Element for coating surfaces and relative use

Abstract

 An element is described for coating surfaces made of ceramic material and/or natural stone and the relative use. The element comprises a tile made of ceramic material and/or natural stone coupled with a support made of polymeric and/or copolymeric material by means of a thermo-adhesive copolymer which adheres to a surface of the tile and to a surface of the support.

Description

[0001] The present invention relates to an element for coating surfaces and the relative use.

[0002] The present invention derives from the technical sector of the building industry, in particular in the field of coatings for surfaces made of ceramic material and/or natural stone for decorative and/or protective purposes for floors and wall surfaces.

[0003] Among the methods for coating surfaces with ceramic materials and/or natural stone, the technique based on the positioning of coating elements on the surface to be covered made of the above materials by means of specific supports, has become widespread. This coating or flooring technique comprises the laying of a series of supports, made of metal or plastic material, on the surface to be coated, which offer a rest surface for tiles made of ceramic material, natural stone or other kinds of material.

[0004] In order to guarantee the fixing of the coating to the surface, each support has connecting means which allow each of said supports to be connected to the one immediately adjacent to it. For a greater stability of the tile, the support can also be equipped with a frame, protruding with respect to the surface on which the tile rests, suitable for housing the tile in its interior. In this case, the frame also occupies the intermediate space between one tile and another, i.e. the so-called "grout line".

[0005] This coating technique of surfaces according to the known art has a series of drawbacks. For example, the coatings thus obtained are unstable.

[0006] In the case of coatings for horizontal surfaces, i.e. floors which have to sustain considerable weights, both static and moving, the tiles tend to become detached from the respective supports, coming out of the framework. Furthermore, in the case of floors, as the supports are generally only resting on the surface to be coated, the whole coating element can move, creating problems of vibrations and stability of the flooring structure. The duration with time of these coatings is consequently rather limited.

[0007] Furthermore, as the grout lines between the tiles are occupied by the frames of the supports, which prevent them from being filled with traditional filling materials, these floorings do not guarantee the impermeability of the coating to water infiltrations.

[0008] In the case of vertical building walls, this coating technique cannot be applied and it is therefore necessary to fix the tiles with traditional fixing means using gluing mortar, thus making all maintenance and necessary modification operations after the production of the coating, for example, modifications of use of the building wall, extremely complex.

[0009] At present therefore, in the field of surface coatings, the problem is strongly felt, of finding an element and/or process for coating horizontal or vertical surfaces, with ceramic materials and/or made of natural stone which allows coated surfaces to be obtained rapidly and simply, also avoiding having to resort to the intervention of qualified operators.

[0010] The objective of the present invention is therefore to find an element for coating surfaces and the relative coating process, capable of overcoming the drawbacks described by the state of the art.

[0011] An object of the present invention relates to an element for coating surfaces comprising a tile made of a ceramic material and/or natural stone coupled with a support made of polymeric and/or copolymeric material wherein:

• said tile has at least one contact surface;
• said support has at least one contact surface and a rest surface;

said element being characterized in that the tile is coupled with the support by means of a thermo-adhesive copolymer which contemporaneously adheres to the contact surface of the tile and contact surface of the support.

[0012] A second object of the present invention relates to a coated surface comprising at least one element for coating surfaces, said element comprising a tile made of ceramic material and/or natural stone coupled, by means of a thermo-adhesive copolymer, with a support made of polymeric and/or copolymeric material, characterized in that:

• said support has a rest surface,
• said rest surface is coupled with the surface to be coated by means of a thermo-adhesive copolymer which adheres contemporaneously to the rest surface of the support and surface to be coated.

[0013] A further object of the present invention relates to a coated surface comprising at least two coating elements wherein:

• each element comprises a tile made of ceramic material and/or natural stone coupled by means of a thermo-adhesive copolymer with a support made of polymeric and/or copolymeric material, said support having a rest surface;
• each element is provided with connecting means suitable for fixing said element to at least one further element adjacent to it, also provided with connecting means;

said coated surface being characterized in that each element is connected to at least a second element adjacent to it.

[0014] In particular, said element for coating surfaces according to the present invention is used under dry conditions, without the use of mortar or glues.

[0015] The following figures are enclosed with the description for a better understanding of the present invention:

• Figure 1 illustrates a schematic representation in perspective of a support made of polymeric and/or copolymeric material;
• Figure 2 illustrates a detail in perspective of an element for coating surfaces;
• Figure 3 illustrates a sectional detail of two elements for coating surfaces reciprocally connected.

[0016] The element for coating surfaces according to the present invention comprises a tile made of ceramic material and/or natural stone coupled with a support made of polymeric and/or copolymeric material.

[0017] For the purposes of the present invention, the term "tile" refers to a slab, having any thickness, form and dimension which can have a decorative and/or protective function, suitable for being used for covering wall surfaces and floorings inside and outside buildings. Of the two surfaces of the slab, one acts as a protective and/or decorative coating and the other as a contact surface for coupling with the support.

[0018] The materials of which the above tiles are made essentially comprise all types of ceramics, klinker, as well as natural stones such as granite and marble.

[0019] The support made of polymeric and/or copolymeric material coupled with the tile is a support which has a contact surface suitable for supporting a tile in one or more points of the surface of the tile. The support also has a rest surface suitable for being positioned completely or only on some points on the surface to be coated.

[0020] The supports can be made of any type of material, preferably plastic material. Preferred plastic materials comprise polymers and/or copolymers such as polypropylene, polyethylene, polystyrene, polyester, polyvinylchloride, polyamide, polyurethane, ABS, polycarbonate, etc. and/or mixtures thereof.

[0021] More preferably, due to the optimum cost/performance ratio, the plastic materials are selected from polypropylene, polyethylene, polystyrene and/or mixtures thereof, as such, and also filled or reinforced.

[0022] The advantage of the above plastic materials is that they provide a mechanically resistant base on which the tiles can be positioned, without excessively increasing the overall weight of the element for coating the surfaces. On the contrary, a suitable choice of the design of the support and materials forming it can result in the production of coating elements which are even lighter than traditional tiles, at the same time guaranteeing an identical tensile strength.

[0023] The support is preferably in the form of a perforated grid, having any form and dimension, to guarantee a homogeneous weight distribution of the tile on it and on the surface to be coated and, in the case of use for floorings, also for a more homogeneous distribution of the additional weight that the elements for coating surfaces must support due to the static weights that can be rested on them (for example furniture) or people walking on top of them.

[0024] An example of a support made of polymeric and/or copolymeric material in the form of a perforated grid which can be used for the purposes of the present invention is illustrated in Figure 1.

[0025] An object of the present invention also relates to the use of an element comprising a tile made of ceramic material and/or natural stone coupled with a support made of polymeric and/or copolymer material for coating surfaces.

[0026] The process for coating surfaces which comprises the application of an element for coating surfaces according to the present invention comprising a tile made of ceramic material and/or natural stone coupled with a support made of polymeric and/or copolymer material, can be effected by means of an activation phase of the thermo-adhesive copolymer interposed between the rest surface of the support and the surface to be coated, by heating to a temperature varying from 70 to 180°C and the subsequent application of said element to the surface to be coated.

[0027] The application of the element to the surface to be coated is favoured by the exertion of a moderate pressure.

[0028] For coupling the tile and support to form the element for coating surfaces, thermo-adhesive copolymers are used, comprising at least one monomeric unit capable of providing the copolymer with thermo-adhesive properties. The monomeric unit is selected from the group of ethyl vinyl acetate, vinyl acetate, acrylic, methacrylic and maleic units.

[0029] The monomeric unit which give the copolymer adhesive properties is present in a concentration varying from 20 to 30% by weight with respect to the total weight of the dry copolymer. When the monomeric unit is ethyl vinyl acetate, the preferred concentration is 25% by weight with respect to the total weight of the dry copolymer.

[0030] The above polymeric compounds are characterized in that, at temperatures close to their melting point, generally within the range of 70°C to 180°C, they have tack properties. The copolymers melt at the melting point, becoming adhesive and capable of chemically binding themselves to various types of materials, including ceramic and/or natural stone surfaces. When the temperature drops to below the melting point, the copolymer solidifies, remaining attached to the material with which it has come into contact.

[0031] Depending on the nature of the tile and that of the support to be coupled, it is possible to select the thermo-adhesive copolymer with the most appropriate chemical properties for obtaining a high adhesion degree and duration of the coupling.

[0032] Copolymers which generally have the best adhesive properties for the purposes of the present invention are those comprising ethyl vinyl acetate units.

[0033] The advantage of copolymers comprising monomeric units of the ethyl vinyl acetate type lies in the temperature at which these become adhesive (80-100°C) and in the high adhesion degree they have with respect to ceramic material and/or natural stone. Furthermore, at these temperatures there is a reduction in both the risks of damage on the decorated part of the tiles and risks of the formation of mechanical stress between the support and tiles, which can be caused by the different duration of the cooling process in the two materials during the application. The different cooling rates are linked to the different heat dispersion capacities of the support and tiles.

[0034] As a result of their chemical nature, the above thermo-adhesive copolymers have a considerable duration and a good resistance to atmospheric agents. This makes them particularly suitable for the production of outside wall surfaces.

[0035] The coupling of the tile to the relative support by means of the thermo-adhesive copolymer can be effected in different ways.

[0036] In a preferred embodiment, the thermo-adhesive copolymer can be used in the form of a "leaflet" or membrane, to be interposed between the tile and the support to be coupled with, which can be made of any polymeric and/or copolymeric material, even non-thermo-adhesive. The subsequent heating to the melting point of the thermo-adhesive copolymer allows the copolymer to be chemically bound to the contact surfaces of the tile and support, allowing them to adhere to each other.

[0037] The copolymer in the form of a membrane can also be used for the application of the support to the surface to be coated, by interposing the membrane between the rest surface of the support and the surface to be coated and activating it by heating.

[0038] The leaflet of thermo-adhesive copolymer, whose thickness depends on the kind of copolymer and desired adhesion degree, can be produced in sheets having various dimensions, for example using casting or "bubble" techniques commonly used for the production of copolymeric film. If necessary, the sheets are then cut into leaflets according to the form and dimension of the support and/or tile to which they are to be applied.

[0039] In another preferred embodiment, the thermo-adhesive copolymer can be applied on the surface of the support during the production process of the support itself by "overmoulding". In this way, the contact surface of the support consists of the thermo-adhesive copolymer. To effect the coupling with the tile, the contact surface of the ceramic or natural stone tile must be rested on the contact surface of the support and heat supplied until the copolymer melts. As a result of the heating, the copolymer melts, chemically binding itself to the two surfaces.

[0040] In all the above procedures for making the copolymer adhesive and effecting the coupling of the tiles with the support, it is not necessary to supply heat directly to the support. It is in fact possible to also supply heat indirectly, for example by heating the coating surface of the tile with a suitable device (for example an infrared-ray device, hot air blower, etc.) The heat accumulated by the tile is then transferred to the underlying contact surface and subsequently to the thermo-adhesive copolymer which, upon melting effects the coupling of the tile with the support.

[0041] In a further preferred embodiment of the present invention, the rest surface of the support can also be produced with a thermo-adhesive copolymer. Alternatively, the thermo-adhesive copolymer can be overmoulded on the rest surface of the support analogously to what is described for the production of the contact surface of the support. The production of the rest surface of the support with a thermo-adhesive copolymer allows the whole element for coating surfaces, i.e. the tile coupled with the support, to be fixed to the surface to be coated by heating and pressure of the element against the surface itself (for example cementitious mass), analogously to what is illustrated for the coupling of the tile with the support.

[0042] By resting the rest surface of the support on the surface to be coated and supplying heat to the element, for example, the melting of the thermo-adhesive copolymer is induced with the consequent adhesion of the element to the surface to be coated, thus allowing the element to remain fixed in its application position.

[0043] In a preferred embodiment of the invention, the form of the contact surface of the support is such as to comprise an edge or frame which occupies the grout line between one tile and the next.

[0044] In the case of square- or rectangular-shaped coating elements, for example, the form of the contact surface of the support can comprise an edge which occupies the grout lines of two adjacent sides of the element, forming an "L". The application of the elements to the surface to be coated is therefore effected by positioning the coating elements so that all the grout lines between one tile and those adjacent to it are occupied by an edge.

[0045] The edge or frame has the surface exposed, i.e. that on the same side as the surface of the tiles having a protective and/or decorative function, made of thermo-adhesive copolymer. The thermo-adhesive copolymer can be applied by overmoulding to the surface of the edge or frame or applied on said surface of the edge or frame as a leaflet having a suitable shape and dimension.

[0046] After heating, during the formation of the coating of a surface, the thermo-adhesive copolymer present on the exposed surface of the edge or frame, chemically binds itself to the tiles, forming a layer which keeps two adjacent tiles coupled, guaranteeing impermeability of the coating to water. The impermeability of the coating thus obtained is much higher than that which can be obtained according to the known art with the use of traditional fillings made of plastic material of the grout lines. As these fillings are only resting and lightly pressed onto the tiles, they do not seal the junction points between one grout line of one side of the tile and that of the adjacent side, thus allowing the penetration of liquids. Furthermore, this plastering operation, necessary for filling the grout lines, is normally extremely dirty and difficult to clean and first requires an interval of 48 hours between the gluing and plastering, followed by a subsequent interval of 24 hours before cleaning at the end of the operation.

[0047] The high impermeability of the coatings obtained with the present invention makes the use of the present invention particularly suitable for the production of coatings in environments where the formation of mildew should be avoided (for example medical environments).

[0048] For the purposes of the present invention, in order to produce coatings having a greater stability, each element for coating surfaces can be also be conveniently provided with connecting means which allow the reciprocal anchoring of elements situated on the surface to be coating in an adjacent position. The connecting means, for example, can be included in the support made of polymeric and/or copolymeric material in the edge which occupies the grout lines between two adjacent tiles, when present.

[0049] Figure 2 illustrates a detail in perspective of an element for coating surfaces (1) comprising a tile (2) coupled with a support (3) by means of a thermo-adhesive copolymer (4), connecting means (5 and 6) and an edge (7) which occupies the grout lines between adjacent tiles. In the case illustrated in Figure 2, the connecting means consist of two connecting elements (5 and 6): the first connecting element (5) is wedge-shaped and is part of the support, from which it protrudes with respect to the rest surface of the support itself; the second connecting element (7) consists of a cavity, suitably shaped for coupling by insertion with the connecting element (5) belonging to a second support (not shown), said cavity being situated inside the edge (7). The edge (7) has a surface made of thermo-adhesive copolymer which can be activated by heating (8) (for example a leaflet of a thermo-adhesive copolymer).

[0050] Figure 3 shows a sectional view of two elements for coating surfaces connected by means of the connecting means illustrated in Figure 2.

[0051] An object of the present invention also relates to a kit for producing one or more coating elements comprising at least one tile made of ceramic material and/or natural stone, a support made of polymeric and/or copolymeric material and a thermo-adhesive copolymer capable of coupling the tile to the support by contemporaneously adhering to the contact surface of the tile and contact surface of the support.

[0052] Alternatively, the kit can be prepared for the production of a coating of a surface. In this case, the kit comprises at least one element for coating surfaces, said element comprising a tile made of ceramic material and/or natural stone coupled by means of a thermo-adhesive copolymer to a support made of polymeric and/or copolymeric material, and optionally a thermo-adhesive copolymer capable of coupling said element to the surface to be coated.

[0053] There are numerous advantages offered by the element for coating surfaces according to the present invention with respect to the state of the art.

[0054] Unlike the elements for coating surfaces known in the state of the art in which the tile and support are kept separate, the coupling of the tile to the support by means of a thermo-adhesive copolymer according to the present invention allows surfaces to be coated efficiently, rapidly and simply.

[0055] One of the advantages of the present invention lies in the fact that the coating of the surfaces coated with the elements according to the present invention is firmly fixed, both when the coating is effected by means of a thermo-adhesive copolymer placed between the rest surface of the support and the surface to be coated, and also when the elements on the surface to be coated are only reciprocally connected (in the case of floorings). Furthermore, the coating tiles remain perfectly anchored to the support without the possibility of any movement and without being subject to vibrations.

[0056] In the case of vertical walls, the connecting system in a frame is substituted by insertion connections of the "male/female" type. The elements for coating surfaces are applied to a rest base, fixed to the wall to be coated, comprising a sheet made of plastic material, for example of the same kind used for the support of the element. The sheet made of plastic material are drilled, the holes being the connecting means capable of coupling by insertion with the connecting means of the coating element. The sheet can be fixed both directly to the wall and also, by means of separators again made of plastic material, at a sufficient distance for forming a hollow space which allows the passage of wires, tubes or the like.

[0057] The coated surfaces which can be obtained with the present invention are also resistant to severe environmental conditions, for example under the action of atmospheric agents, thus proving to be ideal for coating not only internal wall surfaces but also outside wall surfaces of buildings.

[0058] The possibility of gluing an element according to the present invention to a surface to be coated by the simple heating of said element also allows the coating to be easily effected by inexpert persons.

[0059] Furthermore, due to the fact that the element according to the present invention can be glued to the surface to be coated, it is also possible to coat vertical surfaces simply and rapidly.

[0060] Another advantage is linked to the possibility of using thermo-adhesive copolymers of different chemical natures in relation to the material of which the tile is made and the support to be coupled.

[0061] A further advantage derives from the possibility of creating complex modules by pre-assembling various tiles coupled with the respective supports forming three-dimensional structures, having any shape or dimension, which are subsequently applied to the surfaces to be coated according to the application techniques described above. The complex modules can also comprise further decorative or functional elements for the coating of a surface. It is possible, for example, to produce preassembled structures of the type: (i) walls or floors to be applied in small environments, such as hotel bathrooms; (ii) stair steps; (iii) floors comprising coating elements coupled with skirting boards; (iv) mosaic-type decorations of any size; (v) floors comprising coating elements coupled with fairleads or other pipings which can be used in the field of restructuring, avoiding building works with supporting elements or the like.

Claims

1. An element for coating surfaces comprising a tile made of a ceramic material and/or natural stone coupled with a support made of polymeric and/or copolymeric material wherein:

- said tile has at least one contact surface;

- said support has at least one contact surface and a rest surface;

said element being characterized in that the tile is coupled with the support by means of a thermo-adhesive copolymer which contemporaneously adheres to the contact surface of the tile and the contact surface of the support.

2. The element for coating surfaces according to claim 1, wherein the thermo-adhesive copolymer is activated by heating to a temperature varying from 70 to 180°C, preferably from 80 to 100°C.

3. The element for coating surfaces according to claim 1 or 2, wherein the thermo-adhesive copolymer is a copolymer comprising at least one monomeric unit selected from the following group of units: ethyl vinyl acetate, vinyl acetate, acrylic, methacrylic, maleic and/or mixtures thereof, preferably the ethyl vinyl acetate unit.

4. The element for coating surfaces according to claim 3, wherein the monomeric unit is present in a concentration varying from 20 to 30% by weight with respect to the total weight of the dry copolymer.

5. The element for coating surfaces according to claim 3, wherein the monomeric unit is ethyl vinyl acetate in a concentration equal to about 25% by weight with respect to the total weight of the dry copolymer.

6. The element for coating surfaces according to any of the claims from 1 to 5, wherein the support is a polymer and/or copolymer selected from polypropylene, polyethylene, polystyrene, polyester, polyvinylchloride, polyamide, polyurethane, ABS, polycarbonate, and/or mixtures thereof, it is preferably polypropylene, polyethylene, polystyrene and/or mixtures thereof.

7. The element for coating surfaces according to any of the claims from 1 to 6, wherein the support made of polymeric and/or copolymeric material is in the form of a grid.

8. The element for coating surfaces according to any of the claims from 1 to 7, wherein the contact surface of the support consists of a thermo-adhesive copolymer comprising at least one monomeric unit selected from the following group of units: ethyl vinyl acetate, vinyl acetate, acrylic, methacrylic, maleic and/or mixtures thereof, preferably the ethyl vinyl acetate unit.

9. The element for coating surfaces according to any of the claims from 1 to 7, wherein the contact surface and the rest surface of the support consist of a thermo-adhesive copolymer comprising at least one monomeric unit selected from the following group of units: ethyl vinyl acetate, vinyl acetate, acrylic, methacrylic, maleic and/or mixtures thereof, preferably the ethyl vinyl acetate unit.

10. The element for coating surfaces according to claim 9, wherein the contact surface and the rest surface of the support consist of the same thermo-adhesive copolymer.

11. The element for coating surfaces according to claim 9, wherein the contact surface and the rest surface of the support consist of different thermo-adhesive copolymers.

12. The element for coating surfaces according to any of the claims from 1 to 11, wherein the polymeric support comprises connecting means suitable for fixing said element to at least a further element adjacent thereto also equipped with connecting means.

13. Use of an element according to any of the claims from 1 to 12 for coating surfaces.

14. A process for coating surfaces which comprises the application of an element according to any of the claims from 1 to 12, characterized by an activation phase of the thermo-adhesive copolymer interposed between the rest surface of the support and the surface to be coated, by heating to a temperature ranging from 70 to 180°C and the subsequent application of said element to the surface to be coated.

15. A coated surface comprising at least one element for coating surfaces, said element comprising a tile made of ceramic material and/or natural stone coupled, by means of a thermo-adhesive copolymer with a support made of polymeric and/or copolymeric material, characterized in that:

- said support has a rest surface,

- said rest surface is coupled with the surface to be coated by means of a thermo-adhesive copolymer which adheres contemporaneously to the rest surface of the support and the surface to be coated.

16. A coated surface comprising at least one coating element according to any of the claims from 1 to 12, said element comprising a tile made of ceramic material and/or natural stone coupled, by means of a thermo-adhesive copolymer, with a support made of polymeric and/or copolymeric material, characterized in that:

- said support has a rest surface,

- said rest surface is coupled with the surface to be coated by means of a thermo-adhesive copolymer which adheres contemporaneously to the rest surface of the support and the surface to be coated.

17. A coated surface comprising at least two coating elements, wherein:

- each element comprises a tile made of ceramic material and/or natural stone coupled, by means of a thermo-adhesive copolymer, with a support made of polymeric and/or copolymeric material, said support having a rest surface;

- each element is equipped with connecting means suitable for fixing said element to at least a further element adjacent to it, also equipped with connecting means;

said coated surface being characterized in that each element is connected to at least a second element adjacent to it.

18. A coated surface comprising at least two coating elements according to any of the claims from 1 to 12, wherein:

- each element comprises a tile made of ceramic material and/or natural stone coupled, by means of a thermo-adhesive copolymer, with a support made of polymeric and/or copolymeric material, said support having a rest surface;

- each element is equipped with connecting means suitable for fixing said element to at least a further element adjacent to it, also equipped with connecting means;

said coated surface being characterized in that each element is connected to at least a second element adjacent to it.

19. The coated surface according to any of the claims 17 or 18, wherein each element is equipped with connecting means suitable for fixing said element to at least a further element adjacent to it, also equipped with connecting means.

20. A kit for producing one or more coating elements according to any of the claims from 1 to 12 comprising at least one tile made of ceramic material and/or natural stone, a support made of polymeric and/or copolymeric material and a thermo-adhesive copolymer capable of coupling the tile to the support by adhering contemporaneously to the contact surface of the tile and the contact surface of the support.

21. A kit for producing a coating surface comprising at least one coating element according to any of the claims from 1 to 12 and, optionally, a thermo-adhesive copolymer capable of coupling said element to the surface to be coated.

Drawing