AU2013101431A4 - A Composite Tile and Method of its Manufacture - Google Patents

Abstract

A decorative composite tile is described. The decorative composite tile includes a glass tile element including an upper surface and a lower surface, a layer of translucent, coloured glaze applied to the lower surface of the glass tile element, and a layer of foil applied to the coloured glaze on the lower surface of the glass tile element. A method of manufacturing a composite tile is also described, the method including the steps of applying a translucent coloured glaze to an upper surface of a glass tile element, and applying a foil layer to the translucent coloured glaze on the lower surface of the glass tile element. 22 Figure 2

Description

1 A COMPOSITE TILE AND METHODS FOR ITS MANUFACTURE Field of the invention [001] The present invention relates generally to composite tiles, substantially of a decorative kind. The composite tile is of the kind that is mounted to a wall or ceiling by adhesive. Background of the invention [002] Glass mosaics and tiles are popular and used in many different ways. However, a metallic appearance is often desired. [003] There are different ways to simulate a metallic appearance in glass tiles. However, there are limitations to the known methods, including that they create a dull or unrealistic metallic effect in the finished product. Furthermore, the known methods are limited in colour range or high in cost to produce. [004] One known method of simulating a metallic appearance in glass tiles is inorganic pigment application. This method involves inclusion of mica powder within colour pigment, the pigment being embedded in the glass tile element itself. This type of mosaic has a certain degree of gloss, high adhesion and low manufacturing costs, but results in a poor and unrealistic metallic appearance. [005] Another known method of simulating a metallic appearance in a glass tile is organic pigment application. The advantage of this method is a low manufacturing cost, however, only a limited number of colours allow a realistic metallic appearance, these colours being limited essentially to gold and silver. Additionally, because of the nature of such organic pigments, they often degrade easily in the presence of harsh environmental conditions. [006] Yet another method involves adhesion of a thin metal foil to a rear face of a glass mosaic tile to give a realistic metallic appearance. One drawback of this method is that there are only a very few varieties of foil available, so that colour choice is again limited to aluminium, gold and copper. [007] Still another known method is to use stained glass. This particular method includes the step of electroplating the glass surface in the presence of a vacuum.

2 This process has very limited colour selection and involves costly processes which are also damaging to the environment. [008] The present invention seeks to provide a new composite tile. [009] 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 the document, act or item of knowledge or any combination thereof was at the priority date: part of common general knowledge; or known to be relevant to an attempt to solve any problem with which this specification is concerned. [010] In the specification and the claims which follow, translucent coloured glaze is to be understood as being a colourant or tint for adding colour, for example to a paint, in a granular or liquid form and similar to a paint pigment or paint additive. Summary of the invention [011] In accordance with a first aspect of the present invention there is provided a composite tile including: a glass tile element including an upper surface and a lower surface; a layer of translucent coloured glaze applied to the lower surface of the glass tile element; and a layer of foil applied to the translucent coloured glaze on the lower surface of the glass tile element. [012] The upper surface on the glass element could be flat, textured, ribbed, hatched, lumpy, bumpy or smooth. Optionally the composite tile further includes a contoured upper surface on the glass tile element for improved decoration. The contoured upper surface may provide improved grip. [013] Optionally the layer of foil includes a pattern formed therein so that the pattern is visible behind the glass tile element, albeit slightly magnified because of the refractive index of the glass. [014] Optionally the composite tile further includes a protective layer applied to a lower surface of the layer of foil so as to facilitate protection of the foil layer and to 3 facilitate adhesion of the decorative tile during installation. Optionally the protective layer is a coating of ceramic powder and epoxy resin. [015] In some embodiment the glass tile element may be a coloured glass element so as to affect the colour of the final assembly when viewed through the coloured glass tile element. [016] A backing web may be applied to the foil so that several decorative tiles may be set out on the web to form a tesserae or mosaic. [017] According to another broad form of the invention there is provided a method of manufacturing a composite tile, the method including the steps of: applying a translucent coloured glaze to a lower surface of a glass tile element; and applying a foil layer to the translucent coloured glaze on the lower surface of the glass tile element. [018] The application of the translucent coloured glaze may be conducted by suitable methods including spray painting, screen printing or other painting. Preferably however, the application of the translucent coloured glaze to the surface of the glass tile element is screen printing. [019] Optionally the application of the translucent coloured glaze includes fusing the glaze to the lower surface of the glass tile element at high temperatures. [020] A temperature of approximately 8600C has been found to be suitable for fusing the glaze and glass, or for providing an undulated or contoured surface to the top surface of the glass tile element. [021] Optionally the method further includes the step of applying a protective layer to a lower side of the foil layer to facilitate protection of the foil and facilitate adhesion of the decorative tile element to a surface during installation. [022] Optionally the method further includes the step of machining the upper surface to provide a flat surface or smooth surface portion. [023] Optionally the application of the foil layer includes the step of adhering the foil to the translucent coloured glaze with an adhesive. [024] Optionally the method includes the step of cutting, folding or otherwise forming the layer of foil into a selected shape or pattern. Optionally the shape is 4 regular or irregular. Regular shapes may include circles, rings, rectangles, squares, any regular polygons, trapeziums, and other shapes. Irregular shapes may be any suitable shape. [025] Optionally the method further includes the step of using a coloured glass element to which the transparent coloured glaze is applied. [026] Optionally the method further includes the step of applying a protective layer to a lower face of the foil layer. The application of the protective layer to the lower face may include any suitable method including screen printing or painting. [027] Optionally the method further includes the step of forming the foil layer into a shape to provide a textured visual effect. Optionally the method includes the step of rolling or otherwise impressing a pattern or shape into the foil layer to provide a textured visual effect. [028] Preferably however, the application of the protective layer to the lower face of the foil includes spraying a mixture coating of ceramic powder and epoxy resin. [029] In accordance with a third aspect of the present invention there is provided a composite tile including: a glass tile element including an upper surface and a lower surface; and a layer of patterned foil applied to the lower surface of the glass tile element. [030] Optionally the composite tile includes a layer of translucent coloured glaze applied to the lower surface of the glass tile element. [031] In accordance with a fourth aspect of the present invention there is provided a method of manufacturing a composite tile, the method including the steps of: providing a glass tile element including an upper and a lower surface; forming grooves or a raised pattern into a layer of foil; and adhering the grooved or patterned layer of foil to the lower surface of the glass tile element. Brief Description of the drawings [032] The invention will now be further explained and illustrated by reference to the accompanying drawings in which: 5 [033] Figure 1 is a schematic plan view of a composite tile in accordance with one preferred embodiment of the present invention; [034] Figure 2 is an elevation section schematic 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; [035] Figure 3 is a schematic plan view of a tesserae or mosaic comprising a plurality of composite tiles shown in Figures 1 and 2, the plurality of composite tiles disposed on a webbing mat; [036] Figure 4 is an elevation section schematic view similar to Figure 2 but for a different optional embodiment of the present invention, having no translucent coloured glaze on a bottom face of a glass tile element; and [037] Figure 5 is an elevation section schematic view similar to Figures 2 and 4 but for a different optional embodiment of the present invention, the embodiment having no protective layer underneath a foil layer and no webbing to join several tiles. Detailed description of optional embodiments [038] Referring to the Figures there is shown a composite tile generally indicated at 10, the tile being in accordance with a preferred embodiment of the present invention. [039] There is shown, with particular reference to Figure 2, the composite tile 10 including a glass tile element 12 comprising an upper surface 13 and a lower surface 15, and a layer of translucent, coloured glaze 14 applied to the lower surface 15. The translucent, coloured glaze 14 can be in the form of enamel colour in powdered or paint form and to apply is screen printed onto the lower surface 15. [040] An adhesive layer 16 is disposed on the layer of translucent, coloured glaze 14, so as to adhere a layer of foil 18 in the form of a metal foil or metal alloy foil 19 to the layer of translucent, coloured glaze 14. [041] A protective layer 20 is affixed to a lower surface of the foil. The protective layer 20 is applied by spraying and is in the form of a mixture of ceramic powder 6 and epoxy resin 22. The protective layer 20 also facilitates improved adhesion to mounting adhesive (not shown) and a mounting surface (not shown). [042] A webbing 25 may be applied to an underside of the protective layer 20, and many composite tiles 10 may be glued to the webbing so as to form a mosaic or tesserae shown in Figure 3. The webbing arrangement 25 speeds installation of the plurality of composite tiles 10. [043] In describing other optional embodiments, like numerals denote like elements of other optional embodiments. [044] Referring to another optional embodiment, shown in Figure 4, there is shown a composite tile 110 including a glass tile element 112 comprising an upper surface 113 and a lower surface 115. [045] An adhesive layer 116 is disposed on the lower surface 115, so as to adhere a layer of foil 118 in the form of a metal foil or metal alloy foil 119 to the layer of translucent, coloured glaze 114. [046] A protective layer 120 is affixed to a lower surface of the foil 118. The protective layer 120 is applied by spraying and is in the form of a mixture of ceramic powder and epoxy resin 122. The protective layer 120 also facilitates improved adhesion to mounting adhesive (not shown) and a mounting surface (not shown). [047] A webbing 125 may be applied to an underside of the protective layer 120, and many composite tiles 110 may be glued to the webbing so as to form a mosaic or tesserae shown in Figure 3. The webbing arrangement 125 speeds installation of the plurality of composite tiles 110. [048] Referring to yet another optional embodiment, shown in Figure 5, there is shown a composite tile 210 including a glass tile element 212 comprising an upper surface 213 and a lower surface 215, and a layer of translucent, coloured glaze 214 applied to the lower surface 215. The translucent, coloured glaze 214 can be in the form of enamel colour in powdered or paint form and to apply is screen printed onto the lower surface 215. [049] A layer of foil 218 in the form of a metal foil or metal alloy foil 219 is disposed on the layer of translucent, coloured glaze 214.

7 [050] In order to produce the composite tile 10 (as with 110 and 210) a glass tile element 12 in the form of a sheet or panel (not shown) is selected and a translucent coloured glaze 14 is applied by suitable painting means, including spray painting or, more typically, screen printing, to the lower surface 15 of the glass tile element 12. The glaze 14 is applied and then cured onto the glass tile element 12 by being baked in a low temperature oven for a selected time. That is, pre-kiln preparation will require the clear coloured enamel to be Baked between 250'C to 300'C, depending on the colour used. [051] The glass tile element 12 is cut from the sheet or panel, but cut from the side that was not glazed, so as to take care not to scratch the coloured glazing. [052] The tile element 12 is then fired in a high temperature kiln at approximately 8600C and then fused to the glass tile element 12. Each tile element 12 is placed so that the lower surface 15 is facing upwards so as not to damage the glazing 14. Thus, the top surface 13 of each tile element is placed face-down into a tray. The tray may have a flat base or an undulated or contoured base so that the top surface 13 of the tile element 12 may conform to an undulated or contoured surface in the high temperature kiln. This is useful to provide a different decorative effect on the face on upper surface 13, or decorative or other surfaces to the upper surface 13. [053] The upper surface 13 is then polished so as to provide a glossy and flat finish surface. Alternatively the surface could be left untouched as to create a different matt surface finish. [054] Manual grinding of upper edges may then be required to remove any sharp edges from the polished top surface. In some embodiments depending on various factors (in one embodiment, that shown in Figure 5) the heat from the kiln itself may take care of removing the sharp edges. [055] The metal foil 18 is then applied or adhered with adhesive 16 to the transparent coloured glazing 14 and the protective layer 20 is then sprayed on to the foil 18. In one embodiment, a rake, or ridged roller, or other knurler, may be used to roll a pattern 40 into the foil before it is applied. The pattern shown in the drawings is a parallel-lined pattern 40 but there may be knurls, hatches, curves, circles or indeed any suitable pattern impressed into the foil. This pattern is then 8 visible from the upper surface of the tile 13 once the foil 18 is glued to the glaze 14. [056] The adhesive 16 may be any suitable adhesive including UV-curing adhesive. For best performance, the surfaces are cleaned, dried and all grease is removed. The UV adhesive is applied to the translucent coloured glazing 14 and then the foil 18 is applied to the glazing 14. Any bubbles are removed from underneath the foil 18 by squeezing them to the side. The composite tile, foil-side up, is placed under a UV-light of suitable wavelength and intensity. The foil typically is not repeatedly pressed onto the glaze 14. [057] In preferred embodiments of the process, the partially-complete composite tile (glass tile 12, glaze 14, adhesive 16 and foil 18) is rolled between two rubber coated rollers to squeeze the air bubbles out and then passed through on a conveyer belt through a UV oven (not shown). The glass tile element 12 is then fed through the UV source at a selected speed to provide sufficient adhesive curing time. [058] The glass tile element 12 may be a translucent coloured glass tile element so as to provide a different colour of the composite tile 10 - the colour being a combination of the coloured glass tile element and the translucent coloured glaze. [059] The protective backing in the form of ceramic powder and resin mix, is sprayed onto the aluminium foil 18 on the lower surface of same. [060] The composite tiles 10 are then baked to solidify the backing ceramic mix. [061] The tiles 10, 110, 210 are then arranged in a jig (not shown) to form the mosaic pattern shown in Figure 3. Then the cotton web 25 is glued onto the back of the composite 10 to form the composite tile 10 shown in Figure 3. [062] 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. [063] Modifications and improvements to the invention will be readily apparent to those skilled in the art. Such modifications and improvements are intended to be within the scope of this invention.

Claims (5)

1. A composite tile including: a glass tile element including an upper surface and a lower surface; a layer of translucent, coloured glaze applied to the lower surface of the glass tile element; and a layer of foil applied to the layer of translucent, coloured glaze on the lower surface of the glass tile element.

2. The composite tile in accordance with claim 1 further including a contoured upper surface on the glass tile element for a selected visual effect.

3. The composite tile in accordance with claim 1 or 2 wherein the foil includes a pattern formed therein so as to be visible behind the glass tile element.

4. The composite tile in accordance with any one of claims 1 to 3 wherein the glass tile element is formed from coloured glass.

5. A method of manufacturing a composite tile, the method including the steps of: applying a translucent coloured glaze to a lower surface of a glass tile element; and applying a foil layer to the translucent coloured glaze on the lower surface of the glass tile element.