Tile Support Plate Recesses and Mat for Stress Distribution
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Solution Overview
Problem
Existing support plates for ceramic and stone tile installations continue to introduce stress cracking and delamination due to residual stresses between the tile, mortar, and substrate, despite efforts to minimize these issues.
Innovation Solution
A support plate design featuring a sheet material with recesses and slots that include an underlay mat, where the slots and recesses are filled with mortar to provide increased durability and mechanical bonding, reducing empty cavity regions and enhancing the support plate's strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of stationary object
If thin-set mortar systems are used to reduce installation cost and weight, then installation cost and weight are reduced, but stress at the interface between mortar, substrate, and ceramic tile increases causing cracking and delamination
Solution Approach 1:
The support plate acts as an intermediary layer between the thin-set mortar and the substrate. It distributes the bond stresses over a larger area and prevents stress concentration at the interface, thereby eliminating cracking and delamination while enabling the use of thin-set mortar systems
Solution Approach 2:
The support plate changes the stress distribution parameters by providing a larger bonding area and more uniform stress distribution. This transforms the stress concentration problem into a distributed stress system that the thin-set mortar can handle
2Reliability
If support plates are used to decrease stress differences, then stress cracking and delamination are reduced, but device complexity increases
Solution Approach 1:
The support plate is designed as a thin, flexible mat that can conform to the substrate surface. This simple, flexible structure provides the necessary stress distribution function without adding significant complexity to the installation system
Solution Approach 2:
The support plate combines different materials (fabric substrate, polymer coating, adhesive layers) into a composite structure that provides multiple functions (stress distribution, bonding, flexibility) in a single component, reducing overall system complexity
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 support plate design significantly reduces stress cracking and delamination of tiles and grout by distributing stress more evenly and providing a stronger mechanical bond between the tile, mortar, and substrate, classified as 'EXTRA HEAVY' performance level according to the TCNA Handbook.
Implementation Method 1
an underlay mat of non-woven fabric material having a first side bonded to the bottom surface of the sheet material
Implementation Method 2
the slots and recesses are filled with mortar to provide increased durability and mechanical bonding
Data Source
AI summary
A support for installing facing materials such as ceramic tiles on a substrate, such as, floors, walls and ceilings. The support plate has a plurality of spaced apart raised portions and recesses in the plate material, and a plurality of openings extending through the top surface and bottom surface of the plate material. The openings exposing a mat layer attached to the bottom of the support plate. Support plates of the invention are used for tile installations between a substrate and tile. Thin-set mortar that is used to secure the tile to the support plate flows into the recesses and into the openings forming a continuous bond between the mortar, openings and mat layer to provide a strong bond between the support plate, mortar and the tiles.