Laminated Tile Adhesive Bonding via Polyurethane Polymerization
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Solution Overview
Problem
Existing laminated tiles composed of a ceramic or natural stone upper layer and a concrete base fail to withstand temperature and humidity fluctuations, leading to fracture and deterioration when used outdoors, making them unsuitable for large-scale outdoor applications.
Innovation Solution
A manufacturing method for laminated tiles that uses a water polymerizable polymerization system, specifically a polyurethane adhesive with di-isocyanate monomers, to achieve excellent adhesive strength between the ceramic or solid tile body and the concrete body, ensuring a stress-free bonding that remains stable under varying weather conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional adhesive methods are used to bond solid tile body and concrete body, then the manufacturing process is simple, but the adhesive strength is insufficient and the bond fails under temperature and humidity fluctuations
Solution Approach 1:
The patent changes the chemical parameters of the adhesive system by using a two-component polyurethane system (isocyanate + polyol) instead of conventional single-component adhesives. This chemical parameter change enables the adhesive to maintain flexibility and bonding strength under varying temperature and humidity conditions, resolving the contradiction between adhesive strength and environmental resistance.
Solution Approach 2:
The patent creates a composite adhesive system combining isocyanate monomers with polyol compounds to form polyurethane polymers. This composite material approach provides both high adhesive strength and flexibility to withstand environmental fluctuations, simultaneously achieving improved strength and reliability.
2Strength
If rigid bonding is used between solid tile body and concrete body, then the bond is strong initially, but the bond becomes stressed and fails under weather conditions
Solution Approach 1:
The patent employs a dynamic bonding system where the polyurethane adhesive can flex and adapt to dimensional changes in the concrete and tile. This dynamic property allows the bond to maintain integrity under weather-induced expansion and contraction, achieving both initial strength and long-term stability without stress accumulation.
Solution Approach 2:
The polyurethane adhesive layer acts as a flexible bonding film between the rigid tile and concrete. This flexible intermediate layer accommodates differential movement and thermal expansion, preventing stress buildup while maintaining strong initial adhesion, thus resolving the contradiction between rigid bond strength and compositional stability.
3Ease of manufacture
If traditional manufacturing methods are used, then the process is straightforward, but the laminated tiles suffer from fracture and deterioration in outdoor conditions
Solution Approach 1:
The patent modifies the manufacturing process by introducing a two-component adhesive system that requires mixing and controlled application. While this adds some process complexity, it dramatically improves outdoor durability by creating a flexible, weather-resistant bond that prevents tile fracture and deterioration, justifying the increased manufacturing effort.
Solution Approach 2:
The polyurethane adhesive serves as an intermediary material between the tile and concrete that provides weather protection. This intermediary layer shields the bond line from direct environmental exposure, preventing deterioration while maintaining a relatively simple manufacturing process through direct application methods.
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 results in laminated tiles that are substantially resistant to moisture and temperature fluctuations, with adhesive strength exceeding that of the concrete itself, allowing for durable outdoor use without fracture or deterioration.
Implementation Method 1
a water polymerizable polymerization system, which is a polymerization system that comprises water for polymerization of the monomers
Implementation Method 2
a primer composition that comprises monomers that form part of a water polymerizable polymerization system... polymerizing said primer composition for obtaining a laminated tile with an elastic bonding between the solid tile body and the concrete body
Implementation Method 3
during polymerization the adhesive is not completely hardened and therefore will adapt to the shape and size of the concrete on the one hand and the shape and size of the solid tile body on the other hand. Such yields a bonding that virtually is stress free
Data Source
Figure 1~2
AI summary
The present invention relates to a method for manufacturing a laminated tile comprising a mutually connected solid tile body and concrete body, said method comprising the steps of: a) applying a primer to a first surface of said solid tile body, wherein said primer comprises monomers that form part of a water polymerizable polymerization system, b) applying a concrete mixture on top of said tile's first surface, c) hardening said concrete mixture and said primer at least partially for obtaining a green laminated product, and d) optionally fully hardening said concrete and said primer for obtaining said laminated tile if said full hardening was not obtained in step c). The invention also relates to a laminated tile, comprising a mutually connected solid tile body and a concrete body, said solid tile body and concrete body being connected through an adhesive, said adhesive being the polymerization product of monomers that form part of a water polymerizable polymerization system.