Ceramic Floor Elements with Resin Layers and Mechanical Coupling

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Solution Overview

Problem

Existing ceramic tile installations face challenges such as labor-intensive installation, reduced impact strength, noise, and water permeability in floating floor coverings, and difficulty in replacing individual tiles without damaging adjacent ones.

Innovation Solution

A floor element comprising a decorative ceramic layer, a resin intermediate layer with a modulus of elasticity greater than 0.1 GPa, and a support layer with coupling elements, which enhances impact resistance and mechanical locking without adhesives.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If traditional adhesive installation is used, then impact strength and noise attenuation are improved, but installation labor and time increase significantly

Engineering Contradiction:

Improveimpact strengthVSAvoidinstallation speed

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

The patent extracts the adhesive bonding function and replaces it with a mechanical coupling system. The coupling elements (click-lock mechanism) are integrated into the support layer edges, allowing floor elements to be connected mechanically without adhesives, thereby improving installation speed while maintaining structural integrity

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent changes the bonding mechanism from chemical (adhesive) to mechanical (coupling elements). The support layer is designed with specific geometric features (edges with coupling elements) that enable mechanical interlocking, fundamentally changing how floor elements are attached while improving installation efficiency

Inventive Principle:

Principle #35Parameter changes

2Productivity

If floating floor covering is used, then installation labor is reduced, but impact strength and noise attenuation deteriorate

Engineering Contradiction:

Improveinstallation speedVSAvoidimpact strength

Core Design Contradiction:

ProductivityVSStrength

Solution Approach 1:

The patent creates a composite structure where a rigid support layer (providing strength) is combined with a decorative layer (ceramic, stone, or composite material). This composite construction maintains high impact strength while the integrated coupling elements enable floating installation, resolving the contradiction between ease of installation and structural performance

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The coupling elements feature curved or angled surfaces that enable a click-lock mechanism. The edges of the support layer are shaped to interlock mechanically, providing both the floating installation capability and the structural strength needed to resist impact loads

Inventive Principle:

Principle #14Spheroidality (Curvature)

3Ease of repair

If individual tiles need to be replaced, then floor maintenance is improved, but risk of damaging adjacent tiles increases

Engineering Contradiction:

Improvetile replacement easeVSAvoiddamage to adjacent tiles

Core Design Contradiction:

Ease of repairVSObject-affected harmful factors

Solution Approach 1:

The patent divides the floor covering into discrete, modular floor elements that are mechanically connected but not permanently bonded. Each element can be independently accessed and replaced by disengaging the coupling mechanism, allowing easy maintenance without affecting surrounding tiles

Inventive Principle:

Principle #1Segmentation

4Ease of operation

If mechanical coupling is used, then installation simplicity is improved, but water penetration resistance deteriorates

Engineering Contradiction:

Improveinstallation simplicityVSAvoidwater penetration resistance

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent merges the mechanical coupling function with the water resistance function into a single integrated edge structure. The coupling elements are designed to create both mechanical interlocking and water-tight sealing, eliminating the need for separate grouting operations while maintaining both simplicity and reliability

Inventive Principle:

Principle #5Merging (Combining)

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 provides improved impact strength and noise reduction, allowing for easier installation and replacement of tiles while maintaining a level surface, with impact resistance comparable to traditionally adhesive-installed tiles.

Implementation Method 1

an intermediate layer comprising a resin material... wherein the resin material has a modulus of elasticity greater than 0.1 GPa

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS12366074B2Floor element for forming a floor covering, a floor covering, and a method for manufacturing a floor element

Publication Date: 2025.07.22 DAL-TILE LLC

AI summary

A floor element for forming a floor covering, the floor element comprising a decorative layer comprising a ceramic material, an intermediate layer comprising a resin material, and a support layer arranged below the decorative layer, wherein the support layer comprises edges provided with coupling elements configured to realize a mechanical coupling with coupling elements of an adjacent floor element and wherein the resin material comprises a modulus of elasticity greater than 0.1 GPa, preferably greater than 0.5 GPa, even more preferably greater than 1 GPa.