Resin-Integrated Ceramic Floor Elements for Adhesive-Free Coupling
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Solution Overview
Problem
Existing ceramic tile installations are labor-intensive, costly, and require professional expertise, while floating installations lack impact strength and are prone to noise and water penetration, making them unsuitable for commercial use.
Innovation Solution
A ceramic tile with a decorative layer bonded to a support layer via a resin intermediate layer that permeates the decorative layer's pores, enhancing impact resistance and mechanical coupling without additional reinforcing elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If ceramic tiles are installed with adhesive bonding to a rigid subfloor, then impact strength and fatigue strength are improved, but installation labor and time increase significantly
Solution Approach 1:
The floor covering is divided into modular floor elements that can be mechanically coupled together without requiring adhesive bonding to a subfloor. Each element includes coupling elements that interlock with adjacent elements, allowing the system to achieve structural integrity through modular assembly rather than traditional adhesive installation methods.
Solution Approach 2:
The adhesive bonding mechanism is replaced with a mechanical coupling system. Coupling elements such as tongues, grooves, or interlocking profiles enable floor elements to be joined together through mechanical engagement rather than chemical adhesion, eliminating the need for adhesive application and subfloor bonding.
2Strength
If ceramic tiles are installed with adhesive bonding, then impact strength is improved, but professional competence and installation cost increase
Solution Approach 1:
The flooring system is segmented into self-contained modules with integrated coupling elements that enable straightforward mechanical assembly. This segmentation allows individuals to install the flooring without requiring professional tiling expertise, as the interlocking mechanism guides the assembly process.
Solution Approach 2:
The floor elements are designed to be self-assembling through their mechanical coupling systems. The coupling elements are configured to automatically align and lock together when floor elements are placed adjacent to each other, eliminating the need for professional adhesive application skills and ensuring consistent, reliable installation.
3Loss of time
If floating floor covering without adhesive is used, then installation labor is reduced, but impact strength and fatigue strength decrease significantly
Solution Approach 1:
The floor element combines multiple materials and structural components including the decorative ceramic layer, support layer, and mechanical coupling elements. This composite construction allows the element to achieve sufficient impact strength through the combined properties of its components while maintaining the benefits of adhesive-free installation.
4Ease of operation
If floating floor covering without adhesive bonding is used, then installation simplicity is improved, but water penetration in joints increases
Solution Approach 1:
A waterproofing layer or grout joint system acts as an intermediary between the mechanical coupling elements and the environment. This intermediate layer prevents water from penetrating through the joints between floor elements, maintaining the water imperviousness required for hygienic surfaces while preserving the simplicity of mechanical installation.
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 solution achieves impact strength comparable to adhesive-bonded tiles, reduces installation complexity, and minimizes noise and water penetration, while maintaining a lightweight and thin profile.
Implementation Method 1
an intermediate layer having a resin material that permeates a lower surface of the decorative layer
Data Source
AI summary
A floor element for forming a floor covering, wherein the floor element comprises a decorative layer made of a ceramic material and a support layer arranged below the decorative layer, wherein the support layer comprises edges provided with coupling elements configured to allow a mechanical coupling with coupling elements of an adjacent floor element and wherein the floor element comprises an intermediate layer having a resin material that permeates a lower surface of the decorative layer. A method for manufacturing a floor element, comprising the steps of: (i) providing a decorative layer made of a ceramic material; (ii) providing a support layer; (iii) providing a resin material for bonding the decorative layer and the support layer together; (iv) pressing the layers together for forming the floor element such that the resin material permeates the ceramic layer.