Mosaic Panel Manufacturing via Thermo Moulded Plastic Sheet
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Solution Overview
Problem
The existing method of applying loose mosaic tiles to a wall or floor using tile mats is laborious and expensive.
Innovation Solution
A method involving a transparent plastic sheet with a mosaic tile structure and groove pattern, created through thermo moulding or 3D printing, which is then printed and optionally reinforced, allowing for a cost-effective application similar to loose tiles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If loose mosaic tiles are stuck to a gauze mat and applied to walls or floors, then the mosaic panel can be applied to surfaces, but the method is laborious and expensive
Solution Approach 1:
The patent creates a plastic sheet that copies the appearance and structure of traditional mosaic tiles, including the tile patterns and groove structures. This allows the mosaic effect to be reproduced without using actual loose tiles, thereby reducing labor and material costs while maintaining the aesthetic appearance.
Solution Approach 2:
The patent changes the material parameter from traditional ceramic or glass tiles to plastic material. This parameter change enables more efficient manufacturing processes such as injection molding or extrusion, which can produce mosaic panels continuously at lower cost and higher speed compared to manual tile application.
2Ease of manufacture
If a plastic sheet with mosaic structure is used instead of loose tiles, then manufacturing cost is reduced, but the appearance must remain similar to traditional mosaic panels
Solution Approach 1:
The plastic sheet is designed with segmented structures that divide it into individual tile-like sections separated by grooves. This segmentation reproduces the characteristic appearance of traditional mosaic panels while allowing the entire structure to be manufactured as a single integrated plastic component, maintaining both aesthetic fidelity and manufacturing efficiency.
Solution Approach 2:
The patent applies different surface treatments or textures to different local areas of the plastic sheet to match the specific appearance characteristics of traditional mosaic tiles. The grooves between tiles may have different finishes or profiles to accurately reproduce the grout lines and tile surfaces, ensuring high appearance fidelity.
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
Enables a cost-effective manufacturing of mosaic panels with a true-to-nature appearance, reducing labor and material costs while maintaining aesthetic quality.
Implementation Method 1
applying the tile structure and the groove pattern is effected by thermo moulding of the plastic sheet such that channels are formed at small distances from each other
Implementation Method 2
subsequently applying a print to the rear side of the transparent plastic sheet
Implementation Method 3
subsequently, the grooves are pointed which are present in the visible side of the sheet
Data Source
AI summary
A tile structure and a groove pattern are formed from a transparent plastic sheet 1 by means of thermo moulding. A transparent plastic sheet 1 is started from which is inserted between two mould parts and subsequently heated inductively. Subsequently, the two mould parts are brought together where the softened plastic sheet 1 is deformed while a tile structure and a groove pattern are formed in the plastic sheet. A print is then applied to the rear side 1b of this transparent plastic sheet 1 after which the plastic sheet 1 is glued with the printed side to a reinforcement sheet 11 by means of an adhesive paste 13. The glued panel showing the grooves on the visible side la is finally pointed with a flexible pointing agent 15. The final result is a mosaic panel 21 having a photo print or graphical pattern built up from ostensibly loose mosaic glass stones which as a whole are similar to a mosaic glass structure.