Modular Tile Panels with Thinset Bonding for Waste Reduction
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Solution Overview
Problem
Existing tile setting methods are time-consuming and wasteful, with significant material waste and dimensional errors due to on-site layer application, and prefabricated solutions are costly and heavy, requiring excessive shipping resources.
Innovation Solution
A tile setting structure comprising modular wall and floor panels with layered construction, including a first rigid layer, a second rigid layer, and a waterproofing layer, attached with thinset mortar, allowing for efficient off-site fabrication and on-site assembly, reducing waste and shipping costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If on-site layer application is used, then flexibility in installation is improved, but time consumption and material waste increase significantly
Solution Approach 1:
The patent applies preliminary action by pre-assembling complete wall panels with all layers (cement backing board, vapor barrier, waterproofing membrane) and tiles attached in a factory setting before delivery to the construction site. This off-site fabrication eliminates on-site layer application, significantly reducing installation time while maintaining design flexibility through modular panel configurations.
Solution Approach 2:
The patent segments the wall structure into modular panels that can be independently fabricated, transported, and installed. Each panel is a self-contained unit with standardized dimensions, allowing parallel fabrication and streamlined on-site assembly. This segmentation resolves the contradiction by enabling factory precision work while simplifying field installation.
2Adaptability or versatility
If on-site layer application is used, then adaptability to site conditions is improved, but material waste increases substantially
Solution Approach 1:
The patent uses preliminary action by pre-cutting and pre-assembling all layers and tiles into precisely fitted panels in the factory. This eliminates on-site cutting and material trimming, thereby eliminating the substantial material waste that occurs during field installation while maintaining adaptability through customized panel design for specific site requirements.
Solution Approach 2:
The patent applies parameter changes by optimizing panel dimensions, layer thicknesses, and material specifications during the design phase to achieve precise fits for specific installations. This allows customization for different site conditions while maintaining factory precision, eliminating the need for on-site material adjustment and the associated waste.
3Ease of manufacture
If dimensional errors in studs or substrate are carried through, then construction simplicity is maintained, but aesthetic quality deteriorates
Solution Approach 1:
The patent introduces an intermediary element—the pre-fabricated wall panel—that acts as a buffer between the irregular substrate and the final tile surface. The panel provides a flat, dimensionally stable mounting surface that isolates the tile layer from substrate imperfections, enabling aesthetic quality without compromising construction simplicity.
Solution Approach 2:
The patent applies preliminary action by creating a dimensionally precise intermediate layer (the panel assembly) in the factory before installation. This pre-established reference surface eliminates the need to compensate for substrate errors during tiling, maintaining both construction simplicity and aesthetic quality.
4Productivity
If prefabricated tiled structure or pod is used, then on-site installation efficiency is improved, but shipping costs increase excessively
Solution Approach 1:
The patent segments the complete tiled wall system into modular panels of optimized dimensions for efficient transport. This segmentation allows the structure to be disassembled into manageable units that fit standard shipping containers, reducing shipping energy consumption while maintaining the installation efficiency benefits of prefabrication.
Solution Approach 2:
The patent applies dimensionality change by designing panels that can be flat-packed or efficiently stacked during transport, optimizing space utilization in shipping containers. This dimensional optimization reduces the number of trips required and lowers shipping energy consumption while preserving the rapid installation advantages of prefabricated components.
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 solution enables efficient, cost-effective, and aesthetically pleasing tile installation with reduced material waste and shipping costs, as well as improved dimensional accuracy by allowing for precise off-site panel construction and assembly without reliance on on-site studs.
Implementation Method 1
a second rigid layer attached to the first rigid layer by a thinset mortar, and a waterproofing layer formed of a flexible material and attached to the second rigid layer by the thinset mortar
Implementation Method 2
attaching each of the plurality of wall panels to either the floor panel or one of the other wall panels with a waterproof caulk
Data Source
AI summary
A method of setting tile includes constructing a floor panel and a plurality of wall panels and attaching each of the plurality of wall panels to either the floor panel or one of the other wall panels with a waterproof caulk. Each of the wall panels includes a first rigid layer, a second rigid layer attached to the first rigid layer by a thinset mortar, and a waterproofing layer formed of a flexible material and attached to the second rigid layer by the thinset mortar.