Composite Floor Element Structure for Impact-Resistant Floating Tiles

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Floating installations of ceramic tiles are prone to impact breaking and fatigue due to lack of solid bonding to the subfloor, and the flexibility of the covering reduces the fatigue strength, especially at grout joints.

Innovation Solution

A floor element design comprising a decorative layer, a support layer, and an intermediate layer with offset edges, where the intermediate layer is bonded with a resin or metal plate to enhance rigidity and impact resistance, allowing mechanical coupling with adjacent elements in a 50/50 offset pattern.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If floating installation is used for ceramic tiles, then ease of installation is improved, but impact resistance deteriorates

Engineering Contradiction:

Improveease of installationVSAvoidimpact resistance

Core Design Contradiction:

Ease of operationVSStrength

Solution Approach 1:

The floor element uses a composite structure combining a ceramic decorative layer with a polymeric support layer. The ceramic layer provides aesthetic and durability properties while the polymeric support layer provides flexibility and impact absorption, resolving the contradiction between ease of floating installation and impact resistance.

Inventive Principle:

Principle #40Composite materials

2Ease of operation

If floating installation is used for ceramic tiles, then ease of installation is improved, but fatigue strength deteriorates

Engineering Contradiction:

Improveease of installationVSAvoidfatigue strength

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The composite structure of ceramic decorative layer over polymeric support layer creates a system where the polymeric base absorbs stresses and movements, preventing fatigue propagation to the ceramic tiles while maintaining floating installation advantages.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The polymeric support layer acts as a cushioning layer that absorbs and dissipates impact energies and stresses before they can reach the ceramic decorative layer, preventing fatigue damage in advance.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Reliability

If grout is used to fill joints between tiles, then impermeability is improved, but fatigue resistance deteriorates

Engineering Contradiction:

ImproveimpermeabilityVSAvoidfatigue resistance

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The invention extracts the grout from the joint area and replaces it with a mechanical coupling system between support layers. The coupling elements (tongue and groove) provide both impermeability through continuous support layer contact and fatigue resistance through flexible mechanical connection, eliminating the contradictory role grout played in traditional installations.

Inventive Principle:

Principle #2Taking out (Extraction)

Data Source

PatentUS20260028832A1Floor element for forming a floor covering and a floor covering

Publication Date: 2026.01.29 DAL-TILE LLC

AI summary

Floor element for forming a floor covering, wherein the floor element comprises a decorative layer, a support layer, and optionally an intermediate layer disposed between the decorative layer and the support layer, wherein the decorative layer is made of a brittle material, wherein the floor elements comprises edges provided with coupling elements adapted to cooperate with coupling elements of an adjacent similar floor element in said floor covering and wherein the intermediate layer comprises at least one edge that is offset relative to a respective edge of the decorative layer.