Moisture-Curable Adhesive for Large Format Tile Installation
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Solution Overview
Problem
Current methods for mounting large format tiles, especially gauged porcelain panels, on wall surfaces face challenges such as breakage, adhesion issues, messy application processes, and difficulty in repositioning due to the use of traditional ceramic tile adhesives, which result in inefficiencies and potential failures.
Innovation Solution
A moisture-curable adhesive composition comprising silane-terminated polyalkylene oxide or polyurethane, amino-silane modified wollastonite fibers, and a combination of treated and untreated fillers, along with a rheology modifier, is applied to the back surface of large format tiles, allowing for improved sag resistance and repositionability without the need for a 'back buttering' step.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional ceramic tile adhesive is used to mount large format tiles, then the adhesive provides initial bonding strength, but the tile cannot be repositioned and is prone to breakage during installation
Solution Approach 1:
The adhesive composition transitions from a flexible, repositionable state during installation to a rigid, strong bond after curing. The uncured adhesive allows tile repositioning while maintaining bonding capability, and upon curing through moisture reaction, develops full structural strength to prevent future movement and breakage.
2Ease of manufacture
If traditional mortar-based adhesive is used, then the adhesive can be applied to tile surfaces, but the application process is messy and creates excessive dust
Solution Approach 1:
The invention replaces the mechanical mixing and application of traditional mortar with a pre-formulated adhesive composition that requires no mixing. The adhesive comes ready-to-apply in a controlled formulation, eliminating dust generation from mixing operations and reducing mess during application while maintaining effective bonding capability.
3Reliability
If traditional mortar adhesive is used with back buttering step, then the adhesive coverage is improved, but the labor time and complexity increase significantly
Solution Approach 1:
The invention combines the adhesive application into a single step that eliminates the separate back buttering process. The adhesive composition is designed to provide adequate coverage and bonding when applied in one operation, merging what were traditionally two distinct steps (surface coating and back buttering) into a single efficient application process.
4Strength
If traditional inorganic binder is used, then the adhesive can bond tiles to surfaces, but the cured material is difficult to remove from grout lines without damaging tiles
Solution Approach 1:
The invention changes the chemical composition parameters of the adhesive from traditional inorganic mortar to a silane-based polymer system. This parameter change allows the adhesive to maintain strong bonding properties while becoming removable from grout lines using plastic tools, enabling easy correction of installation errors without tile damage.
5Ease of operation
If traditional mortar method is used, then the adhesive can be applied to vertical surfaces, but sag resistance is insufficient for large format tiles
Solution Approach 1:
The invention uses a composite adhesive composition containing silane-terminated polyalkylene oxide polymer, amino-silane modified wollastonite fibers, and a blend of treated and untreated fillers. This composite structure provides both application ease and superior sag resistance, with the polymer matrix offering flexibility and the fiber-filler network providing structural stability to prevent sagging of large format tiles on vertical surfaces.
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 adhesive composition provides strong, durable bonds with minimal sagging and void formation, enabling easier installation and repositioning of large format tiles, while reducing waste and labor costs, and improving sound abatement and impact resistance.
Implementation Method 1
A moisture-curable adhesive composition comprising silane-terminated polyalkylene oxide or polyurethane
Implementation Method 2
silane-terminated polyalkylene oxide or polyurethane, amino-silane modified wollastonite fibers
Implementation Method 3
amino-silane modified wollastonite fibers having an average aspect ratio of from about 1.5:1 to about 12:1 and an average fiber length of from about 6 μm to about 825 μm
Implementation Method 4
along with a rheology modifier
Implementation Method 5
a combination of treated and untreated fillers
Data Source
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AI summary
A moisture-curable adhesive composition comprises a polymer component selected from a silane-terminated polyalkylene oxide and/or a polyurethane; a plurality of amino-silane modified wollastonite fibers having an average aspect ratio of from about 1.5:1 to about 12:1 and an average fiber length of from about 6 µm to about 825 µm; at least two fillers, wherein one of said fillers is untreated and a second of said fillers is treated with a modifier selected from the group consisting of a fatty acid derivative, a silane, a titanate, and mixtures thereof wherein at least one of said fillers is irregularly shaped; and a rheology modifier. The composition preferably further comprises a plurality of irregularly-shaped crumb rubber particles having an average particle size of between about 0.5 to 1.5 mm. The composition is useful for adhering tiles to surfaces, especially large format tiles to substantially vertically-extending wall surfaces.