# US 12,179,457 B2 · Composite structure for applying tiles to a surface, and systems and methods of using same

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- Number: US 12,179,457 B2
- Document ID: US12179457B2
- Status: Granted
- Kind: B2
- Application number: 16/787,694
- Filed: 2020-02-11
- Published: 2020-08-13
- Granted: 2024-12-31
- Earliest claimed: 2019-02-11
- Assignees: Columbia Insurance Company
- Applicants: Columbia Insurance Company
- Inventors: Thomas Odum; James Burns
- Web page: https://patentgrep.com/patent/US12179457B2

## CPC

- B32B 13/04: comprising such {water setting} substance as the main or only constituent of a layer, {which is} next to another layer of {the same or of} a {different material (next to a glass layer B32B17/06)}
- C04B 28/04: Portland cements
- B32B 3/04: characterised by {at least one} layer folded at the edge, e.g. over another layer {; characterised by at least one layer enveloping or enclosing a material}
- B32B 5/022: {Non-woven fabric}
- B32B 5/024: {Woven fabric}
- B32B 5/026: {Knitted fabric}
- B32B 5/028: {Net structure, e.g. spaced apart filaments bonded at the crossing points}
- B32B 5/08: the fibres or filaments of a layer being of different substances {, e.g. conjugate fibres, mixture of different fibres}
- B32B 5/10: characterised by a fibrous {or filamentary} layer reinforced with filaments
- B32B 5/26: another layer {next to it} also being fibrous or filamentary {(relative arrangement of fibres or filaments of different layers B32B5/12)}
- B32B 7/12: using interposed adhesives or interposed materials with bonding properties
- B32B 9/002: {comprising natural stone or artificial stone}
- B32B 9/005: {comprising one layer of ceramic material, e.g. porcelain, ceramic tile (layered products with at least two ceramic layers composed mainly of ceramic B32B18/00)}
- B32B 9/04: comprising such {particular} substance as the main or only constituent of a layer, {which is} next to another layer of {the same or of} a {different material (next to a glass layer B32B17/06; layered products with at least two ceramic layers composed mainly of ceramic B32B18/00)}
- B32B 9/047: {made of fibres or filaments}
- B32B 13/02: with fibres or particles {being present as additives in the layer}
- B32B 13/14: next to a fibrous or filamentary layer
- B32B 19/04: next to another layer of {the same or of} a {different material (next to a glass layer B32B17/067)}
- B32B 19/06: next to a fibrous or filamentary layer
- B32B 21/10: Next to a fibrous or filamentary layer
- B32B 37/10: characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
- C04B 7/02: Portland cement
- C04B 11/00: Calcium sulfate cements
- C04B 20/0048: {Fibrous materials}
- C04B 28/14: containing calcium sulfate cements {(gypsum-paper plates E04C)}
- C04B 30/02: containing fibrous materials
- C04B 37/008: {by means of an interlayer consisting of an organic adhesive, e.g. phenol resin or pitch}
- E04F 15/02155: {Adhesive means specially adapted therefor, e.g. adhesive foils or strips}
- B32B 2260/021: Fibrous or filamentary layer
- B32B 2260/044: Water-setting substance, e.g. concrete, plaster
- B32B 2262/0246: Acrylic resin fibres
- B32B 2262/0253: Polyolefin fibres
- B32B 2262/0261: Polyamide fibres
- B32B 2262/0276: Polyester fibres
- B32B 2262/0292: Polyurethane fibres
- B32B 2262/101: Glass fibres
- B32B 2262/12: Conjugate fibres, e.g. core/sheath or side-by-side
- B32B 2262/14: Mixture of at least two fibres made of different materials
- B32B 2307/7163: Biodegradable
- B32B 2307/718: Weight, e.g. weight per square meter
- B32B 2307/732: Dimensional properties
- B32B 2419/00: Buildings or parts thereof
- B32B 2419/04: Tiles for floors or walls
- C04B 2111/00637: {as glue or binder for uniting building or structural materials}
- C04B 2111/60: Flooring materials
- C04B 2235/5252: having a specific pre-form
- C04B 2237/341: Silica or silicates
- C04B 2237/38: Fiber or whisker reinforced
- E04F 13/0887: {Adhesive means specially adapted therefor, e.g. adhesive foils or strips}
- E04F 13/142: {with an outer layer of ceramics or clays}
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE
- E04F: FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS (windows, doors E06B)

## Abstract

A composite structure for use in tiling surfaces is disclosed. The composite structure can include a fiber matrix impregnated with a water-activated setting material. The composite structure can be wet and then compressed between a tile and an application surface. The composite structure can cure to provide a support surface for the tile.

## Claims

### Claim 1

A composite structure having respective upper and lower surfaces and a circumferential outer surface extending between the upper and lower surfaces, the composite structure comprising:
a fiber matrix having a first side, a second side, and a circumferential edge that extends between the first side and the second side of the fiber matrix;
a water-activated setting material, wherein the fiber matrix is impregnated with the water-activated setting material; and
a scrim that holds the water-activated setting material in engagement with the fiber matrix, wherein the scrim circumferentially surrounds and covers the circumferential edge of the fiber matrix and defines at least a portion of the circumferential outer surface of the composite structure,
wherein the fiber matrix and water-activated setting material define the upper and lower surfaces of the composite structure,
wherein the composite structure is deformable prior to setting of the water-activated setting material so that the lower surface of the composite structure conforms to an underlying application surface.

### Claim 2 (depends on 1)

The composite structure of claim 1, wherein the composite structure has an uncompressed thickness between two millimeters and twenty millimeters.

### Claim 3 (depends on 1)

The composite structure of claim 1, wherein the fiber matrix comprises a nonwoven material.

### Claim 4 (depends on 3)

The composite structure of claim 3, wherein the nonwoven material comprises a nonwoven batt comprising fibers having a denier ranging from 4 to 150, wherein the fibers are positioned in an open pattern.

### Claim 5 (depends on 3)

The composite structure of claim 3, wherein the fiber matrix comprises fibers in a velour pattern.

### Claim 6 (depends on 3)

The composite structure of claim 3, wherein the fiber matrix comprises at least one of a three-dimensional spunbond, a three-dimensional woven fabric, or a three-dimensional knitted fabric.

### Claim 7 (depends on 1)

The composite structure of claim 1, wherein the water-activated setting material comprises Portland cement or gypsum.

### Claim 8 (depends on 1)

The composite structure of claim 1, wherein the water-activated setting material is configured to set within five to ninety minutes of application of water to the water-activated setting material.

### Claim 9 (depends on 1)

The composite structure of claim 1, wherein the composite structure has an uncompressed thickness, and wherein the composite structure is deformable by at least 25-50% of its uncompressed thickness.

### Claim 10

A tile assembly comprising:
a tile defining a top surface and a bottom surface, wherein the tile is a ceramic tile, a porcelain tile, a concrete tile, a natural stone tile, or a quartz tile; and
a composite structure having respective upper and lower surfaces and comprising:
a fiber matrix; and
a water-activated setting material, wherein the fiber matrix is impregnated with the water-activated setting material,
wherein the composite structure is deformable prior to setting of the water-activated setting material so that the lower surface of the composite structure conforms to an underlying application surface,
wherein the tile is directly bonded, by the water-activated setting material, to the composite structure.

### Claim 11 (depends on 10)

The tile assembly of claim 10, wherein the tile is a ceramic tile.

### Claim 12 (depends on 10)

The tile assembly of claim 10, further comprising a hot-melt glue that bonds the tile to the composite structure.

### Claim 13 (depends on 3)

The composite structure of claim 3, wherein the fiber matrix comprises a melamine sponge.

### Claim 14 (depends on 10)

The tile assembly of claim 10, wherein the composite structure has a circumferential outer surface extending between the upper and lower surfaces, wherein the fiber matrix has a first side, a second side, and a circumferential edge that extends between the first side and the second side of the fiber matrix, and wherein the composite structure further comprises a scrim that holds the water-activated setting material in engagement with the fiber matrix, wherein the scrim circumferentially surrounds and covers the circumferential edge of the fiber matrix and defines at least a portion of the circumferential outer surface of the composite structure.

### Claim 15 (depends on 1)

The composite structure of claim 1, wherein the fiber matrix comprises at least one post-consumer carpet material.