DESC:FORM 2

THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENTS RULES, 2003

COMPLETE SPECIFICATION
[See section 10, Rule 13]

A METHOD OF MANUFACTURING COLORED
GLASS REINFORCED COMPOSITE TILES;

ARVIND LIMITED, A COMPANY INCORPORATED UNDER THE COMPANIES ACT, 1956, WHOSE ADDRESS IS NARODA ROAD, AHMEDABAD -380025, GUJARAT, INDIA

THE FOLLOWING SPECIFICATION PARTICULARLY DESCRIBES THE INVENTION AND THE MANNER IN WHICH IT IS TO BE PERFORMED.

Field of the invention
The present invention relates generally to a method ofmanufacturing composite tiles and more particularly, to a method of manufacturing colored glass reinforced composite tiles.

Background of the invention
Tiles are often used to form wall and floor coverings, and can range from simple square tiles to complex mosaics. Tiles are most often made of ceramic, typically glazed for internal uses and unglazed for roofing, but other materials are also commonly used, such as glass, cork, concrete and other composite materials, and stone.
A conventional process of manufacturing ceramic tiles involvesvarious stepssuch as batching, mixing and grinding, spray drying, forming, drying, glazing and firing.Several pollutants are generated during the various manufacturing stepssuch as fluoride and lead compounds,which are generated during the firing and glazing processes. Further, wastewater and sludge are alsoproduced during milling, glazing, and spray-drying.The waste water and sludge may contain micro-pollutants, which, if not disposed properly, may cause pollution.A manufacturer that manufactures the abovementioned ceramic products needs to control emission of the pollutants in order to meet air and water pollution control standards.
Further, the conventionalproduction process also faces several disadvantages such as long set-up time, difficulty in color management, frequent tile breakage and the like.Moreover, the conventional method of tile manufacturing is complex.
Therefore, there is need for a method of manufacturinga tile that overcomes at least one of the above mentioned drawbacks of the prior art.

Summary of the invention
In an aspect, provided herein is a method for manufacture of a colored, glass reinforced, composite tile comprising
i) applying a gel coat comprising a polymer and a dye to a mold for a tile;
ii) curing the gel coat to form a cross-linked polymer;
iii) adding a resin mix to the mold;
iv) inserting a grid mesh in the resin mix layer
v) pouring the resin mix on the grid mix into the mold;
vi) compressing the contents of the mold in a heated hydraulic press to cure the contents of the mold; and
vii) un-molding the cured composite tile.
In some embodiments, the dye in step (i) can be a pigment or any other suitable dye. In an embodiment the dye is indigo dye. In some embodiments, the gel coat comprises a polyester or an iso phthalate resin, or a combination thereof.In some embodiments, the grid mesh is a non-metallic grid mesh.In some embodiments, the grid mesh comprises a fiber having upto 150 GSM comprising polyester roving.In some embodiments, the grid mesh is coated with polyvinyl chloride (PVC).
In some embodiments,the resin mix comprises a modified acrylic polymer, marble powder, ceramic powder, glass flex or glass dust, one or more than one catalysts, one or more than one accelerators, one or more than one promoters, one or more than one polymer dispersants, one or more than one flame retardants, one or more than one viscosity modifiers, or a combination thereof. In one instance, the composite tile is manufactured from a resin mix comprising at least the ingredients shown in Table 2.
In some embodiments,the modified acrylic polymer comprises methacrylic-urethane oligomers in methyl methacrylate. In some of such embodiments,flame resistant material is also added to the mixture, where the flame retardants comprise polyvinyl chloride or polyoxy-benzyl-methylen-glycol-anhydride, or a combination thereof.
In some embodiments,the ceramic powder is silicon nitride powder.
In some embodiments,the glass flex or glass dust is in the form of glass powder, glass crust, chop strand fiberglass mat or recycled fiber glass.
In some embodiments,the resin mix further comprises grain flax, sawdust, hemp fiber, silica, jute fiber, cotton waste, or fiber waste dust, or a combination thereof.
Also provided herein is acolored, glass reinforced, composite tile prepared according to the method described above and herein.

Detailed description of the invention
In the following description, for purpose of explanation, specific details and examples are set forth in order to provide an understanding of the invention. It will be apparent, however, to one skilled in the art that the invention may be practiced without these details. One skilled in the art will recognize that embodiments of the present invention, some of which are described below, may be incorporated into a number of methods.
References in the specification to “one embodiment” or “an embodiment” mean that a particular feature, structure, characteristic, or function described in connection with the embodiment is included in at least one embodiment of the invention. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment.
Described herein is a method for manufacturing composite tiles including composite tiles comprising ceramics. The high process temperatures required for making ceramic composites generally preclude the use of organic, metallic or glass fibers. Only fibers stable at temperatures above 1000 °C have been typically used, such as fibers of alumina, mullite, SiC, zirconia or carbon.
However, it has been found that glass powder can be incorporated in composite tiles. Accordingly, provided hereinis a method of manufacturing colored glass reinforced compositetiles.
Advantageously the method described herein utilizesrecycled fiberglass waste rather than, for example, ceramic sheets which reduces cost of goods and/or material costs. The method also eliminates disposal costs and reduces air pollution associated with usage of fiberglass reinforcement. Further, the method described herein does not increase the time required for manufacture of composite tiles.
An embodiment of the present invention provides a method of manufacturing colored glass reinforced composite tiles. The method,in a first step,includespreparing a suitable mold. In an example, the mold is prepared in such a way so as to form mirror image of a required shape of the tile.
In a next step, for making a tile,a gelcoat having an indigo mix is applied to the mold. In an example, the gelcoat is a modified resin and is applied to the mold in a liquid state.The gel coat provides a high-quality finish on a visible surface of a fiber reinforced composite. Thegel coats are cured to form cross-linked polymers and are subsequently backed with composite polymer matrix, often mixtures of polyester resin and fiberglass or resin with glass.
In a next step, a resin mix is poured in the mold in a predefined proportion. In a preferred embodiment of the present invention, the resin mix is poured up to 3mm thickness in the mold to produce 6mm thickness tile. However, it is understood here that the amount of the resin mix poured in the moldor the depth to which the resin is poured in the mold depends on thickness of the tile to be manufactured.In an example, acrylic resinsand/or modified acrylic resins may be used in the resin mix.
In a next step, a GEO grid mesh is inserted on the resin mix layer and remaining amount of the resin mix is poured to form the tile in a semi-liquid form. In a next step, the tile which is in the semi-liquid form is compressed in a hydraulic press. In a preferred embodiment of the present invention, the tile is compressed in the hydraulic press at about 80 °C for 1 hour and the hydraulic press device may be heated at about 150 °C. However, it may be apparent to a person of ordinary skill in the art that the temperature of the hydraulic press and the duration of heating the tile in the hydraulic press may vary according to quality requirements of the tiles.
The hydraulic press device includes two aluminum plates. The tile to be compressed is placed on thealuminum plates of the hydraulic press. In a preferred embodiment of the present invention, the temperature is maintained uniformly and is controlled by a programmablelogic controller (PLC). After apredetermined curing cycle, the tileis removed from the mold.
The gelcoat forms a barrier coat, and typically comprises polyester or iso phthalate resin. The gel coat functions as a top most exterior all weather protecting layer and also provides a hard surface with good abrasive resistance. The presence of the gel coat allows for the tiles to be used in flooring, park slides, and/or as a “skin” for glass reinforced composite.
The resin mix comprises various ingredients including modified acrylates. In one embodiment, a modified acrylate is prepared by adding methacrylic-urethaneoligomers toa solution of methyl methacrylate (MMA), or by use of non-halogenated, modified acrylic polymers such as MODAR® resins. Surface resistivity can be engineered by addition of iso phthalate resins. In addition, polyvinyl chloride (PVC) or Bakelite® chips or granules may be added to get modified acrylic resins. In addition to a catalyst, at least one promoter is required to make a resin cure at room temperature. Generally, the promoter is mixed in thoroughly before adding the catalyst.
The proper choice of a catalyst impacts the chemical resistance in the tile. Care must be taken not to select catalysts that are too fast or slow in curing the polymers in the resin mixture. Unusually fast or slow cure times could result in reduced corrosion resistance in the final cured product. Methyl ethyl ketone (MEKP) is the most widely used catalyst system. MEKP is used with promoters, usually up to about 6% kg/mt2 of the total weight of the composition to be cured.
The catalyst then reacts with the promoter to cause the resin to gel. Promoter levels can also be adjusted to shorten or lengthen a gel time as needed.Cobalt Naphthenate or Octoate is a typical preferable promoter. Cobalt solutions are blue or purple liquids that are used with MEKP and cymyl hydro peroxide (CHP) catalyst systems. When used at temperatures below 70°F (24°C), cobalt should preferably be cut in styrene monomer prior to addition to the resin. Dilution in styrene will prevent small particles of cobalt from forming and will facilitate uniform mixing.Examples of promoters include and are not limited to cobalt octane 3% styrene based, dimethyl aniline, diethyl aniline and the like.
Dimethyl aniline (DMA)is a yellow amine liquid with a strong odor. DMA can be used with MEKP, benzoyl peroxide (BPO) (ambient cure), and CHP catalyst systems. The addition of DMA is not required with MEKP and CHP systems. However, small amounts of DMA may be used in conjunction with cobalt to improve Barcol development (hardness) and/or shorten the cure time at cool temperatures. With ambient temperature BPO systems, the addition of DMA is preferred. Diethyl aniline (DEA) is another amine that can also be used. DEA is approximately half as reactive as DMA, therefore, if 0.1% DMA is called for, 0.2% of DEA should be added to achieve the same reactivity. Cobalt naphthenate or 6% or 12% cobalt octane and dimethyl aniline (DMA) or diethyl aniline (DEA) are suitable promoters.
Optionally, accelerators are included in the resin mixture. Examples of accelerators include and are not limited to MEKP which is typically supplied at 9% active oxygen content.
Accelerators accelerate the curing process but when the process is conducted at room temperature, promoters may be added to accelerate the accelerators.
Geogrids are manufactured from high tenacity, high molecular weight, polyester yarns, woven into a stable interlocking grid, placed under tension, and then PVC coated to provide damage protection during installation. They are developed for the reinforcement of glass reinforced concrete. In an embodiment, the tiles described herein comprise geogrids and are also glass fiber/powder/dust reinforced. Advantageously, the tiles described herein are biologically inert, resistant to most naturally encountered chemicals, including alkalis and acids, resistant to ultra violet exposure and installation damage, resistant to long-term creep ?and yet flexible enoughto allow for easy installation.
It may be apparent to a person of ordinary skill in the art that the abovementioned steps of the method of manufacturing composite tiles may be performed in any order, either sequentially or simultaneously.
Further, the present invention includes chemical and/or mechanical and/or electronic systems that perform the above mentioned method of manufacturing composite tiles.
Table 1 shows an example of composition of elements along with composition used for manufacturing of colored glass reinforced composite tiles asdescribed above. The composition disclosed in the example does not limit the present invention to the said composition only and various compositions are possible and based on the quality, cost and colour of the tile required.

Table 1:
GEL COAT
polyester, iso-phthalate resin, or combination thereof INDIGO DYE
Indigo pigment paste is added to the gel coat solution 0.6kg/mt2
RESIN MIX

MODIFIED ACRYLIC
Methacrylic-urethane oligomers in a solution of methylmethacrylate (MMA)
(i.e., MMA/ MODAR® resin);
Polyvinyl chloride (PVC) or polyoxybenzylmethylenglycolanhydride (Bakelite®) chips or granules, or a combination thereof, are added to the acrylate resinto provide fire resistance 3.5 kg/mt2
GLASS FLEXOR DUST
Glass fiber or glass bubbles or waste fiber dust ground to a powder POWDER/CRUST FORM 2.0 kg/mt2
MARBLE POWDER 300 TO 400 MESH 2.0 kg/mt2
Silicon Nitride Powder Si3N4 1.0 kg/mt2
GEO GRID 4*4 MESH
Low grams per square meter (GSM)fiber comprising polyester roving The grid or mesh is coated with PVC

1.0 kg/mt2
PROCESS ADDITIVES 0.5 kg/mt2
ACCELERATOR Cobalt octane 3% styrene based 0.08 kg/mt2

Table 2 provides an example of composition of the resin mix used for manufacturing of colored glass reinforced composite tiles asdescribed above. The composition disclosed in the example does not limit the present invention to the said composition only and various compositions are possible and based on the quality, cost and colour of the tile required.

Table 2
MODIFIED ACRYLIC RESIN 30kg
Martinal® alumina trihydrate(ATH)
Viscosity modifier 30 kg
DecaBromo diphenyl dioxide
Viscosity modifier 0.6 kg
Cobalt octane 3% styrene based
Promoter (up to 10 % by weight) 0.75 kg
Methyl Ethyl Ketone Peroxide (MEKP) 9 % Oxygen content
Accelerator 0.75 kg
SOLPLUSTMD-540
polymeric dispersant / viscosity modifier 0.3 kg
TEP (Trichloro Ethyl phosphate)
Viscosity modifier 0.9 kg

Table 3 provides an example ofpreferred reinforcement material selection for manufacturing of colored glass reinforced composite tiles in accordance with the present invention.
Table 3
GLASS REINFORCMENT NATURAL FIBER WOOD COTTON WEST GRAVEL/CRUST
CHOP STRAND MATT GRAIN FLAX SAWDUST CRUST MARBLE AGGREGATE
GEO GRID HEMP FIBER SILICA CERAMIC POWDER
RECYCL FIBER JUTE FIBER COTTON WASTE FIBER WASTE DUST

The process of manufacturing tiledisclosed and claimed herein, is simple, requires less set-up time and color management is easy. Moreover, the as the tiles comprises fibers, they are durable and cost effective.
The embodiments of the invention shown and discussed herein are merely illustrative of modes of application of the present invention. Reference to details in this discussion is not intended to limit the scope of the claims to these details, or to the figures used to illustrate the invention.
It is understood that various omission and substitutions of equivalents are contemplated as circumstance may suggest or render expedient, but such are intended to cover the application or implementation without departing from the spirit or scope of the present invention.

,CLAIMS:WE CLAIM:
1. A method for manufacture of a colored, glass reinforced, composite tile comprising:
i) applying a gel coat comprisinga polymer and a dye to a mold for a tile;
ii) curing the gel coat to form a cross-linked polymer;
iii) adding a resin mix to the mold;
iv) inserting a grid mesh in the resin mix layer;
v) pouring the resin mix on the grid mesh of step iv into the mold;
vi) compressing the contents of the mold in a heated hydraulic press to cure the contents of the mold; and
vii) un-molding the cured composite tile.
2. The method as claimed inclaim 1, wherein the dye in step (i) is preferably indigo dye.
3. The method as claimed inclaim 1, wherein the gel coat comprises a polyester or an iso phthalate resin, or a combination thereof.
4. The method as claimed inclaim 1, wherein the grid mesh is a non-metallic grid mesh.
5. The method as claimed inclaim 1 or 4, wherein the grid mesh comprisesupto150 GSMfiber comprising polyester roving.
6. The method as claimed inone of the preceding claims 1,4 and 5, wherein the grid mesh is coated with polyvinyl chloride.
7. The method as claimed inclaim 1, wherein the resin mix includes a modified acrylic polymer, marble powder, ceramic powder, glass flex or glass dust, one or more than one catalysts, one or more than one accelerators, one or more than one promoters, one or more than one polymer dispersants, one or more than one flame retardants, one or more than one viscosity modifiers, or a combination thereof.
8. The method as claimed inclaim 7, wherein the modified acrylic polymer comprisesmethacrylic-urethane oligomers in methyl methacrylate.
9. The method as claimed inclaim 7, wherein the flame retardants comprise polyvinyl chloride or poly-oxy-benzyl-methylene-glycol-anhydride, or a combination thereof.
10. The method as claimed in claim 7, wherein the ceramic powder is silicon nitride powder.
11. The method as claimed in claim 7, wherein the glass flex or glass dust is in the form of glass powder, glass crust, chop strand fiberglass mat or recycled fiber glass.
12. The method as claimed inclaim 7, wherein the resin mix further comprises grain flax, sawdust, hemp fiber, silica, jute fiber, cotton waste, or fiber waste dust, or a combination thereof.

13. A colored, glass reinforced, composite tile prepared according to the method of claim 1.