Mosaic Panel PVC Glue Point Formation System
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Solution Overview
Problem
Existing methods for forming mosaic panels using PVC points are inefficient due to high energy consumption, complex machinery, and suboptimal adhesion, particularly with water-based glues and large curing ovens, which result in increased costs and labor, and often lead to misalignment and quality issues.
Innovation Solution
A system utilizing an elastic silicone grid with cells to hold tiles and a Teflon-coated plate with strategically positioned holes for PVC glue points, combined with a movable glue distribution head for precise glue application and infrared drying, reduces energy consumption and ensures accurate alignment and adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional curing ovens are used to harden PVC points at 180°C for 15 minutes, then adhesion strength is improved, but energy consumption and cycle time increase significantly
Solution Approach 1:
The patent changes the curing parameters by reducing both temperature (from 180°C to lower temperatures) and time (from 15 minutes to shorter durations), achieving adequate adhesion with significantly reduced energy consumption while maintaining bond strength
Solution Approach 2:
The patent replaces the traditional thermal curing system with an alternative hardening mechanism that does not require high-temperature ovens, substituting the thermal field with a more energy-efficient process while achieving the same adhesion result
2Strength
If traditional curing ovens are used to harden PVC points, then adhesion strength is improved, but production cycle time increases
Solution Approach 1:
The patent reduces the curing time parameter from 15 minutes to a shorter duration by optimizing the hardening process, thereby decreasing cycle time while still achieving sufficient adhesion strength for production requirements
3Ease of operation
If water-based vinyl glue is used on fiberglass netting, then flexibility and ease of manipulation are improved, but adhesion quality deteriorates due to glue deterioration and insufficient surface exposure
Solution Approach 1:
The patent replaces the reusable fiberglass netting with disposable paper backing that is discarded after application, eliminating the problems of glue deterioration and insufficient surface exposure while maintaining ease of manipulation during installation
Solution Approach 2:
The patent extracts the problematic fiberglass netting and vinyl glue system from the process, replacing it with a simpler paper-based system that achieves both ease of manipulation and reliable adhesion without the deterioration issues
4Strength
If complex machinery with large curing ovens is used to dispense and harden PVC points, then adhesion strength is improved, but device complexity and cost increase
Solution Approach 1:
The patent extracts the large curing oven from the machinery system, replacing it with a simpler hardening approach that achieves adequate adhesion without requiring complex thermal processing equipment, thereby reducing overall device complexity and cost
Solution Approach 2:
The patent uses disposable paper backing that eliminates the need for complex reusable machinery components, simplifying the overall system while maintaining adhesion quality through the disposable nature of the backing material
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 approach simplifies the production process, reduces energy consumption, and ensures high-quality, accurately aligned mosaic panels with improved adhesion and reduced labor, while maintaining affordability and speed.
Implementation Method 1
the glue points are applied at the base of the tiles lying with the back face on a layer of Teflon®-coated material (to prevent adhesions). The plasticised PVC has a substantially liquid consistency at the application temperature (room temperature) and must be hardened by heating.
Data Source
Figure 1
Figure 2
Figure 3~5
AI summary
The present invention relates to the field of mosaic panels for coverings and floors, and more specifically, to the one of systems for forming the aforesaid panels. More specifically, the invention relates to a new system for connecting the tiles to one another to form the panel that represents a basic panel product in the practice of placing mosaics. For this purpose, an apparatus and a method are provided for joining adjacent tiles (T) by PVC-like glue points, wherein a glue distribution and scraping means (3) is used to distribute and scrape the glue over a stencil member (2) such that the glue drips though holes (12) in the stencil member (2) while the tiles (T) are being held in cells (11) of a grid (1) made of an elastic, soft and nonstick material.