Surface-covering article used to produce seamless surface coverings

Abstract

A surface-covering article used to produce surface coverings is described. The surface-covering article includes a plurality of tiles disposed adjacent to each other. A first layer made of a first type of resin is applied to one side of the plurality of tiles. A second layer made of a second type of resin is applied to and around another side of the plurality of tiles and into any gap between adjacent tiles to enclose the plurality of tiles within the first and second layers of resin. The second type of resin of the second layer of resin bonds with the first type of resin of the first layer to join the resin layers permanently to each other and to the enclosed plurality of tiles, thereby producing a seamless surface-covering article made of multiple encapsulated tiles and having a continuous surface of resin that seals said any gap between adjacent tiles.

1 . A surface-covering article, comprising: 
 a plurality of tiles disposed adjacent to each other;    a first layer made of a first type of resin, the first layer of resin being applied to one side of the plurality of tiles; and    a second layer made of a second type of resin, the second layer of resin being applied to and around another side of the plurality of tiles and into any gap between adjacent tiles to enclose the plurality of tiles within the first and second layers of resin, the second type of resin of the second layer of resin bonding with the first type of resin of the first layer to join the resin layers permanently to each other and to the enclosed plurality of tiles, thereby producing a seamless surface-covering article made of multiple encapsulated tiles and having a continuous surface of resin that seals said any gap between adjacent tiles.    
   
   
       2 . The surface-covering article of  claim 1 , further comprising a layer of reinforcing material disposed between the first layer of resin and second layer of resin to distribute a load force throughout the layer of reinforcing material when the load force is applied to the surface-covering article.  
   
   
       3 . The surface-covering article of  claim 2 , wherein the layer of reinforcing material is porous to allow bonding of the first type of resin of the first layer to the second type of resin of the second layer through the reinforcing material.  
   
   
       4 . The surface-covering article of  claim 2 , wherein the layer of reinforcing material comprises fiberglass.  
   
   
       5 . The surface-covering article of  claim 2 , wherein the layer of reinforcing material comprises a fine-spun fiberglass.  
   
   
       6 . The surface-covering article of  claim 2 , wherein the layer of reinforcing material comprises a decorative pattern.  
   
   
       7 . The surface-covering article of  claim 2 , further comprising a layer of decorative material disposed between the first layer and the second layer.  
   
   
       8 . The surface covering article of  claim 7 , wherein the layer of reinforcing material is porous to allow bonding of the first type of resin of the first layer to the second type of resin of the second layer through the decorative material.  
   
   
       9 . The surface-covering article of  claim 1 , wherein each tile includes decorative material.  
   
   
       10 . The surface-covering article of  claim 1  wherein the first type of resin and the second type of resin are each selected from the group consisting of phenols, saturated polyesters, unsaturated polyesters, polymers, methylmethacrylates, acrylics, bisphenols, isophthatics, orthophthalics, terephalics, thrixotropics, non-thrixotropics, bisphenol fumerates, urethanes, thermoplastics, and epoxies.  
   
   
       11 . The surface-covering article of  claim 1 , wherein the first type of resin of the first layer and the second type of resin of the second layer are of the same type of resin base.  
   
   
       12 . A surface covering comprising: 
 a resin-based slurry layer disposed on a surface; and    a surface-covering article set in the slurry layer, the surface-covering article including a plurality of tiles disposed adjacent to each other, a first layer of resin applied to one side of the plurality of tiles, a second layer of resin applied to and around another side of the plurality of tiles and into any gap between adjacent tiles to enclose the plurality of tiles within the first and second layers of resin, the second layer of resin bonding with the first type of resin of the first layer to join the resin layers permanently to each other and to the enclosed plurality of tiles.    
   
   
       13 . The surface covering of  claim 12 , wherein each tile of the surface-covering article comprises a top surface, a bottom surface, and a reinforcing layer disposed between the top surface and the bottom surface.  
   
   
       14 . The surface covering of  claim 12 , wherein each tile of the surface-covering article comprises a top surface, a bottom surface, and decorative material disposed between the top surface and the bottom surface.  
   
   
       15 . The surface covering of  claim 12 , further comprising a resin-based top coat applied to the surface-covering article, the resin-based top coat bonding to the resin-based slurry layer and to the surface-covering article, to encapsulate the surface-covering article within the top coat and slurry layer.  
   
   
       16 . A surface covering comprising: 
 a surface-covering article including a plurality of tiles disposed adjacent to each other, a first layer of resin applied to one side of the plurality of tiles, a second layer of resin applied to and around another side of the plurality of tiles and into any gap between adjacent tiles to enclose the plurality of tiles within the first and second layers of resin, the second layer of resin bonding with the first type of resin of the first layer to join the resin layers permanently to each other and to the enclosed plurality of tiles; and    a resin-based top coat applied to the surface-covering article, the top coat bonding to and encapsulating the surface-covering article.    
   
   
       17 . The surface covering of  claim 16 , wherein each tile of the surface-covering article comprises a top surface, a bottom surface, and a reinforcing layer disposed between the top surface and the bottom surface.  
   
   
       18 . The surface covering of  claim 16 , wherein each tile of the surface-covering article comprises a top surface, a bottom surface, and decorative material disposed between the top surface and the bottom surface.