Ceramic Floor Element With Resin-Bonded Floating Tile Structure
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Solution Overview
Problem
Existing ceramic tile installations are labor-intensive, costly, and require professional expertise, while floating floor coverings lack impact strength and are prone to noise and water penetration, making them unsuitable for commercial use.
Innovation Solution
A floor element comprising a ceramic decorative layer bonded to a support layer via a resin intermediate layer that permeates the decorative layer's lower surface, enhancing impact resistance and mechanical coupling without additional reinforcing elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If ceramic tiles are installed using adhesive bonding to a rigid subfloor, then impact strength and fatigue strength are improved, but installation labor intensity and cost increase significantly
Solution Approach 1:
The floor covering is divided into modular floor elements that can be mechanically coupled together without requiring adhesive bonding to the subfloor. Each element includes coupling elements (protrusions and recesses) that enable self-assembly, eliminating the need for professional installation labor while maintaining structural integrity through the modular interlocking design
Solution Approach 2:
The floor elements are designed to be self-assembling through mechanical coupling features. The coupling elements allow the elements to interlock with adjacent elements automatically when placed together, eliminating the need for adhesive application and professional installation expertise, thereby reducing labor intensity while maintaining impact strength
2Ease of operation
If floating floor covering without adhesive bonding is used, then installation labor and time are reduced, but impact strength and fatigue strength are significantly reduced
Solution Approach 1:
Multiple functional features are merged into a single support layer structure. This layer simultaneously provides mechanical support, contains the coupling elements for element interlocking, and includes damping elements that absorb impact energy. This integration allows the floating floor to achieve adequate impact strength without adhesive bonding to the subfloor
Solution Approach 2:
Damping elements are incorporated into the support layer structure in advance to cushion impact forces before they reach the ceramic tiles. These elements absorb shock and reduce the transmission of impact forces, enabling the floating floor configuration to maintain sufficient impact strength without adhesive bonding
3Device complexity
If floating floor covering without adhesive bonding is used, then installation complexity is reduced, but water penetration through joints increases
Solution Approach 1:
A grout layer is introduced as an intermediary substance that fills the joints between floating floor elements. This grout creates a water-tight barrier that prevents water penetration while allowing the elements to remain mechanically coupled without adhesive bonding to the subfloor, thus maintaining installation simplicity while addressing water protection
4Strength
If additional reinforcing elements are added to improve impact resistance, then impact strength is improved, but device complexity and manufacturing complexity increase
Solution Approach 1:
The support layer is constructed as a composite structure combining rigid support material with flexible damping elements. This composite design provides both mechanical support and impact absorption within a single integrated layer, avoiding the need for separate reinforcing elements and reducing overall structural complexity while maintaining impact strength
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution achieves impact strength comparable to adhesive-bonded tiles, reduces installation complexity, and minimizes noise and water penetration, while maintaining a lightweight and thin profile.
Implementation Method 1
an intermediate layer having a resin material that permeates a lower surface of the decorative layer
Implementation Method 2
resin material that permeates the decorative layer's lower surface
Data Source
AI summary
A floor element for forming a floor covering, wherein the floor element comprises a decorative layer made of a ceramic material and a support layer arranged below the decorative layer, wherein the support layer comprises edges provided with coupling elements configured to allow a mechanical coupling with coupling elements of an adjacent floor element and wherein the floor element comprises an intermediate layer having a resin material that permeates a lower surface of the decorative layer. A method for manufacturing a floor element, comprising the steps of: (i) providing a decorative layer made of a ceramic material; (ii) providing a support layer; (iii) providing a resin material for bonding the decorative layer and the support layer together; (iv) pressing the layers together for forming the floor element such that the resin material permeates the ceramic layer.