Ceramic Tile Panel High-Viscosity Adhesive Bonding
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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 polymer-, mineral-, or wood-based core layers, they are prone to fracturing and breakage due to uneven support and thermal stress caused by adhesive application.
Innovation Solution
A panel design featuring a ceramic tile with a bottom surface having pores, where an adhesive layer with a viscosity higher than 1,000 Pas is applied between the ceramic tile and a core layer with complementary coupling parts, providing sufficient adhesion without permeating into the tile body, thus preventing thermal stress and facilitating easy installation and removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional ceramic tiles are installed on mortar with cavities on the back surface, then adhesion strength is improved, but installation complexity and removal difficulty increase
Solution Approach 1:
The invention segments the bonding interface by introducing a separate adhesive layer that is applied to the core layer rather than requiring cavities in the tile. This separates the adhesion function from the tile structure itself, allowing standard flat tiles to be used while still achieving strong bonding through the adhesive layer applied to the core layer's surface.
Solution Approach 2:
The adhesive layer acts as an intermediary between the ceramic tile and the core layer. Instead of the tile directly contacting mortar or requiring cavity modifications, the adhesive layer mediates the bonding process, providing a simple application method that achieves strong adhesion without modifying the tile structure.
2Ease of operation
If adhesive layer is applied between ceramic tile and core layer, then installation ease is improved, but thermal stress and breakage risk increase
Solution Approach 1:
The adhesive layer is applied locally to the core layer surface rather than throughout the entire tile structure. This localized application minimizes the adhesive's presence in the thermal expansion zone while still providing necessary bonding, thereby reducing thermal stress accumulation that would otherwise cause cracks and breakage.
3Strength
If adhesive permeates into ceramic tile pores, then adhesion surface area is improved, but staining and discoloration increase
Solution Approach 1:
The invention extracts the adhesive application from the tile pores and relocates it to the core layer surface. By taking out the adhesive from the porous tile structure and applying it to the non-porous core layer surface, the solution achieves adequate adhesion surface area while preventing adhesive penetration into the tile that would cause staining and discoloration.
4Strength
If thick layer of mortar is used for installation, then adhesion strength is improved, but installation precision requirements increase
Solution Approach 1:
The invention changes the parameter of adhesive application from a thick mortar layer to a controlled thin adhesive layer applied to the core layer surface. This parameter change maintains sufficient adhesion strength while significantly reducing the precision requirements for installation, as the adhesive layer provides a consistent bonding surface without requiring the precise leveling needed for thick mortar installations.
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 without compromising their durability, preventing thermal stress-induced fractures and ensuring the tiles' aesthetic integrity by sealing pores and distributing stress evenly.
Implementation Method 1
at least one adhesive layer provided between the ceramic tile and the core layer; wherein the bottom surface of the ceramic tile comprises pores, wherein the pores define a void surface area, and wherein the contact surface area between the adhesive layer and the ceramic tile is defined by the difference between the bottom surface area and the void surface area
Data Source
Figure 1~2
Figure 3~4
Figure 5A~6B
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.