Preassembled Tile Panels with Epoxy Grout for Faster Installation
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Solution Overview
Problem
Traditional tile installation methods are labor-intensive, time-consuming, and costly due to the need for on-site mixing and setting of mortar and grout, which requires significant labor hours and materials.
Innovation Solution
A preassembled tile assembly is manufactured off-site, incorporating epoxy grout between adjacent tiles and metal edges, with optional support rods, to enhance structural integrity and facilitate efficient installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional on-site tile installation methods are used with mortar and grout mixing, then tiles can be installed, but labor hours and installation time increase significantly
Solution Approach 1:
The tile assembly is pre-assembled off-site with epoxy grout already applied between the tiles before shipment to the job site. This preliminary action eliminates the need for on-site mixing and application of mortar and grout, directly reducing installation time and increasing productivity.
Solution Approach 2:
The tile assembly is divided into modular panels that can be pre-assembled and then installed as complete units. This segmentation allows the labor-intensive grouting process to be completed off-site in a controlled environment, then the entire panel is quickly installed at the job site.
2Ease of manufacture
If traditional tile installation with multiple steps is used, then tiles can be installed, but labor costs and material costs increase
Solution Approach 1:
Multiple installation steps (tile setting, grout application, grout cleaning) are merged into a single pre-assembled panel unit. The epoxy grout is applied factory-direct to the tiles before shipping, combining what were previously separate on-site operations into one integrated off-site process, eliminating the need for separate material applications and reducing overall material costs.
3Productivity
If preassembled tile panels are used, then labor hours are reduced, but structural integrity during transport must be maintained
Solution Approach 1:
Epoxy grout is used instead of traditional cement-based grout because epoxy provides superior strength and rigidity. This composite material choice ensures that the pre-assembled tile panels maintain their structural integrity during shipping and handling while still allowing for the labor-saving pre-assembly approach.
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 off-site assembly significantly reduces labor hours and material costs, ensuring quicker and more cost-effective installation with improved structural integrity and transportability.
Implementation Method 1
an epoxy grout is applied to all edges of each of the tile members that has an adjacent tile member
Data Source
AI summary
A method of constructing a tile assembly panel wherein the tile assembly panel is constructed at a location different than that of the installed location of the tile assembly panel. The tile assembly panel includes a plurality of tile members wherein the tile members can be any shape, size and type of tile. The tile members during construction of the tile assembly panel have epoxy grout applied to the lateral edges thereof wherein the lateral edges of the tile members are adjacent other lateral edges of adjacent tile members. The method of the present invention employs a horizontal work surface that is flat and rigid facilitating the ability to place the tile members in the correct location and pattern while securing each tile member to every adjacent tile member. Ensuing construction of the tile assembly panel the tile assembly panel is transported to the installation location for install thereof.