Composite tile systems and methods

Abstract

Composite tile systems and methods are disclosed. Embodiments of this disclosure can comprise a composite floor tile having a ceramic upper layer with one or more reinforcing layers. The reinforcing layer or layers can comprise a reinforcing material, such as fiberglass, and an adhesive. An under layer can be disposed under, or integrated with, the reinforcing layer, and can comprise a ceramic or a polymer laminate. A bottom layer can comprise a pressure sensitive adhesive, or other adhering system, that attaches to various substrates. Embodiments of this disclosure can improve ease of installation of tile, improve strength of tile, and reduce the weight of tile, among other advantages.

What is claimed is: 
     
         1 . A composite tile comprising:
 an upper layer defining the top of the tile;   an under layer disposed under the upper layer; and   a reinforcing layer disposed between the upper layer and the under layer.   
     
     
         2 . The composite tile of  claim 1 , the reinforcing layer comprising fiberglass. 
     
     
         3 . The composite tile of  claim 2 , the reinforcing layer further comprising an adhesive. 
     
     
         4 . The composite tile of  claim 1 , the reinforcing layer comprising at least one of fiberglass, short strand fibers, carpet fibers, and carbon fibers. 
     
     
         5 . The composite tile of  claim 1 , the upper layer and the under layer comprising a ceramic and the reinforcing layer comprising fiberglass and a hot melt adhesive. 
     
     
         6 . The composite tile of  claim 5 , the upper layer and the under layer having the same thickness and the reinforcing layer being thinner than the upper layer and the under layer. 
     
     
         7 . The composite tile of  claim 1 , the upper layer comprising a ceramic and the under layer comprising a polymer laminate. 
     
     
         8 . The composite tile of  claim 7 , the polymer laminate having an embedded filler, the filler comprising at least one of cork, crumb rubber, carpet fibers, and chalk. 
     
     
         9 . The composite tile of  claim 7 , the polymer laminate being a rigid polymer laminate. 
     
     
         10 . The composite tile of  claim 1 , the upper layer comprising porcelain that includes at least one of mullite, kyanite, calcined alumina, and high temperature refractory materials. 
     
     
         11 . The composite tile of  claim 1 , further comprising a bottom layer disposed under the under layer, the bottom layer comprising at least one of a pressure sensitive adhesive, a cork-polymer, and an interlocking fabric. 
     
     
         12 . The composite tile of  claim 1 , further comprising a bottom layer disposed under the under layer, the bottom layer comprising a pressure sensitive double-sided tape. 
     
     
         13 . The composite tile of  claim 1 , further comprising a bottom layer disposed under the under layer, the bottom layer comprising extended edges that extend horizontally beyond the upper layer. 
     
     
         14 . The composite tile of  claim 1 , wherein the upper layer comprises porcelain and is about 3 mm thick, the under layer comprises porcelain and is about 3 mm thick, and the reinforcing layer comprises fiberglass and is about 1 mm thick. 
     
     
         15 . The composite tile of  claim 1 , wherein the reinforcing layer is about 1 mm or less thick. 
     
     
         16 . A composite tile comprising:
 a first, upper layer defining the top of the tile;   a second, reinforcing layer under the upper layer, the second layer comprising fiberglass and a polymer laminate.   
     
     
         17 . The composite tile of  claim 16 , further comprising:
 a bottom layer disposed under the second, reinforcing layer, the bottom layer comprising at least one of a pressure sensitive adhesive, a cork-polymer, and an interlocking fabric.   
     
     
         18 . A method of manufacturing composite tile comprising:
 providing an upper layer;   providing a reinforcing layer on a bottom side of the upper layer;   hot pressing the upper layer and the reinforcing layer together.   
     
     
         19 . The method of  claim 18 , further comprising providing an under layer on a bottom side of the reinforcing layer, and wherein the hot pressing of the upper layer and the reinforcing layer together includes hot pressing the upper layer, the reinforcing layer, and the under layer together. 
     
     
         20 . The method of  claim 18 , wherein providing a reinforcing layer comprises providing an adhesive and providing a reinforcing material onto and into the adhesive.