Seamless Tile Edge Channel Network for Joint-Free Installation
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Solution Overview
Problem
Existing seamless slab installations face challenges with joint areas being weak points for wear, thermal, and mechanical stresses, and anchoring complexities leading to high rejects, especially in commercial applications.
Innovation Solution
The method involves designing edge zones of panels with channel sections that form a continuous duct network, allowing for a joint-free connection using a hardenable filling compound, which is injected and hardens to secure the panels without visible joints, while allowing for conventional fastening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If panels are installed with visible joints using conventional methods, then the installation process is simple, but the joint areas become weak points for wear, thermal stresses, and mechanical damage
Solution Approach 1:
The invention extracts the joint area from the visible surface by creating subsurface channels that extend below the panel edges. The filling compound is placed in these subsurface channels rather than in visible surface joints, effectively removing the weak joint structure from the visible and load-bearing surface while maintaining panel connectivity through the embedded channels.
Solution Approach 2:
The invention transitions the joint structure from a two-dimensional surface feature to a three-dimensional subsurface feature. Channels are created that extend vertically below the panel edges, allowing the filling compound to anchor panels in the depth dimension rather than relying on surface-level joints. This dimensional transition strengthens the connection while keeping the surface seamless.
2Strength
If bonding in the edge area is used to connect panels, then the installation is simpler, but the bonding is insufficient to withstand high mechanical and thermal loads
Solution Approach 1:
The invention embeds channels within the panel edge zones, creating a nested structure where the filling compound is housed inside subsurface channels rather than being applied on the surface. This nesting allows the connection mechanism to be hidden within the panel structure itself, providing strong mechanical anchoring while maintaining a clean external appearance.
Solution Approach 2:
The filling compound acts as an intermediary material that flows into and fills the subsurface channels, creating a mechanical interlock between adjacent panels. This intermediary substance provides the bonding strength needed to withstand loads while allowing for some movement and stress relief, unlike rigid surface bonding methods.
3Stability of the object's composition
If anchoring in a sub-floor is used to secure panels, then the panel stability is improved, but the process becomes extremely complex and leads to high rejects
Solution Approach 1:
The invention segments the anchoring function into two parts: the structural support remains with the sub-floor, while the panel-to-panel connection is achieved through independent subsurface channels formed in the panel edge zones. This segmentation eliminates the need for complex sub-floor anchoring systems while maintaining panel stability through the distributed channel network.
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 enhances physical and chemical resistance, maintains a flat surface with low tolerances, facilitates quick mechanical laying, and ensures walkability shortly after installation, eliminating weak points like joints and improving durability.
Implementation Method 1
filled with a hardenable filling compound during laying... After curing, there is a firm panel bond
Data Source
Figure 1a~4
AI summary
The covering panel (10) has a lower side running in distance to an upper side, and an edge zone connecting the upper and the lower sides. The edge zone has a surface section with a flat upper surface, which is designed for jointless attachment at the corresponding covering panel. Another surface section has an upper surface in which a groove shaped recess extends, and forms a channel section that runs parallel to the upper side of the panel. The former surface section runs perpendicularly to the upper side. An independent claim is also included for a method for displacement of a slab lining with a covering panel.