Tile Panel Positioning Structure for Uniform Locking Gaps
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Solution Overview
Problem
Existing ceramic and stone tiles face challenges in precise positioning and alignment, leading to non-uniform gaps and visible variations between adjacent panels, especially when using mechanical locking systems, which are easily noticeable by the human eye.
Innovation Solution
A panel design incorporating a carrier with a mechanical locking system and a positioning system featuring recesses and positioning members, such as protrusions, to ensure accurate alignment and uniform gaps between tiles, allowing for correct positioning and uniform spacing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a mechanical locking system is used to join adjacent panels, then the panels can be securely connected, but the gaps between adjacent tiles become visible and non-uniform
Solution Approach 1:
The positioning system is divided into multiple positioning members distributed at different locations on the carrier, each responsible for positioning specific tiles. This segmentation allows precise control of each tile's position independently, ensuring uniform gaps while maintaining the mechanical locking system's joining strength.
Solution Approach 2:
The positioning members act as intermediary elements between the carrier and the tiles, providing a reference framework that guides tile placement. These positioning members ensure that tiles are positioned at correct locations and orientations, achieving uniform gaps without compromising the mechanical locking system's functionality.
2Strength
If the ceramic layer is glued to the support member, then the tile is securely attached, but precise positioning and alignment become difficult to achieve
Solution Approach 1:
The positioning members are pre-installed on the carrier before the tiles are glued to the support member. This preliminary positioning establishes reference points that guide the subsequent gluing process, ensuring that tiles are accurately positioned and aligned while being attached, thus achieving both strong adhesion and high positioning accuracy.
3Shape
If adjacent panels are positioned with a small distance between them, then the flooring appears more continuous, but variations in gap distance become more noticeable
Solution Approach 1:
The positioning members provide a physical reference framework that gives immediate feedback during the panel assembly process. As panels are positioned relative to each other, the positioning members ensure that gaps remain consistent, allowing for visual continuity while preventing noticeable variations even in small gap distances.
Data Source
AI summary
The present disclosure relates to a panel (1) comprising a carrier (20) having a first surface (21) and a second surface (22), and a tile (10) comprising, e.g., a ceramic layer or a stone layer, the tile being positioned on and adhered to the carrier (20) by an adhesive and having a first surface (11) and a second surface (12), wherein the first surface (11) of the tile (10) is arranged on the second surface (22) of the carrier (20), wherein the panel (1) is provided with a mechanical locking system (40; 50; 60) for joining the panel (1) to an adjacent panel (1′) along at least one edge of the panel (1), further comprising a positioning system (30) configured to position the tile (10) on the carrier (20), the positioning system (30) being arranged on the first surface (11) of the tile (10) and on the second surface (22) of the carrier (20), the positioning system (30) comprising at least one positioning member (31) and at least one recess (32) configured to receive the at least one positioning member (31). The disclosure also relates to a method to produce such a panel.