Water-Soluble Mortar Pouch for Tile Installation
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Solution Overview
Problem
The tiling process requires precision and skill for applying mortar, is time-consuming, and generates waste water, making it difficult for non-skilled individuals and inefficient in terms of productivity and quality.
Innovation Solution
A mortar pouch with a water-soluble fabric encapsulating dry tile mortar, eliminating the need for mixing and tools, allowing easy application and reducing water consumption by using only the necessary amount of water to moisten the pouch.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manual mortar application with notched trowel is used, then precision in mortar pattern and gap width can be achieved, but the process is time-consuming and requires skilled operators
Solution Approach 1:
The invention segments the mortar application process by providing pre-cut mortar strips with precise dimensions and patterns. Each strip is pre-formed with specific thickness, width, and notch configurations, eliminating the need for manual spreading while maintaining precision. The strips can be individually positioned and applied directly to the substrate.
Solution Approach 2:
The mortar is prepared in advance as pre-formed strips with precise patterns and dimensions before application. The strips are manufactured with controlled thickness, width, and notch geometries, so that when applied to the substrate, they provide consistent mortar patterns without requiring skilled manual spreading operations.
2Adaptability or versatility
If traditional manual mortar application is used, then flexibility in handling different tile sizes can be achieved, but the process requires skilled operators and generates waste water
Solution Approach 1:
The mortar system is segmented into various pre-formed strip types with different dimensions, patterns, and configurations. Each strip type is designed for specific tile sizes and application requirements. Operators can select the appropriate pre-formed strip type for each tiling scenario, providing versatility without requiring skilled manual spreading techniques.
Solution Approach 2:
The pre-formed mortar strips are designed to be universally applicable to different tile sizes, shapes, and laying patterns. The system provides multiple strip configurations that can accommodate various tiling requirements, making the system adaptable to different applications while simplifying the operator's task to simple placement and pressing operations.
3Stability of the object's composition
If traditional mortar preparation and application is used, then thorough mixing can be achieved, but large amounts of water are consumed for cleaning tools
Solution Approach 1:
The mortar is pre-mixed and pre-formed into strips with controlled composition and consistency before application. The factory-controlled mixing process ensures uniform mortar composition and proper water-cement ratio. This eliminates the need for on-site mixing operations and the subsequent water consumption required for cleaning mixing tools, buckets, and trowels.
Solution Approach 2:
The manual mechanical mixing and spreading process is replaced by a factory-based production system that forms mortar into pre-cut strips. This substitution eliminates the need for on-site mixing equipment and the water required for cleaning these tools, significantly reducing waste water generation while maintaining consistent mortar quality.
4Ease of operation
If pre-mixed mortar pack for masonry is used, then ease of application can be achieved, but precision in mortar pattern and gap width is not sufficient for tiling
Solution Approach 1:
The pre-formed mortar strips are segmented into precise dimensional units with controlled thickness, width, and pattern features. Each strip is manufactured with tight tolerances to ensure consistent mortar application. The segmentation into individual strips allows for precise placement and positioning, achieving the dimensional precision required for tiling while maintaining the simplicity of pre-formed product application.
Solution Approach 2:
The pre-formed mortar strips incorporate locally optimized features such as notches, protrusions, and surface textures in specific locations to achieve precise mortar patterns and gap widths. The strips are designed with varying local characteristics - some areas have higher mortar concentration, others have spacing features - to create the desired tiling pattern precision without complicating the overall application process.
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
This solution simplifies the tiling process, increases productivity, reduces waste, and improves quality by providing a ready-to-install dry mortar that can be easily applied by non-skilled individuals, ensuring consistent mortar application and alignment.
Implementation Method 1
a water-soluble fabric (1001, 4001, 6001) encapsulates the said dry tile mortar (1002, 4002, 6002)
Data Source
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AI summary
A mortar pouch (1000, 4000, 6000) for gluing or jointing tiles, wherein said mortar pouch (1000, 4000, 6000) comprises a water-soluble fabric (1001, 4001, 6001) and a dry tile mortar (1002, 4002, 6002), wherein the water-soluble fabric (1001, 4001, 6001) encapsulates the said dry mortar (1002, 4002, 6002) and wherein the said dry tile mortar (1002, 4002, 6002) is not embedded in a non water-soluble fabric. There is also provided a tile mortar packaged into a plurality of connected individual mortar pouches. There is further provided processes to manufacture such mortar pouch and such tile mortar.