Interlocking systems and methods for tile panel mounting
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Solution Overview
Problem
Traditional methods for installing large format tile panels are time-consuming, labor-intensive, and require multiple resources and expertise, especially in environments exposed to water and moisture, such as bathrooms and kitchens, where they can be fragile and challenging to handle.
Innovation Solution
A mechanical mounting system using fastening tracks with attached clips that interlock with receiving bodies mounted to a support structure, allowing for secure attachment without mortar, enabling efficient and reusable installation of tile panels on various surfaces, including vertical, horizontal, and curved surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional mortar installation method is used, then tile panels can be securely attached to substrate, but installation process becomes time-consuming and labor-intensive
Solution Approach 1:
The patent replaces the chemical bonding system (mortar) with a mechanical fastening system consisting of clips, fastening tracks, and receiving bodies. This mechanical system provides secure attachment through physical interlocking while significantly reducing installation time and labor requirements compared to traditional mortar application and curing processes
Solution Approach 2:
The patent introduces intermediary components (clips and fastening tracks) that mediate between the tile panel and the substrate. These intermediaries simplify the installation process by providing a standardized mechanical connection system that eliminates the need for skilled mortar application while ensuring reliable attachment
2Reliability
If traditional mortar installation method is used, then tile panels can be attached to substrate, but multiple resources and expertise are required
Solution Approach 1:
The patent replaces the complex chemical process of mortar installation with a simpler mechanical fastening system. The clips, fastening tracks, and receiving bodies create a straightforward assembly process that reduces the need for specialized expertise and multiple resources while maintaining secure attachment
3Shape
If large format tile panels are used, then aesthetic design is improved, but panels become fragile and challenging to handle
Solution Approach 1:
The patent segments the fastening system into multiple components (clips, fastening tracks, receiving bodies) that distribute the load and provide multiple attachment points across large format tile panels. This segmentation enables secure handling and installation of oversized panels by providing numerous grip points and support locations
4Productivity
If mechanical mounting system with clips and fastening tracks is used, then installation becomes faster and more efficient, but system complexity increases
Solution Approach 1:
The patent designs the clips, fastening tracks, and receiving bodies to serve multiple functions: they provide mechanical attachment, enable quick installation and removal, accommodate various tile panel sizes and shapes, and allow for adjustment during installation. This multi-functionality justifies the increased component complexity by delivering significant productivity benefits
Data Source
AI summary
Interlocking systems that mechanically secure tile panels to a supporting structure are enabled. For example, a panel mounting apparatus can comprise: a panel material comprising a first side and a second side, opposite the first side, a substrate material attached to the second side of the panel material, a fastening track attached to the second side of the panel material, adjacent to the substrate material, a mounting clip attached to the fastening track on a first side of the mounting clip, wherein the mounting clip comprises a projection from a second side of the mounting clip, opposite the first side, and a receiving body comprising locking channel that receives the projection, wherein an internal shape of the locking channel compliments an internal shape of the projection.