Ceramic Tile Panel With High Viscosity Adhesive

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Solution Overview

Problem

Conventional ceramic tiles are difficult to install and remove due to their adhesion to mortar, and when combined with unsupportive substrates, they are prone to fracturing and breakage, especially under temperature fluctuations and stress.

Innovation Solution

A panel comprising a ceramic tile with a bottom surface featuring pores and an adhesive layer with a viscosity higher than 1,000 Pas, which provides sufficient adhesion without permeating into the tile body, and a core layer with complementary coupling parts for easy installation and removal.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional ceramic tiles are installed on mortar with cavities on the back surface, then adhesion strength is improved, but installation difficulty and removal difficulty increase

Engineering Contradiction:

Improveadhesion strengthVSAvoidinstallation ease

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The tile back surface is segmented into cavities and flat areas, where cavities provide adhesion strength while flat areas enable straightforward mortar application and alignment, reducing installation difficulty while maintaining bond strength

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of making the entire back surface cavity-filled for adhesion, the invention inverts the approach by using only specific cavity regions for bonding while leaving other areas flat, thereby reducing the complexity of mortar application and alignment tasks

Inventive Principle:

Principle #13The other way round (Inversion)

2Strength

If ceramic tiles with cavities are combined with unsupportive substrates, then adhesion is improved, but tile breakage and fracturing increase

Engineering Contradiction:

ImproveadhesionVSAvoidtile integrity

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The tile back surface has different local qualities: cavities provide adhesion in specific zones while flat areas provide structural support and stress distribution, preventing breakage when combined with unsupportive substrates

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The flat areas on the tile back surface act as pre-positioned support zones that cushion and distribute stresses before they can concentrate at cavity locations, preventing crack initiation and propagation

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Strength

If adhesive layer is applied to ceramic tiles with pores, then adhesion to core layer is improved, but adhesive permeation into tile body causes stress and breakage

Engineering Contradiction:

Improveadhesion to core layerVSAvoidtile durability

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The adhesive layer is applied selectively to flat areas of the tile back surface, avoiding pore-rich regions. This local application strategy ensures strong adhesion to the core layer while preventing adhesive permeation into the tile body that would cause stress and breakage

Inventive Principle:

Principle #3Local quality

4Strength

If conventional tiles are installed on thick mortar layer, then adhesion is improved, but installation precision and evenness decrease

Engineering Contradiction:

ImproveadhesionVSAvoidinstallation precision

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The tile back surface is segmented into cavities and flat areas, where flat areas serve as precise reference planes for alignment and levelness, enabling installation precision even on thick mortar layers while cavities provide the necessary adhesion strength

Inventive Principle:

Principle #1Segmentation

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 allows for easy installation and removal of ceramic tiles by non-experts, prevents breakage by sealing pores, and maintains the tile's durability and aesthetic integrity, while the high viscosity adhesive prevents ingress and thermal stress.

Implementation Method 1

the adhesive layer has a viscosity of more than 1,000 Pas at time of application

Methodology Applied

Scientific EffectViscosity: Viscometer

Implementation Method 2

at least one adhesive layer is provided between the ceramic tile and the core layer

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentUS11326356B2Floor or wall panel

Publication Date: 2022.05.10 CHAMPION LINK INT

AI summary

The invention relates to a panel, in particular a floor panel or a wall panel configured for forming a floor or wall covering, the panel comprising at least one core layer, the core layer comprising at least one pair of opposite side edges which are provided with complementary coupling parts configured for interconnecting adjacent panels, the core layer comprising an upper core surface and a bottom core surface, and at least one ceramic tile, the ceramic tile comprising an upper surface and a bottom surface and the panel further comprising at least one further layer.