Composite Tile Structure with Interlocking Substrate

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Solution Overview

Problem

Traditional ceramic tile construction methods are labor-intensive, costly, and require skilled workers due to the need for precise leveling and grouting, and they lack durability, noise insulation, and moisture resistance.

Innovation Solution

A composite tile structure comprising a surface layer (ceramic or stone) bonded to a substrate layer (wood, plastic, or composite materials) with interlocking tenon and groove connections, allowing for dry installation and enhanced durability, noise absorption, or insulation through a foam layer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If traditional wet construction methods are used for ceramic tiles, then the tiles can be installed on the floor, but the construction process becomes tedious and complicated requiring skilled workers

Engineering Contradiction:

Improveease of installationVSAvoidconstruction process complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The tile structure is segmented into distinct functional layers: a ceramic surface layer for aesthetics and durability, and a separate substrate layer (wood, plastic, or composite) for structural support and installation flexibility. This segmentation allows each layer to be optimized independently and simplifies the installation process by enabling dry stacking without wet mortar work

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The tile incorporates flexible substrate materials (wood, plastic, or composite materials) that can adapt to floor irregularities, replacing the rigid traditional ceramic-on-mortar system. This dynamic substrate layer absorbs installation variations and eliminates the need for skilled workers to achieve precise leveling

Inventive Principle:

Principle #15Dynamics

2Manufacturing precision

If traditional ceramic tiles are used, then the floor maintains beauty and durability, but gaps between tiles require tile levelers and grouting

Engineering Contradiction:

Improvetile flatnessVSAvoidinstallation simplicity

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

The tile structure features an embedded substrate layer within the ceramic surface layer, creating a composite structure where the flexible substrate compensates for surface irregularities. This nested design allows the tile to self-level without requiring external tile levelers or grouting materials to fill gaps

Inventive Principle:

Principle #7Nested doll (Nesting)

3Manufacturing precision

If skilled workers are used for tile installation, then precise leveling can be achieved, but labor costs increase and skilled workers become scarce

Engineering Contradiction:

Improveleveling precisionVSAvoidinstallation efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The composite tile structure is designed to be self-installing through its flexible substrate layer that automatically adapts to floor variations. The tile performs its own leveling function without requiring skilled workers to manually adjust and level each tile, enabling ordinary workers to achieve precise installation results

Inventive Principle:

Principle #25Self-service

4Reliability

If ceramic tiles are used for floor decoration, then moisture and water resistance is achieved, but noise insulation and shock absorption are lacking

Engineering Contradiction:

Improvemoisture resistanceVSAvoidnoise and shock

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The tile combines ceramic material (providing moisture and water resistance) with flexible substrate materials (wood, plastic, or composite materials) that provide noise insulation and shock absorption. This composite structure integrates multiple material properties into a single tile unit, simultaneously achieving durability, acoustic comfort, and impact resistance

Inventive Principle:

Principle #40Composite materials

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

Facilitates rapid, cost-effective installation with reduced labor requirements, improved durability, noise absorption, and insulation capabilities, enabling precise fitting without skilled workers and enhancing the tiles' resistance to bending and moisture.

Implementation Method 1

the surface layer and the substrate layer are bonded by adhesive

Methodology Applied

Scientific EffectAdhesive bonding: Adhesive

Implementation Method 2

by incorporating a soft foam layer at the bottom of the substrate layer, it provides sound absorption and shock absorption effects

Methodology Applied

Scientific EffectSound absorption: Acoustic Absorption

Implementation Method 3

if a hard foam layer is installed at the bottom of the substrate layer, it can be utilized for efficient insulation purposes

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS20240295128A1Composite tile structure

Publication Date: 2024.09.05 JUUYUAN WOODEN MFG CO LTD

AI summary

A composite tile structure for the rapid laying of multiple tiles on the floor or walls, and includes a surface layer, a substrate layer connected to a bottom of the surface layer, a connecting portion formed to one of two sides of the substrate layer, and an overlapping portion formed to another one of the two sides of the substrate layer. The overlapping portion corresponds in shape to the connecting portion. Multiple of the composite tiles can be assembled with each other by engaging the connecting portion of one tile with the overlapping portion of another composite tile.