Ceramic tile and method of making and using the same

Patent metadata

Field	Value
Publication number	US-9506254-B2
Application number	US-201414562967-A
Country	US
Kind code	B2
Filing date	Dec 8, 2014
Priority date	Dec 26, 2013
Publication date	Nov 29, 2016
Grant date	Nov 29, 2016

Abstract

A ceramic tile includes an opening that is used to help fasten the ceramic tile to a mounting object. The opening can have a relatively small width that can obviate the need for a cap and can allow for less abrading of a polymer compound that is exposed adjacent to a major surface of the ceramic tile. In an embodiment, an insert is placed into the opening in the ceramic tile, and the ceramic tile is fastened to a wall using a welding technique. In other embodiments, different shapes of openings and fastening techniques can be used.

First claim

What is claimed is:

1. An apparatus comprising:
a mounting object having a mounting surface;
a ceramic tile:
having a front surface and a back surface opposite the front surface, wherein the back surface is closer to the mounting surface than the front surface; and
defining a first opening extending through an entire thickness of the ceramic tile, wherein the first opening has a sidewall including a tapered portion and a maximum width of no greater than 1.15 cm;

a non-threaded fastener within a portion of the first opening and having a proximal end, a distal end, and a bore extending completely through the non-threaded fastener,
wherein:
the proximal end is closer to the mounting surface than the distal end;
the non-threaded fastener comprises an insert extending beyond the back surface of the tile such that the proximal end of the non-threaded fastener is closer to the mounting surface than the back surface of the tile and comprises a welding compound under the insert; and
an inner wall of the non-threaded fastener defining the bore is linear through the bore in a cross-sectional view of the non-threaded fastener,

wherein a cap is not included in the first opening.

2. The apparatus of claim 1 , wherein the first opening has a maximum width of no greater than 0.90 cm.

3. The apparatus of claim 1 , further comprising a polymer filled in all remaining portion of the first opening and adjacent to the distal end.

4. The apparatus of claim 3 , wherein the polymer comprises an epoxy, a rubber compound, a polysiloxane, or a combination thereof.

5. The apparatus of claim 1 , wherein a wall thickness of the non-threaded fastener is constantly uniform along a depth of the bore.

6. The apparatus of claim 5 , further comprising a welding compound placed in the bore of the non-threaded fastener.

7. The apparatus of claim 1 , wherein the non-threaded fastener has an outer surface that complements an inner surface within the tapered portion of the first opening.

8. The apparatus of claim 1 , wherein the non-threaded fastener comprises a thermally conductive material.

9. The apparatus of claim 1 , wherein the non-threaded fastener extends within the first opening for at least 40% to not greater than 90% of a depth of the first opening.

10. The apparatus of claim 1 , wherein the insert has a maximum outer width at least 0.30 cm and no greater than 0.80 cm.

11. The apparatus of claim 1 , wherein the first opening further includes a straight portion, wherein the back surface is closer to the tapered portion than the straight portion and the front surface is closer to the straight portion than the tapered portion.

12. The apparatus of claim 1 , wherein the tapered portion extends along substantially an entire depth of the first opening.

13. A method of installing a ceramic tile comprising:
providing a ceramic tile having a front surface and a back surface opposite the front surface, wherein the ceramic tile defines a first opening extending through an entire thickness of the ceramic tile, and the first opening has a maximum width of no greater than 1.15 cm,
positioning the ceramic tile at a desired location with respect to a mounting surface of a mounting object, such that the back surface of the ceramic tile faces the mounting surface;
placing a fastener into a portion of the first opening, wherein the fastener comprises an insert extending beyond the back surface of the tile such that an end of the insert is closer to the mounting surface than the back surface of the tile and comprises a welding compound under the insert;
fastening the ceramic tile to the mounting object, wherein fastening comprises welding the fastener to the mounting surface; and
filling all remaining portion of the first opening with a polymer after fastening the ceramic tile to the mounting object.

14. The method of claim 13 , wherein the fastener comprises a bore extending completely through the fastener.

15. The method of claim 14 , wherein fastening comprises placing the welding compound in the bore of the fastener.

16. The method of claim 15 , wherein the welding compound flows such that a portion of the welding compound is directly under the fastener.

17. The method of claim 15 , wherein the welding compound fills at least 30% and no more than 95% of the bore.

18. The method of claim 15 , wherein the polymeric comprises an electrically conductive or electrically resistive material.

19. The method of claim 15 , wherein the fastener is thermally conductive and helps to dissipate heat during welding to reduce a thermal gradient within the ceramic tile.

20. The method of claim 15 , wherein the fastener is non-threaded.

Assignees

• Saint-Gobain Ceram & Plastics Inc

Inventors

• Hilk Brian A

Classifications

• Y10T428/24273

  including aperture · CPC title

• B28B7/186

  for plates, panels or similar sheet- or disc-shaped objects, also flat oblong moulded articles with lateral openings, e.g. panels with openings for doors or windows, grated girders · CPC title

• E04F13/142 Primary

  with an outer layer of ceramics or clays · CPC title

• E04F13/0837

  extending completely through the covering elements · CPC title