Ceramic Tile Tapered Opening Fastener Protection
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Solution Overview
Problem
Ceramic tiles with large openings face issues with cap protection and polymeric compound abrasion, leading to fastener exposure and reduced service life when used in applications like grain elevators, where mechanical fasteners or welds are subject to wear and tear.
Innovation Solution
Designing ceramic tiles with a smaller opening size and a tapered configuration, along with the use of inserts and polymeric compounds, to reduce abrasion and extend the service life by minimizing the exposure of polymeric materials and protecting fasteners from wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a large opening is used in the ceramic tile for fastener installation, then the fastener can be easily installed, but the polymeric compound is more exposed to abrasion and the fastener is more vulnerable to wear
Solution Approach 1:
The opening transitions from a uniform large opening to a non-uniform opening with a tapered portion that creates local variation in size. The narrowest portion provides enhanced protection for the polymeric compound and fastener while still allowing fastener installation through the wider portions.
2Ease of operation
If a large opening is used in the ceramic tile, then fastener installation is easier, but the service life is reduced due to increased abrasion
Solution Approach 1:
The tapered portion creates a localized narrow region that minimizes the exposure of polymeric compound to abrasion while maintaining adequate opening size for fastener installation, thereby extending the service life of the ceramic tile assembly.
Solution Approach 2:
The tapered configuration is pre-formed in the opening before fastener installation, proactively reducing the exposure area of polymeric material to potential abrasion from conveyed materials, thus preventing wear before it occurs.
3Reliability
If a small opening size is used, then polymeric compound exposure is minimized, but fastener installation becomes more difficult
Solution Approach 1:
The opening employs different local dimensions: wider regions facilitate fastener installation while a narrower tapered portion minimizes polymeric compound exposure. This spatial variation in opening size resolves the contradiction between installation ease and protection.
4Ease of manufacture
If a uniform opening is used, then manufacturing is simpler, but protection during operation is reduced
Solution Approach 1:
The opening transitions from a uniform cross-section to a non-uniform cross-section with a tapered portion. This geometric modification enhances protection for the fastener and polymeric compound while remaining manufacturable through conventional ceramic forming and drilling processes.
Data Source
AI summary
A ceramic tile includes an opening that is used to help fasten the ceramic tile to a mounting object. The opening can have a relatively small width that can obviate the need for a cap and can allow for less abrading of a polymer compound that is exposed adjacent to a major surface of the ceramic tile. In an embodiment, an insert is placed into the opening in the ceramic tile, and the ceramic tile is fastened to a wall using a welding technique. In other embodiments, different shapes of openings and fastening techniques can be used.