PREFABRICATED TILE PANEL SYSTEM AND INSTALLATION METHOD

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit or priority under 35 USC 119(e) of provisional patent application Ser. No. 63/694,606 filed Sep. 13, 2024, all of which is incorporated by reference in its entirety.

FIELD OF THE INVENTION

The present invention relates generally to wall, ceiling, and floor covering systems, and more particularly to prefabricated large-format panel systems for use in wet-area environments such as showers and tub surrounds. Specifically, the invention pertains to a shower wall kit comprising prefabricated panels, a hybrid waterproof adhesive, and integrated waterproofing accessories configured for rapid, direct-to-stud installation.

BACKGROUND

Current tile installation systems include traditional ceramic or porcelain tile applied over cementitious backer boards or mortar beds. Typically, such installations require multiple preparatory layers, including framing, a moisture barrier, a backer substrate (e.g., cement board), thinset mortar, individual tile pieces, and grout. Each layer must be installed in sequence, with intermediate curing or drying times, before the assembly can be exposed to water.

In typical shower installations, a waterproof membrane (such as a sheet or liquid-applied barrier) is applied to the substrate before tile placement. Corners, seams, and transition areas are treated with tape or fabric embedded in waterproofing compounds. This process is labor-intensive, dependent on skilled labor, and subject to variability in workmanship. Improper installation or inadequate curing times can result in water intrusion, mold growth, and premature system failure.

Large-format tile panels (often referred to as gauged porcelain tile panels, GPTP) have been introduced to reduce grout joints and improve aesthetics. However, GPTP systems generally require specialized equipment for handling and cutting, as well as the same multi-layer substrate preparation and waterproofing processes as small-format tile. These steps add time, cost, and complexity, limiting widespread adoption.

Prefabricated shower panels made of fiberglass, acrylic, or composite materials are also known in the art. Such panels can be installed more quickly than tiled assemblies but often lack the appearance, surface durability, and design flexibility of ceramic or porcelain tile. Additionally, most prefabricated panels require mechanical fastening and sealing with surface caulks, which may degrade over time.

Certain composite tile backer boards have been disclosed in the art, such as those employing a high-density thermoset closed-cell rigid polyisocyanurate foam core. One example of such material is manufactured by Johns Manville Inc., and is described in U.S. Pat. No. 11,685,140 (2023) and U.S. Pat. No. 11,773,586 (2023). These backer boards provide a lightweight, dimensionally stable substrate for tile installations and have utility in both external and internal wall systems, including shower enclosures.

However, the use of such backer boards alone does not provide a complete shower or wet-area solution. Conventional installations incorporating these boards still require additional layers and techniques, such as application of polymeric adhesives, precision bracing, waterproof seam tape, and water misting protocols to ensure proper adhesion and sealing. These multi-step processes remain labor-intensive and highly dependent on installer skill.

Other shower enclosure systems disclosed in the art, such as U.S. Application Publication No. 2022/0325531 to Penaloza, U.S. Application Publication No. 2014/0250585 to Slothower, and U.S. Pat. No. 6,851,133 to Nehring, likewise do not teach or suggest the integrated prefabricated wall and flooring panel system of the present disclosure. These references continue to rely on multi-component assemblies, surface caulking, or mechanical fastening, which present limitations in durability, waterproofing reliability, and ease of installation.

Common limitations of existing systems include long installation times, extended cure periods before water testing, reliance on multiple trades or specialized installers, and susceptibility to leaks at seams and flange areas. In many cases, industry-standard installations cannot be water-tested until 24-72 hours after completion, delaying project turnover.

Moreover, conventional installation methods often require wallboard or backerboard behind the decorative surface, adding material cost, installation labor, and thickness to the assembly. This also introduces more interfaces where moisture ingress can occur if detailing is imperfect.

In addition to wall systems, conventional tile flooring and ceiling installations present similar challenges. Standard floor tile assemblies typically involve multiple layers, including a subfloor, a cementitious backer board or uncoupling membrane, thinset mortar, individual tiles, grout, and sealant. Each layer requires careful preparation, sequencing, and drying or curing times, which extends project duration and increases labor costs. Errors in substrate leveling or adhesive application can result in tile lippage, hollow spots, or premature failure under load.

Large-format floor tiles have been introduced to improve aesthetics and reduce grout lines. However, these systems still depend on mortar beds, backer boards, or membranes, and require specialized tools for handling and cutting. Installation is labor-intensive, particularly in larger areas, and uneven curing or substrate movement can lead to cracking or debonding.

Furthermore, traditional flooring methods lack integrated performance features. For example, acoustic dampening in multi-family housing, moisture resistance in wet areas, and crack isolation in substrates typically require separate underlayment products or membranes. These add layers, complexity, and cost, while introducing more seams and interfaces that can fail over time.

Accordingly, there is a growing need for prefabricated flooring systems that simplify installation, integrate waterproofing and performance features, and allow for direct bonding to subfloors without separate underlayment. Such systems should reduce labor steps, shorten cure times, and deliver durable, aesthetically consistent surfaces suitable for both residential and commercial use.

There is also a growing demand for wet-area wall systems that integrate performance features beyond waterproofing, such as fire resistance, acoustic dampening, and compatibility with existing framing layouts without additional blocking or furring.

Thus, a need exists in the market for a prefabricated, large-format tile panel system that can be applied to vertical and horizontal, namely wall, ceiling, and floor assemblies, including showers, bathrooms, kitchens, and other wet-area installations. Such a system should install directly to framing or a suitable substrate without a separate backerboard, incorporate integrated waterproofing and adhesive bonding in a single process, enable rapid readiness for water exposure or use, and provide a durable, aesthetically pleasing surface with enhanced performance characteristics. By simplifying installation, reducing cure times, and minimizing the risk of water intrusion or substrate failure, such a system can improve efficiency and reliability compared to conventional methods.

SUMMARY OF THE INVENTION

The invention disclosed herein provides a prefabricated tile panel system. The prefabricated tile panel system provides at least one prefabricated panel. Each panel has a rigid tile backer board, a structural layer, and an integrated performance surface layer. The rigid tile backer board comprises a high-density, closed-cell polyisocyanurate foam core with coated fiberglass mats. The structural layer can be selected from ceramic or porcelain. The structural layer is bonded to the tile backer board. The integrated performance surface layer is formed external to the structural layer. In addition to the prefabricated panel, the prefabricated tile panel system further provides a hybrid polymer adhesive layer and a cure bond between the prefabricated panels and the support structure. The hybrid polymer adhesive layer is configured for bonding the prefabricated panels directly to a support structure without an intervening substrate. The support structure comprises at least one of a wall framing member, a ceiling joist, a subfloor, or a shower base flange. The cured bond exists between the at least one prefabricated panel and the support structure formed while the panels are braced during adhesive curing.

The invention disclosed herein further provides a prefabricated tile installation kit. The kit comprises at least one prefabricated panel, a hybrid polymer adhesive composition, a grout composition, and a silicone sealant. Each panel comprises a rigid tile backer board, a structural layer, and an integrated performance surface layer. The hybrid polymer adhesive composition is configured for bonding the prefabricated panels directly to a support structure without an intervening substrate. The support structure comprising at least one of a wall framing member, a subfloor, a ceiling joist, or a shower base flange. The grout composition is configured to fill joints between adjacent prefabricated panels. The silicone sealant is configured to provide a flexible water-impermeable joint at at least one transition location.

The invention disclosed herein also provides a method of installation for a prefabricated tile panel system. The method comprises providing a plurality of prefabricated panels, providing a hybrid polymer adhesive configured for bonding the prefabricated panels directly to a support structure without an intervening substrate, and providing a cured bond agent for implementation between the at least one prefabricated panel and the support structure.

An object of the present disclosure is to provide a prefabricated tile panel system that eliminates the need for multiple preparatory layers, including cement backer board, thinset mortar, and waterproofing membranes, thereby simplifying installation.

Another object of the present disclosure is to provide a tile panel system with integrated performance features, including waterproofing, acoustic dampening, and crack isolation, while maintaining the aesthetic and durability benefits of ceramic, porcelain, or stone tile. The system further incorporates seam protection and silicone sealant placement strategies to reduce the risk of water intrusion at joints and movement areas, ensuring long-term reliability in ceiling, wall, and flooring applications.

A further object of the present disclosure is to provide a prefabricated panel system and installation kit that is equally applicable to shower enclosures, wall systems, and flooring systems.

The drawings and specific descriptions of the drawings, as well as any specific or alternative embodiments discussed, are intended to be read in conjunction with the entirety of this disclosure. The invention may be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein; rather, these embodiments are provided by way of illustration only and so that this disclosure will be thorough, complete and fully convey understanding to those skilled in the art. The above and yet other objects and advantages of the present invention will become apparent from the hereinafter set forth Brief Description of the Drawings, Detailed Description of the Invention, and Claims appended herewith.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates an isometric view of a prefabricated tile panel system, with an enlarged detail view showing the layered construction of the prefabricated panel.

FIG. 2 illustrates a prefabricated tile installation kit, showing its principal components.

FIG. 3 illustrates a side perspective view of an exposed shower frame.

FIG. 4 illustrates a preparatory step in which an installer inspects and measures the studs, ensuring they are properly spaced, plumb, and level before beginning installation of the prefabricated panels.

FIG. 5 illustrates a side perspective view of an exposed shower frame with measurement parameters shown in dashed lines.

FIG. 6 illustrates a conceptual view of an installer using a caulking gun to apply a hybrid polymer adhesive to stud surfaces at panel joint locations.

FIG. 7 illustrates a side perspective view of an exposed shower frame with a hybrid polymer adhesive shown on stud surfaces at panel joint locations.

FIG. 8 illustrates a side perspective view of an exposed shower frame with a potable water mist being applied to the hybrid polymer adhesive shown on stud surfaces at panel joint locations.

FIG. 9 illustrates a side perspective view of an exposed shower frame with weatherproofing tape applied over the adhesive.

FIG. 10 illustrates a conceptual view of an installer using a caulking gun to apply a hybrid polymer adhesive over the waterproofing tape at panel joint locations.

FIG. 11 illustrates a side perspective view of an exposed shower frame with a first panel installed.

FIG. 12 illustrates a conceptual view of an installer bracing the first panel and ensuring the panel is flush, plumb, and level prior to installing the next panel.

FIG. 13 illustrates a perspective view of a first prefabricated panel installed against the stud frame with a brace positioned at a central stud location, the brace applying pressure to the panel to maintain flush, plumb, and level alignment during adhesive curing.

FIG. 14 illustrates a conceptual view of an installer applying a bead of adhesive along an end edge of a first prefabricated panel at a joint location prior to installation of a second prefabricated panel.

FIG. 15 illustrates a side perspective view of an exposed shower frame with a second panel installed.

FIG. 16 illustrates a perspective view of a second prefabricated panel installed against the stud frame with its own independent brace.

FIG. 17 illustrates a conceptual view of an installer applying a bead of adhesive along an end edge of a third prefabricated panel at a joint location prior to installation of the third prefabricated panel.

FIG. 18 illustrates a side perspective view of an exposed shower frame with a third panel installed.

FIG. 19 illustrates a conceptual view of an installer applying a bead of adhesive along an end edge of a fourth prefabricated panel at a joint location prior to installation of the fourth prefabricated panel.

FIG. 20 illustrates a side perspective view of an exposed shower frame with a fourth panel installed.

FIG. 21 illustrates a perspective view of a all prefabricated panels installed against their respective studs frame with braces positioned at a central stud locations, the braces applying pressure to the panel to maintain flush, plumb, and level alignment during adhesive curing.

FIG. 22 illustrates a side perspective view of an exposed shower frame following installation of the prefabricated panels, with grout applied at panel joint locations and a silicone sealant installed at transition and movement joint locations.

FIG. 23 illustrates a conceptual view of a flooring installer creating a layout template on a substrate using snap chalk lines, wherein a chalk line tool with powdered chalk is used to mark straight reference lines for panel placement.

FIG. 24 illustrates a top plan view of the layout.

FIG. 25 illustrates an isometric view of the panel.

FIG. 26 illustrates an isometric view of a prefabricated panel with adhesive being applied to an outer surface of the rigid tile backer board layer.

FIG. 27 illustrates an isometric view of a prefabricated panel with misting spray being applied to the adhesive on the outer surface of the rigid tile backer board layer.

FIG. 28 illustrates an isometric view of a panel with suction handle used for applying large format tiles.

FIG. 29 illustrates a top plan view of a flooring layout with a first panel installed, conceptually showing footprint icons on the surface of the panel to represent an installer applying downward pressure on the tile to assist adhesive transfer and curing.

FIG. 30 illustrates a top plan view of a flooring layout with a plurality of panels installed and spacers provided throughout the installation.

FIG. 31 illustrates a top plan view of all the panels installed.

FIG. 32 illustrates a top plan view of a completed flooring installation with all prefabricated panels positioned in place, conceptually showing grout applied along the panel joints.

FIG. 33 illustrates a top plan view of a completed flooring installation with all prefabricated panels positioned in place, conceptually showing a silicone sealant applied at movement joint locations.

FIGS. 34A-34B illustrates a flow chart for a method of applying the panels in a wall installation.

FIGS. 35A-35B illustrates a flow chart for a method of applying the panels in a flooring installation.

DETAILED DESCRIPTION OF THE INVENTION

The invention herein provides a solution for the inefficiencies, complexity, and water-intrusion risks associated with conventional tile installation methods. The invention includes a uniquely configured prefabricated tile panel system capable of being directly bonded to structural substrates using a hybrid polymer adhesive, thereby eliminating the need for separate backerboard, mortar beds, or multi-layer waterproofing assemblies. This simplified system solves the above issues by reducing installation time, minimizing workmanship variability, and delivering an integrated waterproof, durable, and aesthetically finished surface suitable for wall, ceiling, and flooring applications. The system herein creates a solution capable of solving the issues recited above.

Current ceiling, wall, flooring tile installation systems typically rely on multi-layer assemblies requiring numerous sequential steps, including the installation of a substrate such as cementitious backer board, the application of waterproofing membranes, and the use of thinset mortar to set ceramic or porcelain tiles. Each layer demands careful workmanship and sufficient curing time, extending project schedules and increasing labor costs.

Furthermore, in shower assemblies and other wet areas, additional detailing is required to properly seal corners, seams, and penetrations with tapes or reinforcing fabrics embedded in waterproofing compounds. These operations are highly dependent on installer skill, and even small imperfections can compromise system integrity, leading to leaks, mold growth, or premature failure.

While large-format porcelain panels have been introduced to improve aesthetics and reduce grout joints, their installation still depends on the same traditional layering process. Specialized equipment for cutting and handling these oversized panels further increases cost and complexity, and the overall assembly remains susceptible to failure if the substrate or waterproofing layers are compromised.

Flooring installations likewise suffer from similar limitations. Conventional floor tile systems generally require the preparation of a subfloor, placement of an underlayment or uncoupling membrane, and careful leveling before setting tile in mortar. Multiple layers add to the time and cost of installation, and improper preparation can lead to uneven surfaces, cracking, or debonding under load. In addition, performance enhancements such as acoustic dampening, crack isolation, or moisture protection typically require separate membranes or underlayments, increasing the number of materials and interfaces that can fail.

In both wall and floor contexts, current systems share common drawbacks: extended installation times, reliance on multiple trades, prolonged cure periods before water testing or occupancy, and susceptibility to water intrusion at seams, joints, or substrate transitions. These limitations restrict efficiency, increase the risk of installation errors, and make it difficult to deliver durable, reliable, and timely results in both residential and commercial projects.

The current invention solves these problems by providing a prefabricated, large-format tile panel system configured for direct bonding to framing or subfloor substrates using a hybrid polymer adhesive in combination with integrated waterproofing elements. This system eliminates the need for separate backer boards, membranes, or mortar beds, while reducing the number of installation steps and enabling rapid readiness for water exposure. By unifying wall and flooring applications within a single prefabricated panel technology, the invention delivers a durable, waterproof, and aesthetically consistent finish with reduced labor requirements and enhanced performance compared to conventional methods.

The invention provides a prefabricated large-format tile panel system that replaces the complex, multi-layered process of traditional tile installation with a single integrated solution. By combining a lightweight foam-cored backer, a bonded porcelain or ceramic surface, and direct-bond hybrid polymer adhesive technology, the system eliminates the need for separate substrates, thinset, and membranes. Panels are quickly secured to studs, subfloors, or shower bases, with seam tape, grout, and silicone providing a complete waterproof finish. The result is a durable, aesthetically consistent wall or floor system that installs in a fraction of the time of conventional methods, with reduced labor, faster cure times, and greater reliability.

The present invention provides an integrated prefabricated tile panel system and installation method that streamlines both wall and flooring applications in wet-area environments. Unlike conventional tile assemblies requiring multiple substrates, membranes, mortars, and extended curing times, this system employs factory-fabricated large-format panels comprising a rigid polyisocyanurate foam backer board with fiberglass mats, a bonded ceramic or porcelain structural layer, and an external performance surface layer that delivers the aesthetics, durability, and cleanability of traditional tile. The panels are designed for direct bonding to studs, subfloors, or shower base flanges using a hybrid polymer adhesive that cures rapidly, provides waterproofing, acoustic dampening, and crack isolation, and eliminates the need for separate thinset or underlayment products. Waterproof seam tape integrates at wall joints and flange transitions to ensure continuous water resistance, while grout and silicone sealant finalize the assembly to accommodate movement and protect against leakage. Installation is simplified into a series of repeatable steps: measuring framing, applying adhesive beads, misting with water to activate curing, embedding panels under pressure, bracing until set, and finishing with grout and sealant, allowing a watertight, structurally bonded shower or floor system to be completed in a fraction of the time of conventional methods. By combining the performance of advanced materials with reduced labor steps and integrated waterproofing, the invention delivers a robust, aesthetically consistent, and ready-to-use tile surface for residential and commercial construction

The prefabricated tile panel system and installation method of the present invention may be used to provide a prefabricated tile panel system that eliminates the need for multiple preparatory layers, including cement backer board, thinset mortar, and waterproofing membranes, thereby simplifying installation. The prefabricated tile panel system and installation method of the present invention may also be used to provide a tile panel system with integrated performance features, including waterproofing, acoustic dampening, and crack isolation, while maintaining the aesthetic and durability benefits of ceramic, porcelain, or stone tile. The prefabricated tile panel system and installation method of the present invention may additionally be used to provide a prefabricated panel system and installation kit that is equally applicable to shower enclosures, wall systems, and flooring systems. This apparatus and system are particularly shown in FIGS. 1-35.

FIG. 1 illustrates an isometric view of a prefabricated tile panel system 102, with an enlarged detail view showing the layered construction of the prefabricated panel 104.

FIG. 2 illustrates a prefabricated tile installation kit 200, showing its principal components, including a hybrid polymer adhesive composition 118, a grout composition 144, a silicone sealant 146, a prefabricated panel 104, and a waterproof seam tape 130.

FIG. 3 illustrates a side perspective view of an exposed shower frame 120.

FIG. 4 illustrates a preparatory step in which an installer 202 inspects and measures the studs 122, ensuring they are properly spaced, plumb, and level before beginning installation of the prefabricated panels 104.

FIG. 5 illustrates a side perspective view of an exposed shower frame 120 with measurement parameters 154/156 shown in dashed lines.

FIG. 6 illustrates a conceptual view of an installer 202 using a caulking gun 158 to apply a hybrid polymer adhesive 118 to stud surfaces 152 at panel joint locations 166.

FIG. 7 illustrates a side perspective view of an exposed shower frame 120 with a hybrid polymer adhesive 118 shown on stud surfaces 152 at panel joint locations 166.

FIG. 8 illustrates a side perspective view of an exposed shower frame 120 with a potable water 160 mist 162 being applied to the hybrid polymer adhesive 118 shown on stud surfaces 152 at panel joint locations 166, including the end edge 188 of the panel 104.

FIG. 9 illustrates a side perspective view of an exposed shower frame 120 with weatherproofing tape 130 applied over the adhesive 118.

FIG. 10 illustrates a conceptual view of an installer 202 using a caulking gun 158 to apply a hybrid polymer adhesive 118 over the waterproofing tape 130 at panel joint locations 166.

FIG. 11 illustrates a side perspective view of an exposed shower frame 120 with a first panel 104 installed.

FIG. 12 illustrates a conceptual view of an installer 202 bracing the first panel 104 and ensuring the panel 104 is flush, plumb, and level prior to installing the next panel 104.

FIG. 13 illustrates a perspective view of a first prefabricated panel 104 installed against the stud frame 120 with a brace 164 positioned at a central stud location 122, the brace 164 applies pressure to the panel 104 to maintain flush, plumb, and level alignment during adhesive curing.

FIG. 14 illustrates a conceptual view of an installer 202 applying a bead of adhesive 118 along an end edge 188 of a first prefabricated panel 104 at a joint location 166 prior to installation of a second prefabricated panel 104.

FIG. 15 illustrates a side perspective view of an exposed shower frame 120 with a second panel 104 installed.

FIG. 16 illustrates a perspective view of a second prefabricated panel 104 installed against the stud frame 120 with its own independent brace 164.

FIG. 17 illustrates a conceptual view of an installer 202 applying a bead of adhesive 118 along an end edge 188 of a third prefabricated panel 104 at a joint location 166 prior to installation of the third prefabricated panel 104.

FIG. 18 illustrates a side perspective view of an exposed shower frame 120 with a third panel 104 installed.

FIG. 19 illustrates a conceptual view of an installer 202 applying a bead of adhesive 118 along an end edge 188 of a fourth prefabricated panel 104 at a joint location 166 prior to installation of the fourth prefabricated panel 104.

FIG. 20 illustrates a side perspective view of an exposed shower frame 120 with a fourth panel 104 installed. Also shown is an enlarged portion showing a close up of the stud 122, cured bond 128, and the panel 104, all in contact.

FIG. 21 illustrates a perspective view of all prefabricated panels 104 installed against their respective studs frame with braces 164 positioned at a central stud locations 122, the braces 164 applying pressure to the panel 104 to maintain flush, plumb, and level alignment during adhesive curing.

FIG. 22 illustrates a side perspective view of an exposed shower frame 120 following installation of the prefabricated panels 104, with grout 144 applied at panel joint locations 132 and a silicone sealant 146 installed at transition and movement joint locations 148.

FIG. 23 illustrates a conceptual view of a flooring installer creating a layout template 168 on a substrate 124 using snap chalk lines 170, wherein a chalk line tool 172 with powdered chalk is used to mark straight reference lines 170 for panel placement.

FIG. 24 illustrates a top plan view of the layout 168.

FIG. 25 illustrates an isometric view of the panel 104.

FIG. 26 illustrates an isometric view of a prefabricated panel 104 with adhesive 118 being applied to an outer surface 174 of the rigid tile backer board layer 106.

FIG. 27 illustrates an isometric view of a prefabricated panel 104 with misting spray 162 being applied to the adhesive 118 on the outer surface 174 of the rigid tile backer board layer 106.

FIG. 28 illustrates an isometric view of a panel 104 with suction handle 176 used for applying large format tiles.

FIG. 29 illustrates a top plan view of a flooring layout 168 with a first panel 104 installed, conceptually showing footprint 178 icons on the surface 110 of the panel 104 to represent an installer applying downward pressure on the tile to assist adhesive transfer and curing.

FIG. 30 illustrates a top plan view of a flooring layout 168 with a plurality of panels 104 installed and spacers 178 provided throughout the installation.

FIG. 31 illustrates a top plan view of all the panels 104 installed.

FIG. 32 illustrates a top plan view of a completed flooring installation with all prefabricated panels 104 positioned in place, conceptually showing grout 144 applied along the panel joints 132.

FIG. 33 illustrates a top plan view of a completed flooring installation with all prefabricated panels 104 positioned in place, conceptually showing a silicone sealant 146 applied at movement joint locations 148.

FIGS. 34A-34B illustrates a flow chart for a method 300a of applying the panels 104 in a wall installation.

FIGS. 35A-35B illustrates a flow chart for a method 300b of applying the panels 104 in a flooring installation.

In an exemplary embodiment, a prefabricated tile panel system 102 is disclosed. The system 102 includes at least one prefabricated panel 104, though in most applications, will include a plurality of panels, as may be appreciated in example illustrations in FIGS. 1-33, showing four panels 104. It is to be appreciated that the number of panels will vary based on each individual project. Each panel includes a rigid tile backer board 106, a structural layer 108, and an integrated performance surface layer 110.

The rigid tile backer board 106, as shown in FIG. 1, has a high-density, closed-cell polyisocyanurate foam core 112 with coated fiberglass mats 114 on opposing surfaces 116. In some embodiments, the backer board is of the type known in the industry as GoBoard™, which is a lightweight, rigid, and waterproof construction panel suitable for use in wet areas. The backer board 106 provides dimensional stability, resists moisture absorption due to its closed-cell structure, and offers a surface compatible with direct application of polymeric adhesives, mortars, or sealants. In certain embodiments, the backer board 106 is provided in standard sheet form and can be cut, scored, and handled using conventional construction tools without requiring specialized equipment. In some embodiments, the tile backer board 106 has a thickness between about 6 mm and about 16 mm.

The structural layer 108 may be selected from materials including ceramics, porcelains, and the like. The structural layer 108 is bonded to the tile backer board 106.

The integrated performance surface layer 110 is formed external to the structural layer 108. This surface layer 110 functions as the exposed surface of the prefabricated panel 104 and provides both protection to the underlying layers and the desired finished aesthetic. In some embodiments, the surface layer 110 comprises a ceramic or porcelain tile face. Ceramic and porcelain tiles are commonly manufactured with a vitrified surface created during kiln firing, which produces a dense, glass-like outer layer that is integral to the tile body. In certain cases, additional finishes, such as glazing, polishing, or texturing, may be applied to enhance appearance, improve stain resistance, or alter surface friction.

The facing of such panels 104 serves multiple purposes. First, it protects the panel body and the backing layers against wear, scratching, and moisture ingress. Second, it provides ornamentation, enabling a wide range of colors, patterns, and textures for architectural design. Third, it contributes to durability and ease of cleaning; the vitrified or glazed surfaces of porcelain and ceramic tiles are typically more resistant to staining, fading, and chemical attack than natural stone equivalents.

In some embodiments, the performance surface layer 110 enhances affordability and practicality by permitting the use of thinner tile sections or engineered laminates, while still maintaining the appearance and functional benefits of full-thickness porcelain or ceramic. For example, a thin porcelain veneer with a polished surface may be bonded directly to the tile backer board 106 to achieve a lightweight but high-performance panel 104. The performance layer 110 may also contribute to water impermeability, abrasion resistance, and long-term surface stability in both residential and commercial wet-area applications.

In some embodiments, the performance layer 110 is 0-6 mm, while in others, the integrated performance layer 110 has a thickness between about 6 mm and about 15 mm. The layer 110 may also be a glaze or polish on the structural layer 108. Material of the integrated performance surface layer 110 protects the underlying layers 106/108 from dust, water, and other substances that could stain or damage the underlying layers 106/108. The integrated performance surface layer 110 may comprise a materials including synthetic stone, engineered laminate, porcelain, ceramic, natural stone, and/or acrylic.

The prefabricated tile panel system 102 disclosed also includes a hybrid polymer adhesive layer 118 configured for bonding said prefabricated panels 102 directly to a support structure 120 without an intervening substrate. In some embodiments, the adhesive 118 is provided in cartridge form 118b and applied in beads, as shown in FIG. ##, dimensioned to provide both uniform contact and gap-filling capability. The hybrid polymer adhesive layer 118 comprises a moisture-cure polymer formulation with mineral fillers and stabilizers, configured to cure upon contact with misted water 122 and achieve a permanent structural bond. In practice, the adhesive exhibits waterproofing, acoustic damping, and crack isolation properties, allowing the prefabricated panels to be secured without reliance on thinset mortar, backerboard, or mechanical fasteners. One representative embodiment includes a hybrid polymer adhesive of the type commercially available as a 30 oz cartridge adhesive that can be used with the prefabricated panel system 102, though the invention is not limited to any particular manufacturer or brand.

In certain embodiments, the hybrid polymer adhesive layer 118 may be selected from the class of silyl-terminated polymer (STP) adhesives, also referred to as silane-modified polyether or hybrid polymer sealant-adhesives. These formulations are characterized by their ability to combine the elastic, moisture-curing properties of polyurethane with the weatherability and chemical resistance of silicone. Unlike cementitious mortars or two-part epoxies, STP adhesives cure without mixing, exhibit low shrinkage, and bond strongly to a wide range of construction materials including fiberglass, ceramics, metals, and wood substrates. Such adhesives are frequently supplied in high-volume cartridges for construction applications and are engineered to provide structural bonding, moisture impermeability, acoustic dampening, and limited crack-bridging performance. Accordingly, while one representative embodiment employs a 30 oz cartridge adhesive of the HP4 type, the invention is not limited thereto and encompasses equivalent hybrid polymer adhesives commercially available in the construction materials industry.

The support structure 120 is capable of supporting the panels 104, and can range in form from existing wall framing members/studs 122, subfloors 124, to shower base flanges 134. By enabling direct bonding to these base components, the system 102 eliminates the need for multiple intervening substrates such as cement board, uncoupling membranes, or mortar beds. This simplification reduces the number of installation steps and minimizes interfaces where water could penetrate or bond failure could occur. Direct attachment to studs 122 or flanges 134 also allows for precise alignment without introducing additional build-up thickness, preserving available space within wet-area enclosures.

In flooring applications, direct bonding to a prepared subfloor 124 removes the need for separate underlayments, saving material costs and avoiding the cumulative tolerances that can cause uneven surfaces or lippage. Similarly, in wall applications, bonding directly to studs 122 avoids the labor of installing and fastening backer boards, while also removing fastener penetrations that can compromise waterproofing. In both cases, installers are able to work directly on the base structural elements of the building, streamlining workflow and reducing reliance on skilled trades or specialized tools.

The prefabricated tile panel system 102 disclosed also includes a cured bond 128 between the prefabricated panels 104 and the support structure 120, the bond 128 is formed while the panels 104 are temporarily braced during adhesive curing. The bond 128 is established by the hybrid polymer adhesive layer 118 described above, which cures through ambient moisture and misting to form a strong, elastic connection that both structurally secures the panels 104 and seals against water intrusion. Once cured, the adhesive bond 128 (as may be seen in the enlarged portion of FIG. 20) accommodates minor substrate movement while maintaining watertight integrity, thereby eliminating the need for mechanical fasteners or separate membranes. Commercially, such bonds are achieved with single-component moisture-cure hybrid polymer adhesives, such as HP4-type formulations, which combine high bond strength, gap-filling ability, and resistance to water and thermal cycling to provide durable, long-term adhesion in both wall and floor applications.

In some embodiments, as shown in FIGS. 1-22, the at least one prefabricated panel 104 is a plurality of wall panels. In an exemplary embodiment, the panels 104 are installed on a wall, namely, in a shower installation.

In these embodiments with multiple panels 104, the system further includes a waterproof seam tape 130 positioned to overlap joints 132 between adjacent wall panels 104 and extend over a flange 134 of a shower base 136. The waterproof seam tape 130 is a flexible, alkali-resistant membrane designed to bridge joints 132, seams 138, and transitions between panels 104, providing a continuous waterproof barrier across joints 132 that are otherwise vulnerable to leakage. The tape 130 is typically manufactured from a woven or non-woven fabric coated with a waterproofing compound such as polymer-modified elastomer, allowing it to remain dimensionally stable while accommodating minor movement in the assembly. When embedded into the hybrid polymer adhesive, the tape 130 bonds securely to both the back panel surface 140 and flange 134, preventing water ingress at the seam. In some embodiments, the waterproof seam tape 130 overlaps the flange 134 by at least 12.7 mm. The waterproof seam tape 130 extends from a header stud 142 to a bottom edge of the flange 134.

In another exemplary embodiment, a prefabricated tile installation kit 200, as shown in FIG. 2, is disclosed. The kit 200 comprises at least one prefabricated panel 104, a hybrid polymer adhesive composition 118b, a grout composition 144, and a silicone sealant 146.

Similar to above, each prefabricated panel 104 comprises a rigid tile backer board 106, a structural layer 108, and an integrated performance surface layer 110. The rigid tile backer board 106 has a high-density, closed-cell polyisocyanurate foam core 112 with coated fiberglass mats 114. The structural layer 108 may be ceramic or porcelain. The structural layer 108 is bonded to the tile backer board 106. The integrated performance surface layer 110 is formed external to the structural layer 108.

The hybrid polymer adhesive composition 118 is configured for bonding the prefabricated panels 104 directly to a support structure 120 without an intervening substrate. The contemplated support structure 120 can range a wall framing member 122, a subfloor 124, or a shower base 136 flange 134. The grout composition 144 is configured to fill joints 132 between adjacent prefabricated panels 104. The silicone sealant 146 is configured to provide a flexible water-impermeable joint at at least one transition location 148. A transition location 148 is a joint 132 or interface in the prefabricated tile panel system 102 where movement, material change, or dissimilar substrates occur. Examples include the intersection between wall panels and floor panels, the joint between a panel and a shower base flange, the corner junctions of wall panels, and perimeter edges where panels abut framing members or adjoining finish materials. At these locations, rigid grout may crack under movement; thus, a silicone sealant 146 is employed to provide a flexible, water-impermeable joint capable of accommodating thermal expansion, structural deflection, and vibration while maintaining watertightness.

In addition, the hybrid polymer adhesive composition 118b comprises a moisture-curing polymer, mineral fillers, and tackifiers configured to provide moisture impermeability, acoustic damping, and crack isolation properties.

The prefabricated tile installation kit 200 includes a waterproof seam tape 130 positioned to overlap joints 132 between adjacent prefabricated wall panels 104 and extend over a flange 134 of a shower base 136. In some embodiments, the waterproof seam tape 130 is configured to overlap said flange 134 by at least 12.7 mm.

In some embodiments, the grout composition 144 is a pre-mixed polymer-modified grout configured to resist water absorption and staining.

In some embodiments, the silicone sealant 146 comprises a mildew-resistant, neutral-cure silicone configured for vertical and horizontal transitions.

In some embodiments, the prefabricated panels 104 are pre-sized to fit a standard three-wall shower enclosure without on-site cutting, as shown in FIGS. ##-##. In some embodiments, the prefabricated panels 104 are pre-sized for flooring applications to provide a uniform modular layout.

The prefabricated tile 104 installation kit 200 also includes installation instructions 150. These installation instructions 150 include a method of installation for the prefabricated tile panel system. In some embodiments, the set of installation instructions 150 is for vertical and shower applications. In some embodiments, the set of installation instructions 150 is for flooring applications. The instructions include the method 300a/300b steps, as outlined, below.

In another exemplary embodiment, a method 300a/300b of installation for a prefabricated tile panel system 102 is disclosed. The method 300a/300b includes providing 302 a plurality of prefabricated panels 104, as described above, providing 304 a hybrid polymer adhesive 118 configured for bonding the prefabricated panels 104 directly to a support structure 120 without an intervening substrate, and providing 306 a cured bond agent 128 for implementation between said at least one prefabricated panel 104 and said support structure 120 formed while said panels 104 are braced during adhesive curing. The support structure 120 may be a wall framing member 122, a subfloor 124, or a shower base flange 134.

In some embodiments, where the panels 104 are installed on the wall, such as shower applications, the method 300a includes further steps. The method 300a includes evaluating 308 the support framing 120 by verifying 310 that the framing members 122 are spaced 16 inches on center, ensuring 312 that a sister stud 122 is installed at a center of a back wall to accommodate panel joints 132, confirming 314 that the studs are plumb, level, and aligned with one another across all three shower receptor walls, as shown in FIGS. 4 and 5, ensuring 316 installation is on a flat stud wall plane, and making 318 corrective repairs if said conditions are not met.

The method 300a further includes implementing 320 waterproofing seam tape 130, as may be appreciated in FIG. 9, by measuring 322 and pre-cutting 324 lengths of waterproof seam tape 130 to be positioned behind all panel joint locations 164 including the center joint 132 and two corner joints 184 on a standard receptor, and installing 326 said waterproof seam tape 130 from a header stud 142 downward over a shower base flange 134 and terminating at a bottom edge of said flange 134 to provide waterproofing.

The method also includes preparing and installing 328 a hybrid polymer adhesive 118 by applying 330 said adhesive 118 at all panel joint locations 164, dispensing 332 two beads of said adhesive 118 from a container 118b at approximately ⅜-inch to ½-inch diameter per joint location 164 at the center of each stud 122 including the header stud 142, the sister stud 122 at the back wall, and the corner stud interfaces 184, ensuring that adhesive extends the full length of each stud 122, and further applying 334 said adhesive onto the shower base flange 134. This may be seen in FIGS. 6-8.

The method also includes misting 336 the freshly applied hybrid polymer adhesive 118 with potable water 158, as shown in FIG. 8.

The method further includes installing 338 said waterproof seam tape 130 over said hybrid polymer adhesive 118 so as to overlap said shower base flange 134 and terminate at said bottom edge of said flange 134, as may be appreciated in FIGS. 9 and 10.

The method additionally includes installing 340 a first prefabricated panel 104, represented in FIG. 11, with complete contact of a panel backer surface 140 (which may be appreciated in FIG. 26) into all adhesive-covered stud 122 areas, ensuring 342 said seam tape 130 is fully covered with adhesive 118 and the panel 104 is fully embedded, pressing 344 said panel 104 into place with pressure and rubbing down all stud 122 locations and the shower base flange 134 to ensure complete adhesive contact to the header 142 and wall studs 122, and securing 346 said panel 104 with bracing 162 (as shown in FIG. 13) at a center stud location 122 to maintain compression during adhesive curing.

The method also includes applying 348 said hybrid polymer adhesive 118 to a side edge 188 of said first panel 104 (as shown in FIG. 14) and installing 350 a second prefabricated panel 104 (as shown in FIG. 15) with complete contact of its backing into all adhesive-covered stud areas, ensuring 352 that adhesive makes complete contact with both panel edges 188 at a center panel joint 132, pressing 354 said second panel 104 into place with pressure and rubbing down all stud locations and the shower base flange 134 to ensure complete adhesive contact. FIG. 16 illustrates the second panel 104 secured with a second brace 164.

The method also includes applying 356 said adhesive 118 to side edges 188 of subsequent prefabricated panels 104 (as shown in FIG. 17) at the tile backer board 106 and structural layer 108 edges, installing 358 said subsequent panels 104 with complete contact of the backing into adhesive-covered stud areas, ensuring 360 complete adhesive contact at corner panel joints 184, pressing 362 each panel 104 into place with pressure and rubbing down all stud locations and the shower base flange 134 to ensure complete adhesive contact.

The method also includes applying 364 said adhesive 118 to a side edge 188 of a further panel 104 (shown in FIGS. 18 and 20) at the tile backer board 106 and structural layer 108 edge, installing 366 said further panel 104 with complete contact of the backing 140 into adhesive-covered stud areas 122, ensuring 368 adhesive contact at the corner panel joint 184, pressing 370 said further panel 104 into place with pressure and rubbing down all stud locations 122 and the shower base flange 134 to ensure complete adhesive contact.

The method further includes installing 372 temporary braces 162 (shown in FIG. 21) on said prefabricated panels 104 until said hybrid polymer adhesive has achieved an initial set, and applying 374 grout 144 at all panel joint locations 132 including along an upper edge of said shower base 136 and a ceiling edge of the installation, conceptually illustrated in FIG. 22.

In some embodiments, the method is reproduced for ceiling applications, where the studs are the ceiling joists, the adhesive is applied, and the panel 104 is placed in a horizontal orientation and pressed against the ceiling by way of the ceiling joists, and braced with a brace 164, as shown in FIG. 21.

In another exemplary embodiment, a method 300b of installation for a prefabricated tile panel system 102 is disclosed. The method 300b includes providing 302 a plurality of prefabricated panels 104, as described above, providing 302 a hybrid polymer adhesive 118 configured for bonding the prefabricated panels 104 directly to a support structure 120 without an intervening substrate, and providing 304 a cured bond agent 128 (shown in FIG. 20) for implementation between said at least one prefabricated panel 104 and said support structure 120 formed while said panels 104 are braced during adhesive curing. The support structure may be a wall framing member 122, a subfloor 124, or a shower base flange 134.

In some embodiments, where the panels 104 are installed in a horizontal application, such as on the floor, as may be seen in FIGS. 23-33, including shower applications, the method 300b includes further steps. The method 300b includes installing and preparing 376 adhesive 118 on a flooring panel 104 by applying 384 a hybrid polymer adhesive 118 onto said panel 104 using a caulking gun 156, as shown in FIG. 26, dispensing 386 a bead of said adhesive 118 approximately three-eighths inch to one-half inch in diameter positioned about one inch from edges 188 of said panel 104 around an entire perimeter thereof, dispensing 388 said adhesive 118 in a serpentine pattern across a central portion of said panel 104 at intervals of approximately six to eight inches, and misting 390 all applied adhesive immediately and thoroughly with potable water 158, as shown in FIG. 27.

In some embodiments, the step of installing and preparing 376 adhesive on the flooring panel 104 further includes carefully cutting 392 an end of an adhesive tube 118b to remove a seal staple, cutting 378 an adhesive cartridge tip 198 to approximately one-half inch in diameter, loading 380 said adhesive cartridge 118b into a caulking gun 156, and testing 382 on scrap material to ensure a minimum bead diameter of approximately three-eighths inch to one-half inch.

The method also includes placing 394 said flooring panel 104 by carrying 406 and positioning 408 said panel 104 onto a substrate surface where said panel layout 168 has been marked, pressing 410 said panel 104 into said adhesive by applying 412 pressure, as shown in FIG. 29, in close proximity across adhesive-applied portions to ensure transfer of said adhesive to said substrate while avoiding 414 damage to said panel 104, spacing 416 grout spacers 178 between adjacent panels 104 during installation, as shown in FIG. 30, and repeating 418 said placing step for each panel 104 in said flooring installation. This may be appreciated in FIGS. 28-31.

In some embodiments, the step of placing 394 a flooring panel further comprises moving 404 said flooring panel 104 using suction cups or suction cups with rail supports 174, as shown in FIG. 28.

In some embodiments, the step of placing 394 a flooring panel 104 further comprises creating 396 a site plan layout 168 by marking 398 said panel layout 168 on a substrate using snap chalk lines 170, as shown in FIGS. 23-24, adding 400 a minimum grout joint 132 spacing 132b of approximately one-eighth inch, and leaving 402 expansion gaps 182 of approximately one-quarter inch to one-half inch around walls 196 and abutments to accommodate movement.

The method 300b further includes avoiding 420 movement of said flooring panels 104 once placed and permitting said adhesive to cure, cleaning 422 a surface 194 of said panels 104 as needed and allowing said surface to dry, and installing 424 grout 144 at all panel joint locations 132, as shown in FIG. 32.

The method 300b also includes installing 426 a silicone sealant 146 at all movement joint locations 148, as shown in FIG. 33. In some embodiments, the step of installing 426 a silicone sealant 146 at all movement joint locations 148 comprises using a commercial one hundred percent silicone sealant. In some embodiments, the step of installing 426 a silicone sealant 146 at all movement joint locations 148 is carried out in accordance with TCNA EJ171 requirements.

While there has been shown and described above the preferred embodiment of the instant invention it is to be appreciated that the invention may be embodied otherwise than is herein specifically shown and described and that certain changes may be made in the form and arrangement of the parts without departing from the underlying ideas or principles of this invention as set forth in the Claims appended herewith.