IP Library › Granted Patent US 11,858,248
Granted Patent B2
US 11,858,248 · App. 17/438,711 · Granted Jan 2, 2024

Thermoplastic simulated tile

Inventors: Cory Bates (Arlington, TX); William Peck (Arlington, TX)
Assignee: Safety Tubs Company, LLC.
B32B7/023B29C48/08B29C48/21B32B3/266B32B27/08B32B27/302B32B27/308E04F15/02161E04F15/105E04F15/163B29K2101/12B29K2995/002B29L2007/002B29L2009/00B32B2250/246B32B2307/402B32B2307/412B32B2307/732B32B2419/04
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Quick Facts
Patent No.
US 11,858,248
App. No.
17/438,711
Granted
Jan 2, 2024
Kind
B2
Abstract

A multilayer thermoplastic sheet, comprising a first colored thermoplastic layer; a second colored thermoplastic layer; and a third colored thermoplastic layer; wherein at least one of the colored layers is a different color than at least one of the other two colored layers; and a multilayer thermoplastic sheet, wherein the sheet has a total thickness of from about 0.125 inches to about 0.500 inches, and a plurality of lines cut into the surface at depth of from about 0.010 inches to about 0.080 inches. Lines may be cut into a multilayer thermoplastic sheet via computer numerical control (CNC) routing to simulate ceramic tile.

Claims (45)

1. A multilayer thermoplastic sheet, comprising

a first colored thermoplastic layer;

a second colored thermoplastic layer; and

a third colored thermoplastic layer,

wherein

the color of the first colored layer is different than the color of the second colored layer;

and/or the color of the second colored layer is different than the color of the third colored layer,

the multilayer sheet comprises a plurality of grout lines cut into the sheet extending through the first colored layer and partially into the second colored layer, and

the plurality of grout lines are cut into the thermoplastic sheet at a depth from about 0.010 inches to about 0.080 inches.

2. The multilayer thermoplastic sheet according to claim 1 , comprising

a cap layer and/or a base layer; and

a clear and/or tinted layer.

3. The multilayer thermoplastic sheet according to claim 1 , comprising a layer having a printed pattern.

4. The multilayer thermoplastic sheet according to claim 1 , wherein

the color of the first colored layer is identical to the color of the second colored layer; or

the color of the second colored layer is identical to the color of the third colored layer.

5. The multilayer thermoplastic sheet according to claim 1 , wherein a total thickness of the multilayer sheet is from about 0.080 inches to about 0.500 inches.

6. The multilayer thermoplastic sheet according to claim 1 , wherein the third colored layer comprises acrylonitrile-butadiene-styrene copolymer, and the first colored layer and the second colored layer comprise polymethylmethacrylate.

7. The multilayer thermoplastic sheet according to claim 1 , wherein a thickness of the second colored layer remaining in the grout lines is from about 0.002 inches to about 0.018 inches.

8. The multilayer thermoplastic sheet according to claim 1 , wherein a width of the grout lines is from about 0.070 inches to about 0.375 inches.

9. The multilayer thermoplastic sheet according to claim 1 , wherein

the first colored layer has a thickness of from about 7% to about 18% of a total sheet thickness;

the second colored layer has a thickness of from about 7% to about 26% of a total sheet thickness; and

the third colored layer has a thickness of from about 56% to about 86% of a total sheet thickness.

10. The multilayer thermoplastic sheet according to claim 1 , wherein one or more colored layers are white, grey, or black.

11. A method of preparing a multilayer thermoplastic sheet according to claim 1 , the method comprising one or more co-extrusion or co-lamination processes, and comprising computer numerical control (CNC) routing.

12. A multilayer thermoplastic sheet, comprising

a first colored thermoplastic layer; and

a second colored thermoplastic layer,

wherein

the sheet has a total thickness of from about 0.125 inches to about 0.500 inches, a plurality of lines cut into the surface at depth of from about 0.010 inches to about 0.080 inches,

the plurality of cut lines extend partially into the first colored layer and a thickness of the first colored layer remaining in the lines is from about 0.002 inches to about 0.018 inches, and

a width of the cut lines is from about 0.070 inches to about 0.375 inches.

13. The multilayer thermoplastic sheet according to claim 12 , comprising

a cap layer and/or a base layer; and

a clear and/or tinted layer.

14. The multilayer thermoplastic sheet according to claim 12 , comprising a layer having a printed pattern.

15. The multilayer thermoplastic sheet according to claim 12 , wherein the color of the first colored layer is identical to the color of the second colored layer.

16. The multilayer thermoplastic sheet according to claim 12 , wherein the color of the first colored layer is different than the color of the second colored layer.

17. The multilayer thermoplastic sheet according to claim 12 , wherein

the first colored layer has a thickness of from about 7% to about 26% of the sheet total thickness; and

the second colored layer has a thickness of from about 74% to about 93% of the sheet total thickness.

18. The multilayer thermoplastic sheet according to claim 12 , wherein one or more colored layers are white, grey, or black.

19. The multilayer thermoplastic sheet according to claim 12 , wherein the first colored layer and the second colored layer comprise polymethylmethacrylate.

20. A method of preparing a multilayer thermoplastic sheet according to claim 12 , the method comprising one or more co-extrusion or co-lamination processes, and computer numerical control (CNC) routing.