Composite Tile Molding to Prevent Fracture and Delamination
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Solution Overview
Problem
Ceramic tiles used in landscaping are brittle and prone to fracture during manufacturing due to inadequate support, and alignment with concrete bases can lead to delamination issues.
Innovation Solution
A method involving applying adhesive to a tile, positioning it in a mold cavity with a concrete mixture, and applying pressure and/or vibration to form a reinforced tile product, followed by curing in a controlled environment to enhance strength and alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If ceramic tile is used in landscaping without proper support, then installation is simple, but the tile easily fractures due to brittleness
Solution Approach 1:
The patent creates a composite structure by bonding a ceramic tile to a concrete base. The concrete base provides the necessary strength and support while the ceramic tile maintains its decorative properties. This composite approach allows the tile to be used in landscaping applications without the risk of fracture that would occur with ceramic tile alone.
2Strength
If concrete backing is added to ceramic tile to increase strength, then tile strength improves, but the manufacturing process may apply too much stress causing tile breakage
Solution Approach 1:
The patent applies adhesive to the tile surface before placing it on the concrete base. This preliminary application of bonding material ensures that when the concrete is poured and cured, the adhesive is already in position to bond the tile to the concrete without causing stress or damage to the tile during the manufacturing process.
Solution Approach 2:
The adhesive acts as an intermediary bonding agent between the ceramic tile and concrete base. It facilitates the bond while distributing stresses evenly, preventing direct contact between the rigid tile and concrete that would cause stress concentration and potential tile breakage.
3Manufacturing precision
If tile is post-applied to concrete base, then alignment precision is insufficient, but delamination occurs
Solution Approach 1:
The patent positions the tile on the concrete base while the concrete is still in a workable state, before final curing. This allows for precise alignment and adjustment during the bonding process, ensuring that the tile is correctly positioned relative to the concrete base. The adhesive is applied and activated during this preliminary positioning phase, creating a strong bond before the concrete fully cures.
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 method produces a reinforced tile product with improved strength and alignment, reducing breakage and delamination risks, suitable for landscaping applications.
Implementation Method 1
applying an adhesive to a first side of a tile, and after applying the adhesive, facing the first side of the tile toward the concrete mixture in the mold cavity
Implementation Method 2
pressure and/or vibration may be applied to the concrete mixture (before placing the tile on the concrete mixture) to densify the concrete mixture
Implementation Method 3
pressure and/or vibration may be applied to the concrete mixture (before placing the tile on the concrete mixture) to densify the concrete mixture
Implementation Method 4
after removing the tile and concrete mixture assembly from the mold cavity, placing the tile and concrete mixture assembly curing the tile and concrete mixture assembly
Data Source
AI summary
A method and system for manufacturing a tile product includes applying a concrete mixture to a mold, applying an adhesive to a first side of a tile, after the adhesive is applied, facing the first side of the tile toward the concrete mixture in the mold and positioning the first side of the tile on the concrete mixture in the mold and then followed by removing the product from the mold.