emulsion and resin can all vary and still provide the 3-D effect described above. The specific dimensions and materials used can be changed to created different lighting and application characteristics.
A second screening process is used for forming overprint layer 164. A second screen is used that does not have a pattern formed from emulsion. In one example, the second screen comprises a uniform mesh of between about 110-420 threads per inch and is large enough to cover sheet 120. A second resin, clear varnish or clear coat is spread over the second screen applying a second substantially even resin layer over textured layer 130.
The resin used in overprint layer 164 may be less viscous than the resin used to form textured layer 130 and may comprise a mixture of TRPGDA by weight in a range of about 20-25%, resin acrylate by weight in a range of about 50-56%, HDOCA by weight in a range of about 18-22%, and photoinitiators by weight in a range of about 3-5%. Of course other materials can also be used to form overprint layer 164. A third screen pattern is then used for forming the bumps in textured layer 170.
In one example, an offset lithography process is used for applying ink layer 162 on sheet 120 and an inkjet printing process as used to applying ink layer 182 on sheet 140. However, any other process can also be used for applying ink layers 162 and 182, such as a screen printing process similar to that used for applying layers 130, 164, and 170 on sheet 120.
Offset lithography is widely used to produce full color images in mass such as magazines, brochures, posters and books. In the offset lithography example, an image is transferred from a plate wrapped around a cylinder onto sheet 120. The offset lithography process can be used to apply any image, pattern, uniform or non-uniform color, picture, etc. onto sheet 120.
The lithography process breaks down an image into small dots separated into four colors; yellow, magenta, cyan and black known as a four color process. The dots are reproduced onto the printing plate mentioned above. Each color has all the tones necessary to produce a photo quality image in ink layer 162. In one example, the ink used to form ink layer 162 and 182 is made of an elastic material that has similar elastic characteristics as sheet 120 and the resin in layers 130, 164, and 170.
As mentioned above, reflective objects 172, such as glitter, may be mixed into the second textured layer 170. Reflective objects 172 appear at different depths within textured layer 170 and reflect light at different angles accentuating the three dimensional and textured characteristics within tile 100. Objects 172 also may be mixed within other layers of tile 100. Image 142 formed on the top surface of sheet 140 (
Image 142 is physically separated from image 122 formed on sheet 120, bumps 132 formed on textured layer 130, and objects 172 formed in second textured layer 170. Thus, image 142 provides additional 3-D aesthetics within tile 100. In the stone example, image 142 may simulate additional veins of different materials within a rock or stone.
In another example, tile 100 may not be a laminate and may only comprise bottom sheet 120. In this example, dome layer 150 may be applied directly onto a single textured layer 130, applied onto overprint layer 164, or applied onto second textured layer 170.
Different areas of images 250A and 250B may have different levels of opacity. For example, lighter or non-inked areas 252 may be transparent or translucent. Other darker inked areas 254 may be less translucent and/or more opaque. The different levels of opacity further increase the 3-D effects in tile 100 by further simulating different types of materials extending though different depths of a stone.
Referring specifically to
In a second printing, the same image 250B may be printed onto sheet 140 but with an offset 252 with respect to image 250A printed onto sheet 120. Offset 252 of image 250B with respect to image 250A creates a completely new combined image within tile 100. In a third printing, the same image 250B may be printed onto sheet 140 but with an offset 254 with respect to image 250A printed onto sheet 120. Offset 254 of image 250B with respect to image 250A creates a third completely new combined image within tile 100.
Thus, even slight changes in the amount and direction of offsets 252 and 254 of image 250B with respect to image 250A may create an almost infinite number of unique combined images within each tile 100. These unique combined images in tiles 100 further enhance aesthetic appeal and simulate the unique visual characteristics of organic materials.
As explained above, pattern 260 is formed in areas of a screen using a photosensitive emulsion that is applied as either a liquid coating or in sheet form. Black areas 262 create the openings in the mesh and white areas 264 form covered areas in the mesh. Texture pattern 260 is applied over the emulsion and the emulsion is then exposed to light. Areas in the emulsion covered by dark areas 262 in pattern 260 remain soft and are washed out. Other areas in the emulsion under white areas 264 in pattern 260 remain blocked off with emulsion.
In a next operation, the screen is located over sheet 120 and resin is spread over the screen. Using a squeegee, the resin is spread through the unblocked areas in the screen and onto sheet 120 forming raised bump patterns in dark areas 262 while spaces of no resin remain in blocked off white areas 264. The combination of openings in the mesh within each unblocked area form the bumps. The bumps in texture layer pattern 260 may be as random as possible to further simulate organic materials.
The substantially semi-random texture patterns 260, 270, and/or 280 contribute to the aesthetics of tiles 100. For example, texture patterns 260, 270, and/or 280 may reflect and refract light at different semi-random angles within tiles 100 further increasing 3-D characteristics of images within tiles 100.
Texture patterns 260, 270, and/or 280 also may be offset by different amounts and with different orientations with respect to other texture layer patterns in texture layers 132 or 170 and also may be offset by different amounts and orientations with respect to images 122 and 142 printed onto sheets 120 and 140, respectively. Thus, an almost limitless combination of combined texture patterns and images may be created within tiles 100.
Having described and illustrated the principles of the invention in a preferred embodiment thereof, it should be apparent that the invention may be modified in arrangement and detail without departing from such principles. We claim all modifications and variation coming within the spirit and scope of the following claims.
