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Adhesive Applicator and Tiling Process

This invention relates to a tiling process namely a process of cladding a surface with tiles and a device for carrying the process into effect.

This invention is based on the specifications accompanying UK patent applications numbers 9025590.2 and 91093047.7, the contents of which are hereby incorporated by way of reference.

Tiling processes are used widely for the purpose of providing an existing surface with either or both a decorative or protective wear resistant finish. Tiles are generally of rectangular shape and are provided with a front face which is decorative or wear resistant or both and a rear face which is generally considerably rougher than the front face and it's purpose is to carry a layer of adhesive agent so as to enable the tile to be secured to the surface. Tiles can vary considerably depending upon the use to

which they are to be put. Tiles for use in cladding vertical walls and intended mainly for decoration have thicknesses which are usually in the range of 3-10 mm. However when tiles are to be used flooring and which are expected to be subjected to much heavier use will generally be thicker.

In theory a tiling process is not difficult to carry out. The surface to be tiled is prepared to ensure that it is uniform, adhesive is applied to the reverse face of the tile after which the adhesive coated face of the tile is presented to the surface. In practice unless the operative carrying out the tiling process is very skilful the resulting tiled surface is generally uneven and unsightly.

One of the main difficulties encountered by the inexperienced tiler stems from the difficulty of ensuring that each tile, prior to application to the surface, is coated with a layer of adhesive which is both even and of the correct thickness. The present invention is directed to a process of tiling which avoids these difficulties.

Accordingly this invention provides a process of cladding a surface with tiles comprising placing a tile in an applicator having dimensions which conform closely to the dimensions of the tile and a depth which equals the sum of the thickness of the tile and the thickness of the layer of adhesive to be applied to

one of the faces of the tile, applying excess adhesive to the face, removing excess adhesive by drawing a scraping member across opposing parts of the rim of the applicator so as to leave a uniform layer of adhesive on the face, discharging the adhesive coated tile from the applicator and presenting the tile to the surface to be clad.

The adhesive applicator can comprise a base having a recessed frame which is adapted to support a tile. The sides of the base extend above the frame and the top of the base, and the tops of a number of spaced apart ridges which are located at each end of the base occupy the same plane. Grooves are provided between adjacent ridges and the grooves are of equal depth.

The base is used in conjunction with an adhesive spreader which is sufficiently wide to accommodate the width of the base. The spreader is provided with flattened ridges and grooves which are located towards the rear of the spreader and the spreader is dimensioned so that it can be moved along the base. During movement of the spreader over the base the ridges on the spreader slide along the grooves in the base.

The present invention provides one or more embodiments of an adhesive applicator comprising one or more of the following modifications or additional features to the adhesive applicator disclosed in UK patent application no. 9025590.2.

The recessed frame in the base can be modified so that a tile is only supported at the corners at the frame. It has been found helpful only to support the tiles at their corners rather than continuously along the sides and ends of the tile because most tiles are convex in section and if supported continuously along sides and ends, the tile will tend to rock in the base when the applicator is used. The provision of supports for the tile only at the corners of the tile prevents or substantially reduces the likelihood of the tile rocking in the base when the applicator is used.

A further feature comprises the provision of slots along the external edges of the base and the provision of corresponding tongues on the spreader which engage with the slots. The provision of this feature enables the spreader to be accurately guided and attached to the base when adhesive is spread on the tile. The ends of the slots on each side of the base can be relieved so that the spreader can be conveniently and easily attached to the base by the engagement of the tongues on the spreader engaging with the tongues on the base.

In order to accommodate different sizes of tile spacers can be provided for attachment to a side or the sides of the frame and an end or the ends of the frame.

Also in order to accommodate different thicknesses of tile

spacers are provided at each corner in order to locate with the tile supports at the corner of the recess in the base. These spacers can comprise triangular plates having a peg which is engagable with an opening in the support at the corners of the recess in the frame.

The spreader can be made for example in three parts so that when the applicator is packed, the depth of the package can be reduced. For example the spreader can comprise two end pieces which include the tongues and a cross piece on which the ridges and grooves are formed. The cross piece and end pieces can be secured together by engagement of projections on the cross piece with openings provided by each of the end pieces.

A further feature comprises an arrangement which can be used to remove the tile to which adhesive has been applied, from the base. The arrangement can comprise a cross piece which is laid upon a flat surface so that the base complete with the tile in place can be located over the cross piece and the base is lowered over the cross piece so that the base rests upon the flat surface upon which the cross piece is resting. The tile complete with adhesive will be lifted from the base when the face of the tile contacts the cross piece.

The base can comprise two end pieces and two side pieces which can be slidably secured together to form a frame. The frame is

pieces can be formed with longitudinally extending grooves which can be engaged by tongues formed on the ends of the adhesive spreader.

Various steps in the invention process are illustrated but not restricted by the following drawings in which;

Figure 1 (a) is a side view taken in vertical section showing an applicator together with a tile in position during the removal of excess adhesive.

Figure 1 (b) is a side view taken in vertical section of the applicator shown in Figure 1 (a) containing the tile after the coating process has been carried out.

Figure 1(c) is a side view taken in vertical section of the applicator shown in the above figures showing the adhesive coated tile being discharged from the applicator.

The carrying out of the process is illustrated with a tile of rectangular shape, a thickness of 5 mm and made of ceramic material. The tile (1) is placed with decorative face (2) directed towards the bottom (3) of an applicator having internal measurements which just allow the tile to fit easily within the applicator which can be made of any conventional constructional material, for example wood, plastics or metal. The depth of the applicator is 8 mm and the bottom of the applicator is provided

with an aperture (5) having a diameter which conveniently can be about 20 mm. If tiles of different dimensions are to be used then applicators of different dimensions will be necessary. A cement mixture (6) is then spread over the reverse face (7) of the tile (l) after which a scraper (8) having a straight edge and a width greater than the width of the applicator is then drawn across it's rim in direction A whilst the edge is maintained firmly in contact simultaneously with opposing parts of the rim. As a result a uniform layer of cement having a thickness of about 3 mm is formed onto the reverse face of the tile. In order to extract the coated tile from the applicator a probe (9) which can be a finger of the tiler is inserted through aperture (5) and pressed upwards thus lifting the coated tile out of the applicator. The cement coated face of the tile can then be applied to the surface which is to be cladded. since each tile which is positioned on the surface can be made correspondingly uniform and to present a neat and attractive appearance.

The process can be modified in different ways. If for example the thickness of the tile is markedly less than the depth of the applicator the depth of the latter can be reduced by inserting one or more packing plates into the applicator before the tile is introduced. Furthermore the shape of the applicator can be modified readily to permit the coating of tiles having different shapes for example hexagonal.

In order to assist the adhesion of the coated tile to a surface, the layer of adhesive can provided with a pattern of indentations

or ridges preferably during the coating process. This can be achieved with the applicators illustrated in the figures described below in which;

Figure 2a is a perspective view of the applicator and

Figure 2b is a perspective view taken in the direction of B of the part of the applicator shown in Figure 2a.

Figure 3 shows a perspective view of a further form of a base for an adhesive applicator according to the present invention,

Figure 4 shows an arrangement for removing a tile from the base shown in Figure 3,

Figure 5 shows the components of the arrangements shown in figure 4,

Figure 6 shows a part view of a spreader for use with the base shown in figure 3,

Figure 7 shows an exploded end elevation of another form of base for an adhesive applicator according to the present invention.

Figure 8 shows the assembled base of figure 7 together with an adhesive spreader,

Figures 9 and 10 show views similar to those shown in figures 7 and 8 with the base assembled to a narrower width, and

Figure 11 shows a part perspective view of the base shown in figure 7.

With reference to figures 2a and 2b of these drawings the applicator comprises a base (21) which can be made conveniently of moulded plastics, wood or metal. The base is provided with a recessed frame (22) which is adapted to support a tile. The sides of the base (21) extend above the frame (22) and the top of the base and the tops of flattened ridges (23) which are located at each end of the base occupy the same plane. Grooves (24) which are located between the ridges are of equal depth.

The base is used in conjunction with an adhesive spreader (25) which is just wide enough to accommodate the width of the base (21) . An arrangement of flattened ridges (26) , and grooves (27) is located towards the rear of the spreader which is dimensioned so that it can be moved along the base. During its movement the ridges (26) of the spreader (25) slide along grooves (24) of the base.

In order to use the applicator the spreader (25) is advanced so as to expose the frame (22) . A tile is then placed face downwards so that its edges rest on frame (22) . Adhesive is then

applied to the exposed back of the tile after which the spreader is advanced along the applicator. During its movement ridges

(26) of the spreader move along grooves (24) of the base and enter the layer of adhesive thereby cutting a number of channels.

During the process any excess adhesive collects in the head of the spreader (25) and is removed when the spreader reaches the end of its traverse along the tile. The spreader is then removed and coated tile is then separated from the base. This can be achieved in different ways. However one that is especially convenient is to place the base on a block of wood having dimensions slightly less than those of the frame (22) . When a downwards pressure is applied to the base the coated tile is then forced out of the base. Alternatively the frame can be provided with a false bottom which can be forced upwards by means of a spring loaded handle.

Various kinds of adhesives can be used. When for example the tile is made from a plastics material the adhesive may also be made preferably from a plastics material. However cements made of inorganic materials are preferred for tiles made of ceramics.

Referring to Figure 3 of the drawings, a base (121) which can be made conveniently of moulded plastics or, wood or metal, is provided with a recessed frame (122) having triangular corner pieces (122a) each provided with an opening (122b) . The sides of the base (121) extend above the frame (122) and the top of the

base, and the tops of flattened ridges (123) which are located at each end of the base occupy the same plane. Grooves (124) which are located between the ridges (123) are of equal depth.

Referring to figure 6 there is shown part of an adhesive spreader (125) which is used in conjunction with the base (121) , the spreader being sufficiently wide to accommodate the width of the base (121) .

An arrangement of flattened ridges (126) and grooves (127) is located on a cross piece (128) of the spreader. The cross piece (128) can be attached to end pieces (130) only one of which is shown, by means of projections (132) at each end of the cross piece (128) engaging with corresponding slots (134) formed in each end piece (130) . Since the spreader is formed in three pieces it can be conveniently packed flat and not occupy so much room when the adhesive applicator is packed for display and sale.

Referring again to figure 3 the outer edges of the sides of the base (121) are each provided with a slot (121a) . At one end of the base (121) one of the two walls defining each slot (121a) is cut away at (121b) for the purpose described below. The ends of (130) of the spreader (125) are each provided with a tongue (130a) and the tongues (130a) engage with the slots (121a) in the base (121) . The provision of the relief (121b) enables the

tongues (130a) to be readily located in the slots (121a) .

In order to accommodate different sizes and thicknesses of tile in the base (121) , the base (121) can be provided with means to decrease the depth of the recess (122) and to decrease the width and length of the recess (122) .

In order to accommodate tiles of a smaller thickness, spacers (136) which are triangular in shape are provided. Each spacer at (136) has a peg (138) which is locatable with an opening (122b) in each triangular piece (122a) . Thus the depth of the recess can be arranged so that it will accept a tile of a known maximum thickness. Various thicknesses of spacers (136) can then be provided to accommodate tiles of varying lesser thicknesses.

In order to provide for tiles which are lesser width and/or in length than a predetermined maximum size which can be accommodated within the frame (121) , a side spacers (138) and an end spacer (140) can be provided. The side spacer at (138) can be provided with pegs (138a) which can locate with corresponding openings in the side of the frame (121) as illustrated, in order to reduce the width of the frame.

The length of the frame can be reduced by the provision of the end spacer (140) which has similar pegs to that shown with reference to the side space (138) and engagable with openings in

an end of the frame (121) . The spacer of (140) is provided with flattened ridges and grooves which correspond with the ridges and grooves (1223) and (124) in the frame (121).

The adhesive applicator illustrated in figures 3 & 6 is used in a similar manner to that described with reference to figures 2a and 2b. A tile is placed face down in the recess (122) so that it corners rest upon the position (122a) . Adhesive is then applied to the exposed back of the tile and the spreader (125) is attached to the base by engagement of the tongues (130a) with the slots (121a) . The spreader is then advanced along the base (121) and during its movement the ridges (126) of the spreader move along the grooves (124) of the base and enter the layer of adhesive thereby cutting a number of channels. During the process any excessive adhesive collects in the head of the spreader (125) and is removed when the spreader reaches the end of its along the tile. The spreader is then removed from the base and the coated tile is separated from the base.

Referring particularly to figures 4 and 5 the removal of the tile from the base can be conveniently achieved by use of the arrangement shown in these figures. The arrangement comprises a cross piece (142) which can be formed by two strips of wood or plastics (144) , (146) each having a slot so that the strips (144) , (146) can be attached together. The cross piece (142) is laid upon the work surface and the frame (121) in which the tile

is supported is placed over the cross piece (142) and lowered onto the work surface. The tile is engaged by the cross piece and is therefore lifted from the frame. The tile can then be removed from the cross piece and placed where required.

Referring to figure 7 an adhesive applicator includes a base (221) comprising two side pieces (221a) and two end pieces (221b) . The two end pieces (221a) are formed with ridges (223) and grooves (224) in a similar manner to the ridges and groves (23), (24) and (123), (124) of the other embodiments of the invention. The side pieces (221a) are also formed with dove-tail tongues (221c) and two grooves (221d) .

The side pieces (221b) are each formed with two dove-tail slots (221e) , and a groove (221f) . Referring to figure 8, the side pieces (221b) are shown assembled on the end pieces (221a) so that the dove-tail tongues (221c) engage the outer ones of the dove-tail slots (221e) , and a tongue (221g) on each side pieces engages one of the slots (221d) , so that the base (221) can accommodate a relatively wide tile, e.g a 8" wide tile.

The applicator also includes an adhesive spreader (225) as shown in figure 8 comprising a cross piece (228) having an arrangement of flattened ridges (226) and grooves (227) . The cross piece (228) is attached to end pieces (230) by means of projections (232) on each end piece engaging corresponding slots (234) formed

at each end of the cross-piece.

Each end piece (230) is formed with a tongue (230A) so that the assembled spreader can be slidably located on the base (221) with the tongues (230a) engaging the slots (22If) in the side pieces (221b) of the base.

As shown in figures 9 and 10, in which identical components have been given the same references, the side pieces (221b) are slidably located on the end pieces (221a) so that the dove-tail tongues (221c) engage the inner ones of the dove-tail slots (221e) , enabling a narrower tile to be located in the base, e.g a 6" wide tile.

A similar adhesive applicator (225) can be used although it will be obvious that a narrower cross-piece (228) will be necessary.

Referring to figure 11 which shows one of the end pieces (221a) and side pieces (221b) in greater detail, the right hand side piece (221b) is shown in position to locate a narrower tile, eg a 6" wide tile, whilst the left hand side piece (221b) is shown in position to locate a wider tile, eg an 8" wide tile.

It will be appreciated that the adhesive applicator can be sized to accept tiles of a range of sizes, whether square or oblong.

It will be noted from figure 11 that the side pieces are each provided with a loading slot (221h) enabling the adhesive spreader to be readily assembled on the base (221) .

The present invention provides an adhesive applicator having features which make it convenient to use and which allow the applicator to accommodate tiles of different thicknesses lengths and widths.

The present invention also provides a simple means of removing a tile from the applicator once adhesive has been applied to the back of a tile.

Also the present invention provides a spreader which can be conveniently packed flat.